WO2020175333A1 - Rotating electric machine - Google Patents

Abstract

This rotating electric machine (700) is provided with: a bearing (792) for rotatably supporting the rotational axis (701) of a rotor (710); a housing (771) having a bearing holding portion (780) to which the bearing is fixed; and a resolver (800) for outputting a rotation angle signal. An end of the bearing holding portion in the axial direction constitutes an expanded-diameter side fixing portion (783) in which a hole connected to the opening of the end in the axial direction is formed. A portion of the bearing holding portion adjacent to the expanded-diameter side fixing portion in the axial direction constitutes a reduced-diameter side fixing portion (782) in which a hole having a smaller hole diameter than that of the expanded-diameter side fixing portion is formed. The rotational axis is inserted into the respective holes of the expanded-diameter side fixing portion and the reduced-diameter side fixing portion. The bearing is fixed to one of the expanded-diameter side fixing portion and the reduced-diameter side fixing portion. The resolver stator (802) of the resolver is fixed to one of the expanded-diameter side fixing portion and the reduced-diameter side fixing portion to which the bearing is not fixed.

Description

\\0 2020/175333 1 ?01/^2020/006903

Specification

Title of invention: Rotating electric machine

Cross-reference of related applications

[0001] This application was filed on February 25, 2010 in Japanese application number 2 0 1 9-0

Based on No. 3 2 1 84, the contents of which are incorporated herein by reference.

Technical field

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

Background technology

[0003] Conventionally, as described in Patent Document 1, an axle (rotating shaft) fixed to a rotor, a hollow cylindrical wheel support portion, and an axle rotatable relative to the wheel support portion. A rotating electric machine including a bearing that supports the rotating electric machine is known. The bearing is fixed to the inner peripheral surface of the wheel support portion on the one end side in the axial direction.

[0004] The rotating electric machine includes a rotation sensor unit. This unit consists of a detector that is fixed to the side of the wheel support that is opposite to the side where the bearing is fixed in the axial direction, and a gear that is fixed to a position on the axle that faces the detector in the radial direction. And have. The detector detects the positions of the teeth of the gears facing each other in the radial direction, and outputs the rotation angle signal of the rotor based on the position information of the teeth.

Prior art documents

Patent literature

Patent Document 1: Japanese Patent Laid-Open No. 20 1 3 _ 1 8 2 3 1 7

Summary of the invention

In the rotary electric machine described in Patent Document 1, the fixing portion of the detecting portion of the wheel supporting portion is provided on the side of the wheel supporting portion opposite to the fixing portion of the bearing in the axial direction. As a result, the axial distance between the bearing support portion of the axle and the gear fixing portion becomes long. In this case, the runout of the axle becomes large, and the accuracy of detection of the rotational position by the rotation sensor unit may deteriorate.

[0007] The present disclosure has been made in view of the above circumstances, and detects the rotational position of a rotor. \¥0 2020/175333 2 卩 (: 17 2020 /006903

The main purpose is to provide a rotating electric machine capable of improving output accuracy.

[0008] The plurality of aspects disclosed in this specification adopt different technical means from each other in order to achieve the respective objects. The objects, features, and effects disclosed in this specification will become clearer with reference to the following detailed description and the accompanying drawings.

[0009] Means 1 includes a rotor,

A bearing that rotatably supports the rotating shaft of the rotor,

A housing having a bearing holding portion to which the bearing is fixed,

A resolver stator fixed to the bearing holder, and a resolver fixed to a position of the rotary shaft facing the resolver stator in the radial direction, and a resolver outputting a rotation angle signal of the rotor. In a rotating electric machine including,

The axial end portion of the bearing holding portion is a diametrical expansion side fixing portion having a bored hole formed in an opening of the axial end portion,

A portion of the bearing holding portion that is axially adjacent to the expansion-side fixing portion is a reduction-side fixing portion in which a hole smaller than the hole diameter of the expansion-side fixing portion is formed.

The rotary shaft is threaded through the respective holes of the diameter-increasing side fixing portion and the diameter-decreasing side fixing portion,

The bearing is fixed to one of the expanded diameter side fixed portion and the reduced diameter side fixed portion,

The resolver stator is fixed to one of the expanded diameter side fixed portion and the reduced diameter side fixed portion where the bearing is not fixed.

[0010] In the means 1, the diameter expansion side fixing portion and the diameter reduction side fixing portion are adjacent to each other in the axial direction. With this configuration, it is possible to shorten the axial distance between the support portion of the rotary shaft, which is supported by the bearing, and the fixed portion of the resolver ball, and it is possible to reduce runout of the rotary shaft. As a result, runout of the resolver rotor with respect to the resolver stator can be reduced. 〇 2020/175333 3 (:171? 2020/006903

Therefore, the accuracy of detecting the rotational position of the rotor can be improved.

[001 1] In addition, the structure in which the expanding-side fixing portion and the reducing-side fixing portion in which a hole having a smaller hole diameter is formed than the expanding-side fixing portion are axially adjacent to each other are bored in the bearing holding portion. When performing hole drilling by machining or the like, it is possible to continuously machine the expanding-side fixing portion and the reducing-side fixing portion coaxially from the same direction. Therefore, it is possible to increase the concentricity between the bearing fixed to one of the expanded diameter side fixed portion and the reduced diameter side fixed portion and the resolver stator fixed to the other side. As a result, the coaxiality between the resolver rotor and the resolver stator can be increased, and the runout of the resolver rotor with respect to the resolver stator can be reduced. As a result, the effect of improving the detection accuracy of the rotational position can be further enhanced.

[0012] Means 2 is the same as in the means 1, wherein the bearing is a reduced diameter side bearing,

The diameter reducing side bearing is fixed to the diameter reducing side fixing portion,

The resolver stator is fixed to the expansion side fixing portion,

A portion of the bearing holding portion opposite to the diameter-expansion-side fixing portion in the axial direction with the diameter-decrease-side fixing portion sandwiched therebetween is a base-end-side fixing portion having a hole formed therein. Part, the diameter reducing side fixing part and the base end side fixing part, the rotary shaft is passed through the respective holes,

A base end bearing fixed to the base end side fixing portion and rotatably supporting the rotary shaft;

The rotor is fixed to the base end side bearing side in the axial direction of the rotating shaft,

The diameter reducing side bearing and the base end side bearing are radial ball bearings having an outer ring, an inner ring, and a plurality of balls arranged between the outer ring and the inner ring,

An outer diameter dimension of the base end side bearing is larger than an outer diameter dimension of the contraction side bearing.

In the means 2, the rotor is fixed to the base end side bearing side in the axial direction of the rotating shaft. Therefore, the base-end bearing is more susceptible to rotor vibration and eccentric load than the diameter-reducing bearing. Here, in the means 2, the outer diameter dimension of the base end side bearing is larger than the outer diameter dimension of the reduced diameter side bearing. The larger the outer diameter of the bearing, the outer and inner rings 〇 2020/175333 4 卩 (：171? 2020 /006903

The gap between the ball and the ball becomes larger. Therefore, according to the means 2, the effect of absorbing the load of the rotor can be enhanced, and the load acting on the base end side fixed part side of the bearing holding part can be reduced. As a result, it is possible to reduce the runout of the support portion of the rotary shaft due to the reduced diameter side bearing, and to reduce the runout of the resolver rotor with respect to the resolver stator. As a result, the accuracy of detecting the rotational position of the rotor can be improved.

[0014] Means 4 is the annular cover member according to any one of Means 1 to 3, which is fixed to the opening side of the resolver stator and the bearing in the axial direction of the radially enlarged fixing portion. Equipped with.

[0015] According to the means 4, the resolver and the bearing can be protected from foreign matter.

[0016] Means 5 is the device according to any one of Means 1 to 4, which includes a stator facing the rotor in a radial direction,

The rotor is

A carrier having a disk-shaped end plate portion fixed to the rotation shaft, and a carrier arranged coaxially with the rotation shaft;

An annular magnet unit arranged coaxially with the rotating shaft, wherein the magnet unit is

A cylindrical magnet holder whose one end in the axial direction is fixed to the end plate portion,

A magnet that is fixed to the circumferential surface of the magnet holder on the side of the stator in the radial direction and has alternating polarities in the circumferential direction;

The magnet holder is made of a non-magnetic material,

In the magnet, the direction of the easy axis of magnetization is offset from the direction parallel to the axis.

[0017] In the means 5, the magnet holder is made of a non-magnetic material. Therefore, the weight of the rotor can be reduced, and the runout of the rotating shaft can be reduced. As a result, the shake of the resolver rotor with respect to the resolver stator can be reduced, and the accuracy of detecting the rotational position of the rotor can be improved. 〇 2020/175333 卩 (: 171? 2020 /006903

[0018] Here, in the means 5, in the magnet, the direction of the easy axis of magnetization in the 9-axis is

It is offset from the direction parallel to the 9-axis. According to this configuration, magnetic flux leakage from the magnet to the magnet holder can be suppressed, and a reduction in torque of the rotating electric machine can be suppressed, as compared with a configuration including a magnet having a radial orientation. As described above, according to the means 5, the detection accuracy of the rotating position of the rotor can be improved while suppressing the decrease in the torque of the rotating electric machine.

[0019] Means 6 is the means 5, wherein in the magnet, a circle having a center point at the intersection of the 9-axis and the magnetic flux exchange surface between the 9-axis and a radial thickness dimension of the magnet is a radius, When the orientation circle defines the easy axis of magnetization of the magnet, the magnet is configured to include a quarter circle of the orientation circle.

[0020] In the means 6, in the magnet, an arc-shaped easy axis of magnetization is provided so as to cross the nine axes. Among the easy magnetization axes, the strongest magnetic flux is generated by the easy magnetization axis passing through the intersection of the 9th axis and the circumferential surface on the side opposite to the magnetic flux transfer surface in the radial direction, that is, the easy magnetization axis passing through the orientation circle X. According to the means 6, the strongest magnetic flux magnetic flux path can be prevented from being formed on the magnet holder side, and the effect of suppressing magnetic flux leakage from the magnet to the magnet holder can be enhanced.

Brief description of the drawings

[0021] The above and other objects, features and advantages of the present disclosure will be made clearer by the following detailed description with reference to the accompanying drawings. The drawing is [Fig. 1] Fig. 1 is a longitudinal sectional perspective view of a rotating electric machine.

[Fig. 2] Fig. 2 is a vertical cross-sectional view of a rotating electrical machine.

[Fig. 3] Fig. 3 is a sectional view taken along line 111-111 in Fig. 2.

[FIG. 4] FIG. 4 is an enlarged cross-sectional view showing a part of FIG.

[Fig. 5] Fig. 5 is an exploded view of the rotating electrical machine.

[Fig. 6] Fig. 6 is an exploded view of the inverter unit.

[Fig. 7] Fig. 7 is a torque diagram showing the relationship between the ampere-turn of the stator winding and the torque density.

[Fig. 8] Fig. 8 is a cross-sectional view of the rotor and the stator. 20/175333 6 卩 (: 171? 2020 /006903

[FIG. 9] FIG. 9 is an enlarged view of a part of FIG.

[Fig. 10] Fig. 10 is a cross-sectional view of the stator.

[Fig. 11] Fig. 11 is a longitudinal sectional view of the stator.

[Fig. 12] Fig. 12 is a perspective view of the stator winding line.

[FIG. 13] FIG. 13 is a perspective view showing the structure of a conductor.

[Fig. 14] Fig. 14 is a schematic diagram showing the structure of a wire.

[FIG. 15] FIG. 15 is a view showing the form of each conductor in the n-th layer,

[Fig. 16] Fig. 16 is a side view showing the conductors of the nth layer and the _n + 1st layer.

[FIG. 17] FIG. 17 is a diagram showing the relationship between the electrical angle and the magnetic flux density of the magnet of the embodiment.

[Fig. 18] Fig. 18 is a graph showing the relationship between the electrical angle and the magnetic flux density for the magnet of the comparative example.

[Fig. 19] Fig. 19 is an electric circuit diagram of the control system for the rotating electric machine.

[FIG. 20] FIG. 20 is a functional block diagram showing a current feedback control process by the control device.

[Fig. 21] Fig. 21 is a functional block diagram showing torque feedback control processing by the control device.

[FIG. 22] FIG. 22 is a cross-sectional view of a rotor and a stator according to the second embodiment.

[Fig. 23] Fig. 23 is an enlarged view of a part of Fig. 22.

[Fig. 24] Fig. 24 is a diagram specifically showing the flow of magnetic flux in the magnet unit.

[Fig. 25] Fig. 25 is a cross-sectional view of a stator in Modification 1,

[Fig. 26] Fig. 26 is a cross-sectional view of a stator in Modification Example 1,

[Fig. 27] Fig. 27 is a cross-sectional view of a stator according to Modification 2.

[Fig. 28] Fig. 28 is a cross-sectional view of a stator according to Modification 3.

[Fig. 29] Fig. 29 is a cross-sectional view of a stator in Modification 4,

[FIG. 30] FIG. 30 is a cross-sectional view of a rotor and a stator in Modification 7. 〇 2020/175333 7 卩(: 171-1? 2020/006903

[FIG. 31] FIG. 31 is a functional block diagram showing a part of the processing of the operation signal generation unit in Modification 8.

[Fig. 32] Fig. 32 is a flow chart showing the procedure for changing the carrier frequency.

[FIG. 33] FIG. 33 is a diagram showing a connection form of each conductor wire which constitutes the conductor wire group in Modification 9,

[FIG. 34] FIG. 34 is a diagram showing a configuration in which four pairs of conductor wires are arranged in a laminated manner in Modification Example 9.

[FIG. 35] FIG. 35 is a cross-sectional view of an inner rotor type rotor and a stator in Modification 10.

[Fig. 36] Fig. 36 is an enlarged view of a part of Fig. 35.

[Fig. 37] Fig. 37 is a vertical cross-sectional view of an inner rotor type electric rotating machine.

[Fig. 38] Fig. 38 is a vertical cross-sectional view showing a schematic configuration of an inner rotor type rotating electric machine.

[FIG. 39] FIG. 39 is a diagram showing a configuration of a rotating electric machine having an inner rotor structure in Modification 11;

[FIG. 40] FIG. 40 is a diagram showing a configuration of a rotating electric machine having an inner rotor structure in Modification Example 11.

[FIG. 41] FIG. 41 is a diagram showing a configuration of a rotary armature-type rotary electric machine in Modification 12;

[Fig. 42] Fig. 42 is a cross-sectional view showing the structure of the conductor wire in Modification 14, [Fig. 43] Fig. 43 is a diagram showing the relationship between reluctance torque, magnet torque, and port 1\/1. Yes,

[Fig.44] Fig.44 is a diagram showing teeth.

[Fig. 45] Fig. 45 is a perspective view showing the wheel of the in-wheel motor structure and its peripheral structure.

[Fig. 46] Fig. 46 is a longitudinal sectional view of the wheel and its peripheral structure.

[Fig. 47] Fig. 47 is an exploded perspective view of the wheel. 20/175333 8 卩 (: 171? 2020 /006903

[Fig. 48] Fig. 48 is a side view of the rotary electric machine as seen from the protruding side of the rotary shaft.

[Fig. 49] Fig. 49 is a cross-sectional view taken along line 4 9-4 9 of Fig. 48.

[Fig. 50] Fig. 50 is a sectional view taken along line 50--50 of Fig. 49.

[Fig. 51] Fig. 51 is an exploded cross-sectional view of a rotating electric machine.

[Fig. 52] Fig. 52 is a partial sectional view of the rotor.

[Fig. 53] Fig. 53 is a perspective view of a stator winding and a stator core.

[Fig. 54] Fig. 54 is a front view showing the stator windings in a flat state.

[Fig.55] Fig.55 shows the skew of conductors.

[Fig. 56] Fig. 56 is an exploded sectional view of the inverter unit.

[Fig. 57] Fig. 57 is an exploded sectional view of the inverter unit.

[Fig. 58] Fig. 58 shows how the electric modules are arranged in the inverter housing.

[FIG. 59] FIG. 59 is a circuit diagram showing an electrical configuration of the power converter,

[Fig. 60] Fig. 60 is a diagram showing an example of a cooling structure of a switch module.

[Fig. 61] Fig. 61 is a diagram showing an example of a cooling structure of a switch module.

[Fig. 62] Fig. 62 is a diagram showing an example of the cooling structure of the switch module.

[Fig. 63] Fig. 63 is a diagram showing an example of the cooling structure of the switch module.

[Fig. 64] Fig. 64 is a diagram showing an example of the cooling structure of the switch module.

[Fig. 65] Fig. 65 is a diagram showing the arrangement order of the electric modules with respect to the cooling water passage.

[Fig. 66] Fig. 66 is a sectional view taken along line 6 6--6 6 of Fig. 49.

[Fig. 67] Fig. 67 is a sectional view taken along the line 6 7--6 7 of Fig. 49.

[Fig. 68] Fig. 68 is a perspective view showing the bus bar module as a single unit.

[Fig. 69] Fig. 69 is a diagram showing an electrical connection state between each electric module and the bus bar module.

[Fig. 70] Fig. 70 is a diagram showing an electrical connection state between each electric module and the bus bar module.

[Fig. 71] Fig. 71 shows the electrical connection between each electrical module and the busbar module. 〇 2020/175333 9 (:171? 2020/006903

It is a figure showing a state,

[Fig. 72] Fig. 72 is a configuration diagram for explaining a modification 1 of the in-wheel motor.

[Fig. 73] Fig. 73 is a configuration diagram for explaining a second modification of the in-wheel motor.

[Fig. 74] Fig. 74 is a configuration diagram for explaining Modification 3 of the in-wheel motor.

[Fig. 75] Fig. 75 is a configuration diagram for explaining a modification 4 of the in-wheel motor.

[FIG. 76] FIG. 76 is a perspective view showing the entire rotating electric machine in Modification Example 15, [FIG. 77] FIG. 77 is a vertical sectional view of the rotating electric machine,

[Fig. 78] Fig. 78 is an exploded cross-sectional view of the components of the rotating electric machine,

[Fig. 79] Fig. 79 is a longitudinal sectional view of the rotor.

[Fig. 80] Fig. 80 is a partial cross-sectional view showing an enlarged cross-sectional structure of the magnet unit.

[Fig. 81] Fig. 81 is a diagram showing a method for orienting a magnet.

[Fig.82] Fig. 82 is a vertical sectional view of the inner unit.

[Fig. 83] Fig. 83 is a vertical cross-sectional view of the inner unit with the bearings assembled.

[FIG. 84] FIG. 84 is a vertical cross-sectional view of a rotor according to Modification 16.

MODE FOR CARRYING OUT THE INVENTION

[0022] A plurality of embodiments will be described with reference to the drawings. In some embodiments, functionally and/or structurally corresponding parts and/or associated parts may be given the same reference signs, or hundreds or more different reference signs. For the corresponding part and/or the related part, the description of the other embodiments can be referred to.

[0023] The rotary electric machine according to the present embodiment is used, for example, as a vehicle power source. However, rotating electrical machinery is for industrial use, vehicle use, home appliances use, and 08 equipment use. 〇 2020/175333 10 卩 (：171? 2020 /006903

, Can be widely used for amusement machines. Note that in the following embodiments, the portions that are the same ^_ or equivalent to each other, in the drawing, are designated by the same _ code, portions of the ^_ sign of which is incorporated by reference in its description.

[0024] (First Embodiment)

The rotary electric machine 100 according to the present embodiment is a synchronous multi-phase AC motor and has an outer port structure (outer rotation structure). An 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 the rotary shaft 11 and FIG. Fig. 4 is a cross-sectional view (cross-sectional view taken along the line 111-111 in Fig. 2) of the rotating electric machine 10 in the direction of rotation, Fig. 4 is a cross-sectional view showing an enlarged part of Fig. 3, and Fig. 5 is It is an exploded view of the electric machine 10. Note that, in FIG. 3, for convenience of illustration, the hatching showing the cut surface is omitted except for the rotating shaft 11. In the following description, the direction in which the rotary shaft 11 extends is the axial direction, the direction that extends radially from the center of the rotary shaft 11 is the radial direction, and the direction that extends circumferentially around the rotary shaft 11 is the circumferential direction. I am trying.

The rotary electric machine 10 is roughly provided with 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 is assembled in the axial direction in a predetermined order to form the rotating electric machine 10. The rotating electric machine 10 of the present embodiment is configured to have a rotor 40 as a “field element” and a stator 50 as an “armature”, and is a rotating field type rotating electric machine. Is embodied as

[0026] The bearing unit 20 has two bearings 21 and 22 arranged axially away from each other, and a holding member 23 that holds the bearings 21 and 22. .. The bearings 2 1, 2 2 are, for example, radial ball bearings, each having 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. ing. The holding member 23 has a cylindrical shape, and the bearings 21 and 22 are assembled inside the holding member 23. The rotating shaft 11 and the rotor 40 are rotatably supported inside the bearings 21 and 22 in the radial direction. Bearings 2 1, 2 2 〇 2020/175333 1 1 卩(: 171-1? 2020/006903

Therefore, a pair of bearings that rotatably support the rotating shaft 11 is configured.

[0027] In each of the bearings 21 and 22, a ball 27 is held by a retainer (not shown), and the pitch between the balls is maintained in that state. Each of the bearings 21 and 22 has a sealing member at the upper and lower portions in the axial direction of the retainer, and the inside thereof is filled with a non-conductive grease (for example, a non-conductive urea-based grease). In addition, the position of the inner ring 26 is mechanically held by a spacer, and a constant pressure preload is applied so that it projects from the inside in the vertical direction.

[0028] The housing 30 has a peripheral wall 3 1 having a cylindrical shape. 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 opened 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 with a fixing tool such as a screw or rivet in a state where the circular hole 34 is made to pass through the hole 34. There is. A hollow cylindrical rotor 40 and a hollow cylindrical stator 50 are housed in the housing 30, that is, in the internal space defined by the peripheral wall 31 and the end face 32. In this embodiment, the rotating electric machine 10 is an outer rotor type, and the stator 50 is arranged inside the housing 30 in the radial direction of the cylindrical rotor 40. The rotor 40 is cantilevered on the rotating shaft 1 1 on the end face 3 2 side in the axial direction.

The rotor 40 has a hollow cylindrical magnet holder 41 and an annular magnet unit 42 provided inside the magnet holder 41 in the radial direction. The magnet holder 41 has a substantially cup shape and functions as a magnet holding member. The magnet holder 4 1 includes a cylindrical portion 4 3 having a cylindrical shape, a fixing portion (3 3 1116^) 4 4 having the same cylindrical shape and a smaller diameter than the cylindrical portion 4 3, and the cylindrical portion 4 3 and the fixing portion. It has an intermediate part 4 5 which serves as a part for connecting the part 4 4. The magnet unit 4 2 is attached to the inner peripheral surface of the cylindrical portion 4 3.

[0030] The magnet holder 41 is a cold-rolled steel plate with sufficient mechanical strength.

, Forging steel, carbon fiber reinforced plastic

Etc. 〇 2020/175333 12 boxes (：171? 2020 /006903

The rotary shaft 11 is passed through the through hole 443 of the fixed portion 44. The fixed portion 4 4 is fixed to the rotating shaft 1 1 arranged in the through hole 4 4 3. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing portion 44. The fixed portion 44 is preferably fixed to the rotary shaft 11 by spline connection using unevenness, key connection, welding, caulking, or the like. As a result, the rotor 40 rotates together with the rotary shaft 1 1.

Further, the bearings 21 and 22 of the bearing unit 20 are assembled on the outer side in the radial direction of the fixed portion 44. Since the bearing unit 20 is fixed to the end surface 32 of the housing 30 as described above, the rotating shaft 11 and the rotor 40 are rotatably supported by the housing 30. As a result, the rotor 40 is rotatable within the housing 30.

[0033] The rotor 40 is provided with the fixed portion 44 only at one of the two end portions opposed to each other in the axial direction, whereby the rotor 40 is cantilevered on the rotation shaft 1 1. It is being touched. Here, the fixed portion 44 of the rotor 40 is rotatably supported at two different axial positions by the bearings 21 and 22 of the bearing unit 20. That is, the rotor 40 is rotatably supported by the two bearings 21 and 22 spaced apart from each other in one of the two axially opposite ends of the magnet holder 41. Is supported. Therefore, even if 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 displaced to one side with respect to the axial center position of the rotor 40.

[0034] In the bearing unit 20, the bearing 22 located near the center of the rotor 40 (lower side in the figure) and the bearing 2 1 on the opposite side (upper side in the figure) are the outer ring 25 and The clearance between the inner ring 26 and the ball 27 is different, for example, the bearing 2 2 near the center of the rotor 40 has a larger clearance than the bearing 2 1 on the opposite side. Has become. In this case, on the side closer to 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 vibration and the effect of vibration will not occur. Absorbed well. Specifically, the rotor 40 〇 2020/175333 13 卩(：171? 2020/006903

By increasing the play size (gap size) in the bearing 22 located closer to the center (lower side in the figure) by preload, the vibration generated in the cantilever structure is absorbed by the play part. The preload may be a fixed position preload or a constant preload. In the case of fixed position preload, both the bearing 21 and the outer ring 25 of the bearing 22 are joined to the holding member 23 by a method such as press fitting or adhesion. Further, both the bearing 21 and the inner ring 26 of the bearing 22 are joined to the rotary shaft 11 by a method such as press fitting or adhesion. Pre-load can be generated by arranging the outer ring 25 of the bearing 21 at a position different from the inner ring 26 of the bearing 21 in the axial direction. Preloading can also be generated by disposing the outer ring 25 of the bearing 22 at a position axially different from the inner ring 26 of the bearing 22.

[0035] Further, when the constant pressure preload is adopted, the preload panel is used so that the preload is generated from the region sandwiched between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 2 2 in the axial direction. For example, place a wave washer 2 4 etc. in the same area between bearing 2 2 and bearing 2 1. Also in this case, both the bearing 21 and the inner ring 26 of the bearing 22 are joined to the rotating shaft 11 by a method such as press fitting or adhesion. The bearing 21 or the outer ring 25 of the bearing 22 is arranged with a predetermined clearance with respect to the holding member 23. With such a configuration, the paner of the preload panel acts on the outer ring 25 of the bearing 22 in a direction away from the bearing 21. Then, this force is transmitted to the rotary shaft 11 to exert a force that pushes the inner ring 26 of the bearing 21 toward the bearing 22. As a result, the axial positions of the outer ring 25 and the inner ring 26 of both the bearings 21 and 22 are displaced, and the two bearings can be preloaded in the same manner as the fixed position preload described above.

When generating the constant pressure preload, it is not always necessary to apply a paneler to the outer ring 25 of the bearing 22 as shown in FIG. For example, a Baneka may be applied to the outer ring 25 of the bearing 21. Also, place the inner ring 26 of either of the bearings 21 and 22 on the rotating shaft 11 with a predetermined clearance, and press the outer ring 25 of the bearings 21 and 22 into the holding member 23. Alternatively, the two bearings may be preloaded by joining them using a method such as bonding. 〇 2020/175333 14 卩 (：171? 2020 /006903

[0037] Further, when the inner ring 26 of the bearing 21 exerts a force so as to separate from the bearing 22, the inner ring 26 of the bearing 22 also separates from the bearing 21. Is better to use. On the contrary, when the inner ring 26 of the bearing 21 exerts a force so as to approach the bearing 22, the inner race 26 of the bearing 22 also exerts a force so as to approach the bearing 21. Better to let.

[0038] When the present rotating electrical 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 the direction of preload generation may be applied to the mechanism for generating preload, There is a possibility that the direction of gravity applied to the object to which the preload is applied may change. Therefore, when the present rotary electric machine 10 is applied to a vehicle, it is desirable to adopt a fixed position preload.

[0039] The intermediate portion 4 5 have the outer shoulder 4 9 spoon annular inner shoulder 4 9 ₃ and the annular. The outer shoulder portion 4913 is located outside the inner shoulder portion 493 in the radial direction of the intermediate portion 45. Inner shoulder 4 9 ₃ and the outer shoulder 4 9 spoon are spaced apart from each other in the axial Direction of the intermediate portion 4 5. As a result, the cylindrical portion 4 3 and the fixed portion 4 4 partially overlap each other in the radial direction of the intermediate portion 45. In other words, the cylindrical portion 4 3 projects outward in the axial direction with respect to the base end of the fixed portion 4 4 (bottom end on the lower side of the figure). In this configuration, as compared with the case where the intermediate portion 45 is provided in the shape of a flat plate without a step, the rotor 40 is supported on the rotating shaft 11 at a position near the center of gravity of the rotor 40. It is possible to achieve stable operation of the rotor 40.

[0040] According to the configuration of the intermediate portion 45 described above, the rotor 40 has a bearing unit 2 0 at a position that surrounds the fixed portion 4 4 in the radial direction and is inward of the intermediate portion 45. A bearing accommodating recess 46 for accommodating a part of it is formed in an annular shape, and at a position that surrounds the bearing accommodating recess 46 in the radial direction and is on the outer side of the intermediate part 45, a stator 5 described later is formed. A coil housing concave portion 47 for housing the coil end 54 of the stator winding 51 of 0 is formed. The accommodation recesses 46, 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 5 4 of the stator winding 5 1 overlap radially inward and outward. 〇 2020/175333 15 卩 (: 171-1? 2020 /006903

It is arranged to. As a result, the axial length of the rotary electric machine 10 can be shortened.

[0041] The intermediate portion 45 is provided so as to project radially outward from the rotary shaft 11 side. Further, a contact avoidance portion that extends in the axial direction and that avoids contact with the coil end 5 4 of the stator winding 51 of the stator 50 is provided in the intermediate portion 45. The intermediate portion 45 corresponds to the projecting portion.

[0042] The coil end 5 4 can be bent inward or outward in the radial direction to reduce the axial dimension of the coil end 5 4 and reduce the axial length of the stator 50. Is. The bending direction of the coil end 54 should be taken into consideration the assembling with the rotor 40. Assuming that the stator 50 is assembled on the inner side of the rotor 40 in the radial direction, it is preferable that the coil end 5 4 be bent inward in the radial direction on the side of the insertion end with respect to the rotor 40. The coil end on the side opposite to the coil end 54 may be bent in any direction, but a shape bent outward with a spatial allowance is preferable for manufacturing.

[0043] Further, the magnet unit 42 as a magnet portion is composed of a plurality of permanent magnets arranged radially inside the cylindrical portion 43 so that the polarities of the permanent magnets alternate along the circumferential direction. ing. As a result, 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.

[0044] The stator 50 is provided inside the rotor 40 in the radial direction. The stator 5 0 has a stator winding 5 1 formed in a substantially cylindrical (annular) winding shape, and a stator core 5 2 as a base member arranged radially inside thereof. The stator winding 51 is arranged so as to face the annular magnet unit 42 with a predetermined air gap in between. The stator winding 51 consists of multiple phase windings. Each of the phase windings is composed of a plurality of conductor wires arranged in the circumferential direction and connected to each other at a predetermined pitch. In the present embodiment, a three-phase winding wire of re-phase, V-phase and phase and a three-phase winding wire of X-phase, negative phase and phase are used. The child winding 51 is configured as a 6-phase winding.

[0045] The stator core 52 is made of laminated steel plates that are laminated with electromagnetic steel plates that are soft magnetic materials. 〇 2020/175333 16 卩(: 171-1? 2020/006903

It is formed in an annular shape and is assembled inside the stator winding 51 in the radial direction. The electromagnetic steel sheet is, for example, a silicon steel sheet obtained by adding about several percent (for example, 3%) of silicon to iron. The stator winding 5 1 corresponds to the armature winding, and the stator core 5 2 corresponds to the armature core.

[0046] The stator winding 5 1 is a portion that overlaps the stator core 5 2 in the radial direction, and is also a coil side portion 5 3 that is the radial outside of the stator core 5 2 and the axial direction. The stator core 52 has coil ends 5 4 and 5 5 projecting from one end side and the other end side, respectively. The coil side portion 5 3 faces the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction. Rotor

With stator 50 placed inside 40, coil ends on both axial sides

The coil end 54, which is the bearing unit 20 side (upper side in the figure) of 5 4 and 5 5, is housed in the coil housing recess 4 7 formed by the magnet holder 41 of the rotor 40. .. However, details of the stator 50 will be described later.

[0047] The inverter unit 60 is composed of a unit base 61 which is fixed to the housing 30 by fasteners such as bolts, and a plurality of electric components which are assembled to the unit base 61. 6 2 and. Unit base 61 is, for example, carbon fiber reinforced plastic.

It is composed by. The unit base 61 includes an end plate 63 fixed to the edge of the opening 33 of the housing 30 and a casing 64 integrally formed with the end plate 63 and extending in the axial direction. Have The end plate 63 has a circular opening 65 at the center thereof, and a casing 64 is formed so as to stand upright from the peripheral edge of the opening 65.

A stator 50 is attached to 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. casing

By mounting the stator core 52 on the outer side of the stator 64, the stator 50 and the unit base 61 are integrated. Also, since the unit base 61 is fixed to the housing 30, the stator core 52 is assembled to the casing 64. 〇 2020/175333 17 卩(: 171-1? 2020/006903

In the installed state, the stator 50 is integrated with the / \ housing 30.

The stator core 52 is preferably attached to the unit base 61 by adhesion, shrink fitting, press fitting, or the like. As a result, the positional deviation of the stator core 52 from the unit base 61 side in the circumferential direction or the axial direction is suppressed.

[0050] Further, the inside of the casing 6 4 in the radial direction is a housing space for housing the electric component 6 2. In the housing space, the electric component 6 2 is arranged so as to surround the rotating shaft 1 1. There is. The casing 64 has a role as a storage space forming unit. The electrical component 62 is configured to include a semiconductor module 66 that constitutes an inverter circuit, a control board 67, and a capacitor module 68.

The unit base 61 is provided inside the stator 50 in the radial direction, 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 rotating electric machine 10. In this motor housing, the holding member 23 is fixed to the housing 30 on one side in the axial direction across the rotor 40, and the housing 30 and the unit base 61 are on the other side. Are connected to each other. For example, in an electric vehicle or the like which is an electric vehicle, the rotating electric machine 10 is mounted on the vehicle or the like by mounting the motor housing on the vehicle or the like side.

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

[0053] In the unit base 61, the casing 64 includes an end face 7 provided on one side of the tubular portion 71 and one end thereof opposite to each other in the axial direction (end portion on the bearing unit 20 side). Has 2 and. The opposite side of the end face 7 2 among the both axial ends of the tubular portion 7 1 is entirely opened through the opening 65 of the end plate 63. A circular hole 7 3 is formed in the center of the end face 72, and the rotating shaft 11 can be passed through the hole 73. The hole 7 3 has a space between it and the outer peripheral surface of the rotating shaft 11. 〇 2020/175 333 18 卩 (: 171? 2020 /006903

A sealing material 1 71 for closing the voids is provided. The seal material 1 71 is preferably a sliding seal made of, for example, a resin material.

[0054] The tubular portion 71 of the casing 6 4 partitions between the rotor 40 and the stator 50 arranged radially outside thereof and the electric component 62 arranged radially inside thereof. It is a partition part, and the rotor 40, the stator 50, and the electrical component 62 are arranged side by side inside and outside in the radial direction with the tubular part 71 sandwiched therebetween.

[0055] Further, the electric component 62 is an electric component that constitutes an inverter circuit, and is a power running device that causes a current to flow in each of the phase windings of the stator winding 5 1 in a predetermined order to rotate the rotor 40. It has a function and a power generation function that inputs the three-phase AC current flowing in the stator windings 5 1 as the rotating shaft 11 rotates and outputs it as generated power to the outside. The electric component 62 may have only one of the power running function and the power generating function. The power generation function is a regenerative function that outputs the regenerated electric power to the outside when the rotating electric machine 10 is used as a power source for a vehicle, for example.

As a concrete configuration of the electric component 62, as shown in FIG. 4, a hollow cylindrical capacitor module 68 is provided around the rotary shaft 11 and the capacitor module 68 is provided. A plurality of semiconductor modules 66 are arranged side by side in the circumferential direction on the outer peripheral surface of the. The capacitor module 68 includes a plurality of smoothing capacitors 68 ₃ connected in parallel with each other. Specifically, the capacitor 683 is a laminated film capacitor in which a plurality of film capacitors are laminated, and the cross section has a trapezoidal shape. The capacitor module 68 is configured by arranging 12 capacitors 6 8 3 arranged side by side in a ring shape.

[0057] In the manufacturing process of the capacitor 683, for example, a long film having a predetermined width formed by laminating a plurality of films is used, and the film width direction is the trapezoidal height direction, and A capacitor element is made by cutting a long film into an isosceles trapezoidal shape so that the bottom and the bottom are alternated. And that 〇 2020/175333 19 卩(: 171-1? 2020/006903

Capacitor 6 8 3 is manufactured by attaching electrodes etc. to the capacitor element

[0058] The semiconductor module 66 has a semiconductor switching element such as 1\/1/3 and I_0, and is formed in a substantially plate shape. In the present embodiment, the rotating electric machine 10 is provided with two sets of three-phase windings, and since an inverter circuit is provided for each of the three-phase windings, a total of 12 semiconductor modules 6 6 are looped. The semiconductor module group 6 68, which is formed by arranging in parallel with each other, is provided in the electrical component 6 2.

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

The semiconductor module group 6 68 preferably has a spacer 6 9 between the semiconductor module 6 6 and the cylindrical portion 7 1 on the outer peripheral surface side, that is, in the radial direction. In this case, in the capacitor module 68, the cross-sectional shape of the cross section orthogonal to the axial direction is a regular 12-sided polygon, while the cross-sectional shape of the inner peripheral surface of the tubular portion 71 is circular, so the space is small. The inner surface of the support 69 is flat and the outer surface is curved. The spacer 69 may be integrally provided so as to be continuous in an annular shape on the radially outer side of the semiconductor module group 668. The spacer 69 is a good heat conductor, and is preferably a metal such as aluminum or a heat dissipation gel sheet. The cross-sectional shape of the inner peripheral surface of the tubular portion 71 may be the same 12-sided polygon as 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.

[0061] Further, in the present embodiment, the tubular portion 7 1 of the casing 6 4 is provided with the cooling water passage 7 4 for circulating the cooling water, and the heat generated in the semiconductor module 6 6 is It is also discharged to the cooling water flowing through the passage 74. That is, Kashin 〇 2020/175 333 20 (:171? 2020/006903

The Gu 6 4 is equipped with 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 components 62 (semiconductor module 66 and capacitor module 68). The semiconductor module 66 is arranged along the inner peripheral surface of the cylindrical portion 71, and the cooling water passage 74 is provided at a position overlapping the semiconductor module 66 inside and outside in the radial direction.

[0062] Since the stator 50 is arranged on the outer side of the tubular portion 71 and the electric component 62 is arranged on the inner side thereof, the tubular portion 71 is fixed from the outside thereof. As the heat of the determinant 50 is transferred, the heat of the electrical component 6 2 (for example, the heat of the semiconductor module 6 6) is transferred 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 rotary electric machine 10 can be efficiently released.

[0063] Furthermore, at least a part of the semiconductor modules 6 6 that form part or all of the inverter circuit that operates the rotating electric machine by energizing the stator windings 51 is installed in the casing 6 4. It is arranged in a region surrounded by a stator core 52 arranged radially outside the tubular portion 71. Desirably, one semiconductor module 66 is wholly arranged in the region surrounded by the stator core 52. Furthermore, preferably, all the semiconductor modules 66 are entirely arranged in a region surrounded by the stator core 52.

Further, at least a part of the semiconductor module 66 is arranged in a region surrounded by the cooling water passages 74. Desirably, all the semiconductor modules 6 6 are entirely arranged in a region surrounded by the yoke 1 4 1.

[0065] Further, the electrical 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 that face each other in the axial direction, that is, the first end face and the second end face. The first end face of the capacitor module 68 close to the bearing unit 20 faces the end face 72 of the casing 64, and is superposed on the end face 72 with the insulating sheet 75 sandwiched. Also, open the capacitor module 68. 〇 2020/175333 21 卩(：171? 2020/006903

The wiring module 7 6 is mounted on the second end face close to 6 5.

The wiring module 7 6 is composed of a circular plate-shaped main body 7 6 3 made of a synthetic resin material and a plurality of bus bars 7 6

The busbars 76 and 760 make electrical connection with the semiconductor module 66 and the capacitor module 68. Specifically, the semiconductor module 66 has a connecting pin 663 extending from the end face in the axial direction, and the connecting pin 663 is located outside the main body 763 in the radial direction. It is connected to the swamp. Further, the bus bar 760 extends to the side opposite to the capacitor module 68 on the outside in the radial direction of the main body portion 763, and is connected to the wiring member 79 at its tip. (See Figure 2).

As described above, the insulating sheet 75 is provided on the first end surface of the capacitor module 68 facing in the axial direction, and the wiring module 76 is provided on the second end surface of the capacitor module 68. For example, as a heat dissipation path of the capacitor module 68, a path is formed from the first end surface and the second end surface of the capacitor module 68 to the end surface 72 and the tubular portion 71. That is, a path from the first end surface to the end surface 72 and a path from the second end surface to the tubular portion 71 are formed. As a result, in the capacitor module 68, heat can be dissipated from the end surface portion other than the outer peripheral surface where the semiconductor module 66 is provided. In other words, it is possible to dissipate heat not only in the radial direction but also in the axial direction.

[0068] Further, since the condenser module 68 has a hollow cylindrical shape, and the rotary shaft 11 is arranged in the inner peripheral portion thereof with a predetermined clearance, the heat of the condenser module 68 is It can also be released from the hollow part. In this case, the rotation of the rotating shaft 11 causes a flow of air to enhance the cooling effect.

A disk-shaped control board 67 is attached to the wiring module 76.

The control board 6 7 has a printed circuit board (∘) on which a predetermined wiring pattern is formed. On the board, various control circuits and a control device corresponding to a control unit composed of a microcomputer 7 are provided. 7 has been implemented. The control board 67 is 〇 2020/175333 22 卩 (：171? 2020 /006903

It is fixed to the wiring module 7 6 by a fixing tool such as a connector. Control board 6 7 at its center, and a揷通hole 6 7 ₃ for揷通the rotary shaft 1 1.

The wiring module 76 has a first surface and a second surface that face each other in the axial direction, that is, face each other in the thickness direction. The first side faces the capacitor module 68. The wiring module 76 is provided with a control board 67 on its second surface. The bus bar 760 of the wiring module 76 extends from one side of 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 760. For example, a part of the outer edge portion of the circular control board 67 may be cut out.

[0071] As mentioned above, the electrical components 6

2 is housed, and the housing 30, the rotor 40, and the stator 50 are provided in a layered form on the outer side of the housing 2, so that the electromagnetic noise generated in the inverter circuit can be suitably shielded. There is. That is, in the inverter circuit, switching control is performed in each semiconductor module 66 using \^/1\/1 control with a predetermined carrier frequency, and electromagnetic noise may occur due to the switching control. The electromagnetic noise can be suitably shielded by the housing 30 on the radial outside of the electric component 62, the rotor 40, the stator 50, and the like.

Further, by disposing at least a part of the semiconductor module 6 6 in the region surrounded by the stator core 52 arranged radially outside the tubular portion 71 of the casing 6 4, Compared with the configuration in which the semiconductor module 6 6 and the stator winding 5 1 are arranged without the stator core 5 2 interposed, even if magnetic flux is generated from the semiconductor module 6 6, the stator winding 5 1 Hard to affect. Further, even if the magnetic flux is generated from the stator winding 51, the semiconductor module 66 is not easily affected. It is more effective if the entire semiconductor module 6 6 is arranged in the area surrounded by the stator core 52 arranged radially outside the tubular portion 71 of the casing 6 4. .. Moreover, at least a part of the semiconductor module 66 is connected to the cooling water passage. 〇 2020/175333 23 卩 (：171? 2020 /006903

In the case of being surrounded by 7 4, it is possible to obtain the effect that heat generated from the stator winding 5 1 and the magnet unit 4 2 does not easily reach the semiconductor module 6 6.

[0073] In the vicinity of the end plate 63 in the tubular portion 71, the stator 5 on the outer side is provided.

A through hole 7 8 is formed to allow a wiring member 7 9 (see FIG. 2) to electrically connect 0 and the inner electric component 62 to each other. As shown in Fig. 2, the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 760 of the wiring module 7 6 by crimping, welding, or the like. The wiring member 79 is, for example, /<sub bar, and its joint surface is preferably flat and crushed. The through holes 78 are preferably provided at one power point or at a plurality of points, and in the present embodiment, the through holes 78 are provided at two power points. In the configuration in which the through holes 78 are provided at the two power points, it is possible to easily connect the winding terminals extending from the two sets of three-phase windings to the wiring members 79, respectively, and it is possible to perform multi-phase wiring. It is suitable.

As described above, in the housing 30 as shown in FIG. 4, the rotor 40 and the stator 50 are provided in order from the outside in the radial direction, and the rotor unit 0 and the stator unit 50 are arranged in the inside in the radial direction. 60 is provided. Here, when the radius of the inner peripheral surface of the housing 30 is defined as, the rotor 40 and the stator 50 are arranged radially outward from the distance X 0 .705 from the center of rotation of the rotor 40. Are arranged. In this case, the region that is radially inward from the inner peripheral surface of the stator 50 on the radially inner side of the rotor 40 and the stator 50 (that is, the inner peripheral surface of the stator core 52) is the first region X. 1, the area between the inner peripheral surface of the stator 50 and the housing 30 in the radial direction is the second area X 2, and the cross-sectional area of the first area X 1 is the cross section of the second area X 2. The structure is larger than the surface area. In the radial direction, the volume of the first region X 1 is larger than the volume of the second region X 2 when viewed in the range where the magnet unit 42 of the rotor 40 and the stator winding 51 overlap. Has become.

[0075] If the rotor 40 and the stator 50 are magnetic circuit component assemblies, the first region X1 inside the housing 30 that is radially inward from the inner peripheral surface of the magnetic circuit component assembly. Is magnetic in the radial direction The volume is larger than the second region X 2 between the inner peripheral surface of the circuit component assembly and the housing 30.

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

[0077] Generally, as a structure of a stator in a rotary electric machine, a plurality of slots are provided in a circumferential direction on a stator core made of laminated steel plates and having an annular shape, and the stator winding is wound in the slot. Things are known. Specifically, the stator core has a plurality of teeth extending from the yoke in the radial direction at predetermined intervals, and a slot is formed between the teeth that are adjacent to each other in the circumferential direction. In the slot, for example, a plurality of layers of conductor wires are accommodated in the radial direction, and the conductor wires form a stator winding.

[0078] However, in the above-described stator structure, when the stator winding is energized, as the magnetomotive force of the stator winding increases, magnetic saturation occurs in the teeth portion of the stator core, which causes As a result, the torque density of the rotating electric machine may be limited. In other words, in the stator core, it is considered that magnetic saturation occurs because the rotating magnetic flux generated by the energization of the stator windings concentrates on the teeth.

[0079] In general, as a configuration of a PM (Interior Permanent Magnet) rotor in a rotating electric machine, a permanent magnet is arranged on the d axis in the d _ q coordinate system, and a rotor core is arranged on the q axis. It has been known. In this case, the stator winding near the d-axis is excited, and the exciting 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 of the rotor.

[0080] Fig. 7 shows the amperage [AT] and torque density showing the magnetomotive force of the stator winding.

It is a torque diagram which shows the relationship with [N m /L ]. The broken line shows the characteristics of a general PM-type overnight rotating electrical machine. As shown in Fig. 7, in a general rotating electrical machine, increasing the magnetomotive force in the stator causes magnetic saturation at two force points, the tooth portion between the slots and the q-axis core portion. This limits the increase in torque. As described above, in the general electric rotating machine, the ampere-turn design value is limited by A 1. Therefore, in the present embodiment, in order to eliminate the limitation caused by magnetic saturation, the rotating electric machine 10 is provided with the following configuration. In other words, as the first measure, a slotless structure is adopted in the stator 50 to eliminate magnetic saturation that occurs in the teeth of the stator core in the stator, and it is generated in the q-axis core part of the PM mouth. The SPM (Surface Permanent Magnet) rotor is used to eliminate magnetic saturation. According to the first device, the above two force points where magnetic saturation occurs can be eliminated, but the torque may be reduced in the low current region (see the chain line in Fig. 7). Therefore, as the second device,

In order to recover the torque reduction by increasing the magnetic flux of the SPM mouth overnight, we are searching for a polar anisotropic structure in which the magnet magnetic path is lengthened in the magnet unit 42 of the rotor 40 to increase the magnetic force. ..

[0082] As a third device, a flat conductor structure in which the radial thickness of the stator 5 0 of the conductor is reduced in the coil side portion 5 3 of the stator winding 5 1 is adopted to recover the torque reduction. I am trying. Here, it is conceivable that a larger eddy current will be generated in the stator winding 5 1 facing the magnet unit 4 2 due to the above-mentioned polar anisotropic structure with increased magnetic force. However, according to the third device, since the flat conductor structure is thin in the radial direction, it is possible to suppress the generation of radial eddy currents in the stator winding 51. Thus, according to each of the first to third configurations, as shown by the solid line in FIG. 7, while a magnet with a high magnetic force is adopted and a significant improvement in torque characteristics is expected, a magnet with a high magnetic force is used. Concerns about the generation of large eddy currents that can occur can be alleviated.

Furthermore, as a fourth measure, a magnet unit having a magnetic flux density distribution close to a sine wave is used by utilizing a polar anisotropic structure. According to this, the sine wave matching rate can be increased by the pulse control described later to increase the torque, and eddy current loss (copper loss due to eddy current: eddy cur rent loss) can be further suppressed.

The sine wave matching rate will be described below. The sine wave matching rate is the measured waveform and period of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe. 〇 2020/175 333 26 卩 (: 171? 2020 /006903

It can be obtained by comparison with a sine wave with the same peak value. The sine wave matching rate is the ratio of the amplitude of the primary waveform, which is the fundamental wave of the rotating electrical machine, to the amplitude of the measured waveform, that is, the amplitude of the fundamental wave plus other harmonic components. Sine wave As the matching rate increases, the surface magnetic flux density distribution waveform approaches a sine wave shape. When a primary sinusoidal current is supplied from an inverter to a rotating electrical machine equipped with a magnet with an improved sinusoidal matching factor, the waveform of the surface magnetic flux density distribution of the magnet should be close to the sinusoidal shape. Combined with, a large torque can be generated. The surface magnetic flux density distribution may be estimated by a method other than actual measurement, for example, electromagnetic field analysis using Maxwell's equation.

[0085] As a fifth device, the stator winding 51 has a strand conductor structure in which a plurality of strands are gathered together and bundled. According to this, since the wires are connected in parallel, a large current can flow and the generation of eddy currents generated by the wires spread in the circumferential direction of the stator 50 in the flat wire structure is prevented from occurring. Since the area is reduced, it can be more effectively suppressed than the reduction in the radial direction by the third measure. By constructing a plurality of strands twisted together, it is possible to cancel the eddy current with respect to the magnetic flux generated from the conductor by the right-handed screw law in the direction of current flow. ..

[0086] As described above, by further adding the fourth device and the fifth device, the eddy current loss due to the high magnetic force is suppressed while the magnet with high magnetic force, which is the second device, is adopted. However, torque can be increased.

The slotless structure of the stator 50, the flat conductor structure of the stator winding 51, and the polar anisotropic structure of the magnet unit 42 described above will be individually described below. Here, first, the slotless structure in the stator 50 and the flat conductor structure in the stator winding 5 1 will be described. 8 is a cross-sectional view of the rotor 40 and the stator 50, and FIG. 9 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG. FIG. 10 is a sectional view showing a cross section of the stator 50 along the line X--X in FIG. 11, and FIG. 11 is a sectional view showing a longitudinal section of the stator 50. Further, FIG. 12 is a perspective view of the stator winding line 51. In addition, in FIG. 8 and FIG. The magnetization direction of the magnet in the magnet unit 42 is indicated by the arrow.

As shown in FIGS. 8 to 11, the stator core 52 has a cylindrical shape in which a plurality of electromagnetic steel plates are laminated in the axial direction and has a predetermined thickness in the radial direction. The stator winding 5 1 is mounted on the radially outer side of the rotor 40 side. In the stator core 52, the outer peripheral surface on the rotor 40 side is a conductor wire installation portion (conductor area). The outer peripheral surface of the stator core 52 has a curved surface without unevenness, and a plurality of conductor wire groups 81 are arranged at predetermined intervals in the circumferential direction on the outer peripheral surface. 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, a tooth (that is, an iron core) made of a soft magnetic material is not provided between each two adjacent conductor groups 81 in the circumferential direction (that is, a slotless structure). In the present embodiment, the resin material of the sealing member 57 is inserted into the gap 56 of each of the conductor wire groups 81. That is, in the stator 50, the inter-conductor member provided between each conductor group 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 5 7, the conductor wire groups 8 1 are arranged at predetermined intervals in the circumferential direction on the outer side in the radial direction of the stator core 5 2 with a gap 5 6 which is a region between the conductors. The slotted stator 50 is constructed. In other words, each conductor group 8 1 is composed of two conductors 8 2 as described later, and only non-magnetic material is provided between each two conductor groups 8 1 adjacent to each other in the circumferential direction of the stator 50. Are occupied by. The non-magnetic material includes a non-magnetic gas such as air and a non-magnetic liquid in addition to the sealing member 57. In the following, the sealing member 57 is also referred to as a conductor-to-conductor member.

[0089] The configuration in which teeth are provided between the conductor wire 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. Thus, it can be said that a part of the magnetic circuit, that is, the magnet magnetic path is formed between the conductor wire groups 81. In this respect, the configuration in which the teeth are not provided between the conductor wire groups 81 means that the above magnetic circuit is not formed. 〇 2020/175333 28 卩 (：171? 2020 /006903

It is said that there is.

[0090] As shown in Fig. 10, the stator winding (that is, armature winding) 5 1 has a predetermined thickness 2 (hereinafter also referred to as the first dimension) and a width \^/2 (hereinafter, the first dimension). (Also referred to as two dimensions). The thickness 2 is the shortest distance between the outer surface and the inner surface that face each other in the radial direction of the stator winding 51. The width 2 is a stator that functions as one of the polyphases of the stator winding line 51 (three phases in the embodiment: three phases II phase, V phase and three phases or X phase, three phases of negative phase and phase). This is the circumferential length of the stator winding 5 1 that is a part of the winding 51. Specifically, in FIG. 10, when two conductor groups 8 1 adjacent to each other in the circumferential direction function as one of the three phases, for example, II phase, the two conductor groups 8 1 in the circumferential direction are The width is 2 from end to end. And the thickness 2 is smaller than the width \^ 2.

[0091] The thickness D2 is preferably smaller than the total width dimension of the two conductor wire groups 8 1 existing within the width 2. If the cross-sectional shape of the stator winding 5 1 (more specifically, the conductor 8 2) is a perfect circle, an ellipse, or a polygon, the conductor 8 2 along the radial direction of the stator 50 is Of the cross-sections, the maximum radial length of the stator 50 in the cross-section may be 12 and the maximum circumferential length of the stator 50 in the cross-section may be 11.

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 (molding material). That is, the stator winding 51 and the stator core 52 are molded by the molding material. The resin can be regarded as a non-magnetic material or an equivalent material of the non-magnetic material as 3=0.

As seen in the cross section of FIG. 10, the sealing member 57 is provided between the conductor wire groups 81, that is, the gaps 56 are filled with the synthetic resin material. As a result, an insulating member is interposed between each conductor wire group 81. That is, the sealing member 57 functions as an insulating member in the gap 56. The sealing member 5 7 is located outside the stator core 52 in a range including all the conductor wire groups 81, that is, the radial thickness dimension is smaller than the radial thickness dimension of each conductor wire group 81. Range of increase 〇 2020/175 333 29 卩 (: 171? 2020 /006903

It is provided in.

[0094] Also, when viewed in the vertical cross section in FIG. 11, the sealing member 57 is provided in a range including the evening portion 84 of the stator winding 51. Inside the stator winding 51, in the radial direction, a sealing member 57 is provided in a range including at least a part of the axially opposed end faces of the stator core 52. In this case, the stator winding 51 is resin-sealed at the end of the phase winding of each phase, that is, almost the entire terminal except the connection terminal with the inverter circuit.

[0095] In the configuration in which the sealing member 5 7 is provided in a range including the end surface of the stator core 52, the laminated steel plate of the stator core 52 is pressed axially inward by the sealing member 5 7. You can Thus, the sealing member 57 can be used to maintain the stacked state of the steel plates. In this embodiment, the inner peripheral surface of the stator core 52 is not resin-sealed, but instead of this, the entire stator core 52 including the inner peripheral surface of the stator core 52 is made of resin. The structure may be sealed.

[0096] When the rotary electric machine 10 is used as a vehicle power source, the sealing member 57 is made of highly heat-resistant fluororesin, epoxy resin,

Resin, Minami Resin,! _○ It is preferable to be composed of a resin, a silicone resin, a resin, an I resin, or the like. Considering the coefficient of linear expansion from the viewpoint of suppressing cracking due to the difference in expansion, it is desirable that the material is the same as the outer coating of the conductor wire of the stator winding 51. That is, silicone resins having a coefficient of linear expansion that is generally at least twice that of other resins are desirably excluded. For electric products that do not have an engine that uses combustion, such as electric vehicles, 〇 resin, phenol resin, and ¾ resin that have a heat resistance of approximately 180° 〇 are also candidates. This does not apply to areas where the ambient temperature of the rotating electrical machine can be considered to be less than 100 ^° C.

[0097] 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 amount of magnetic flux at the stator is limited depending on the saturation magnetic flux density at the teeth, but the stator core does not have teeth. In this case, the maximum amount of magnetic flux at the stator is not limited. Therefore, it is advantageous in increasing the current passing through the stator winding 51 to increase the torque of the rotating electric machine 100. It is composed.

In the present embodiment, the stator 50 has a structure without the teeth (slotless structure), so that the inductance of the stator 50 is reduced. Specifically, the stator of the present embodiment has an inductance of, for example, about 1 mH in a stator of a general rotating electric machine in which a conductor is housed in each slot partitioned by a plurality of teeth. At 50, the inductance is reduced to about 5 to 60 MH. In this embodiment, the mechanical time constant T m can be reduced by reducing the inductance of the stator 50 even in the rotating electric machine 10 having the outer rotor structure. In other words, it is possible to reduce the mechanical time constant T m while increasing the torque. When the inertia is J, the inductance is L, the torque constant is K t, and the back electromotive force constant is K e, the mechanical time constant T m is calculated by the following equation.

T m = (J X L )/( K t X K e)

In this case, it can be confirmed that the mechanical time constant T m is reduced by reducing the inductance L.

[0099] Each conductor wire group 8 1 on the outer side in the radial direction of the stator core 5 2 is configured by arranging a plurality of conductor wires 8 2 having a flat rectangular cross-section in the radial direction of the stator core 5 2. There is. The conductors 82 are arranged in a direction of “diameter dimension<circumferential dimension” in the cross section. As a result, each conductor wire group 81 is thinned in the radial direction. In addition to reducing the wall thickness in the radial direction, the conductor area extends flat to the area where the teeth were previously, resulting in a flat conductor wire area structure. As a result, the increase in the amount of heat generated by the conductor, which is concerned that the cross-sectional area becomes smaller due to the thinner wall, is suppressed by flattening in the circumferential direction to increase the conductor cross-sectional area. Even with a configuration in which multiple conductors are arranged in the circumferential direction and are connected in parallel, the conductor cross-sectional area is reduced by the amount of the conductor coating, but the same effect can be obtained. In the following, each of the conductive wire groups 81 and each of the conductive wires 82 are also referred to as a conductive member.

[0100] Since there is no slot, the stator winding 51 in the present embodiment has 〇 2020/175333 31 卩 (: 171? 2020 /006903

The conductor area occupied by the stator winding 51 in one round in the circumferential direction can be designed to be larger than the conductor unoccupied area where the stator winding 51 does not exist. It should be noted that in the conventional vehicular rotating electrical machine, the conductor region/conductor non-occupying region in one circumferential direction of the stator winding was naturally 1 or less. On the other hand, in the present embodiment, each conductor wire group 81 is provided such that the conductor area is equal to the conductor non-occupancy area or the conductor area is larger than the conductor non-occupancy area. Here, as shown in FIG. 10, the conductor region in which the conductor 8 2 (that is, the straight line portion 8 3 described later) is arranged in the circumferential direction is defined as the conductor region between the adjacent conductors 8 2. Then, the conductor area is larger than the inter-conductor area in the circumferential direction.

[0101] As a configuration of the conductor wire group 81 in the stator winding 51, the radial thickness dimension of the conductor wire group 81 is smaller than the circumferential width dimension for one phase in one magnetic pole. It has become. That is, in a configuration in which the conductor group 8 1 is composed of two layers of conductors 8 2 in the radial direction and two conductor groups 8 1 are provided in the circumferential direction for each phase in one magnetic pole, the radial direction of each conductor 8 2 When the thickness of the wire is 0, and the width of each conductor 82 in the circumferential direction is, it is configured to be "0 2 <\^0 2". As another configuration, in a configuration in which the conductor group 8 1 is composed of two layers of conductors 8 2 and one conductor group 8 1 is provided in one magnetic pole in the circumferential direction for each phase, \N c _i The conductor wire portions (conductor wire group 8 1) arranged at a predetermined interval in the circumferential direction in the stator winding 5 1 have a thickness in the radial direction. The dimension is smaller than the circumferential width dimension of one phase in one magnetic pole.

[0102] In other words, for each conductor 8 2 one by one, the radial thickness dimension is exactly the circumferential width dimension.

It should be smaller than. Furthermore, the radial thickness dimension of the conductor wire group 81 consisting of two layers of conductor wires 8 2 in the radial direction (2 x 0), that is, the radial thickness dimension of the conductor wire group 8 1 (2 x 0) is Circumferential width dimension

It should be smaller than.

[0103] The torque of the rotating electric machine 10 is approximately inversely proportional to the radial thickness of the stator core 52 of the conductor wire group 81. At this point, the outer side of the stator core 5 2 in the radial direction of the conductor group 8 1 〇 2020/175333 32 卩 (：171? 2020 /006903

The reduced thickness makes it an advantageous structure for increasing the torque of the rotating electrical machine 10. The reason is that the magnetic resistance can be lowered by reducing the distance from the magnet unit 42 of the rotor 40 to the stator core 52 (that is, the distance of the part without iron). According to this, the interlinkage magnetic flux of the stator core 52 by the permanent magnet can be increased, and the torque can be increased.

[0104] Further, by reducing the thickness of the conductor wire group 81, even if the magnetic flux leaks from the conductor wire group 81, it is easy to be collected by the stator core 52, and the magnetic flux is effectively used for improving the torque. It is possible to suppress leakage to the outside without being used. That is, it is possible to suppress a decrease in magnetic force due to magnetic flux leakage, increase the interlinkage magnetic flux of the stator core 52 by the permanent magnet, and increase the torque.

Insulation is ensured between the conductors 8 2 that overlap each other in the radial direction, and between the conductors 8 2 and the stator core 52, which are composed of covered conductors that are covered by two swirls. The insulating coating 82 is composed of a wire 8 6 which will be described later if the wire 8 6 is a self-bonding coated wire, or an insulating member stacked separately from the coating of the wire 8 6. It should be noted that, except for the exposed portion for connection, each phase wire composed of the conducting wire 8 2 is kept insulating by the insulating coating 8 2. The exposed part is, for example, the input/output terminal part or the neutral point part in the case of star connection. In the conductor wire group 81, the resin wires and the self-bonding covered wire are used to mutually bond the conductor wires 82 adjacent to each other in the radial direction. This suppresses the dielectric breakdown, vibration, and sound caused by the rubbing between the conductors 82.

[0106] In this embodiment, the conductor 8 2 ₃ is configured as a plurality of wires 1 1 ^) 8 6 aggregates. Specifically, as shown in FIG. 1 3, the conductor 8 2 ₃ is formed in twisted shape by twisting a plurality of wires 8 6. Further, as shown in FIG. 14, the filaments 8 6 are configured as a composite body in which thin fibrous conductive materials 87 are bundled. For example, the strand 86 is a composite of 0 1 \ 1 (strength carbon nanotube) fiber,

〇 !\1 As a fiber, boron-containing fine particles in which at least part of carbon is replaced with boron 〇 2020/175333 33 卩 (：171? 2020 /006903

Fibers including fine fibers are used. As the carbon-based fine fiber, vapor grown carbon fiber (○○) or the like can be used in addition to the 0\1 \fiber, but it is preferable to use the \0 fiber. The surface of the wire 86 is covered with a polymer insulating layer such as enamel. Further, it is preferable that the surface of the wire 86 is covered with a so-called enamel coating, which is composed of a polyimide coating or an amidimide coating.

[0107] Conductor 82 forms an n-phase winding in stator winding 5 1. And conductor

8 2 (ie conductor 8 2

The individual wires 86 of each are adjacent to each other in contact with each other. The conducting wire 82 has a part where the winding conductor is formed by twisting a plurality of strands 8 6 at one or more positions in the phase, and the resistance value between the twisted strands 8 6 is It is a wire aggregate that is larger than the resistance value of the wire 8 6 itself. In other words, each two adjacent strands 8 6 have a first electrical resistivity in their adjacent direction, and each strand 8 6 has a second electrical resistivity in its longitudinal direction, The 1st electrical resistivity is larger than the 2nd electrical resistivity. Note that the conductor wire 8 2 may be formed of a plurality of wire wires 8 6 and may be a wire wire assembly that covers the plurality of wire wires 8 6 with an insulating member having an extremely high first electrical resistivity. .. The conductor 8 2 ₃ conductors 8 2 is constituted by a plurality of wires 8 6 twisted.

[0108] In the above conductor 8 2 _3, a plurality of wires 8 6 are configured with twisted, generation of eddy current in the wires 8 6 is suppressed, the eddy currents in the conductor 8 2 3 It can be reduced. Further, since each of the strands 86 is twisted, a part where the magnetic field application directions are opposite to each other is generated in one strand 86, and the counter electromotive voltage is offset. Therefore, it is possible to reduce the eddy current. In particular, by constructing the wires 8 6 from the fibrous conductive material 87, it is possible to make the wires thinner and to significantly increase the number of twists, and it is possible to more appropriately reduce the eddy current. it can.

[0109] Note that the method of insulating the wires 8 6 from each other here is not limited to the polymer insulating film described above, and a method of making it difficult for a current to flow between the twisted wires 8 6 by utilizing contact resistance. 〇 2020/175333 34 卩 (: 171? 2020 /006903

May be That is, if the resistance value between the twisted wires 8 6 is larger than the resistance value of the wires 8 6 themselves, the above-mentioned effect will be caused by the potential difference caused by the difference in resistance value. Can be obtained. For example, by using the manufacturing equipment that creates the wires 86 and the manufacturing equipment that creates the stators 50 (armatures) of the rotating electric machine 10 as separate non-continuous equipment, the movement time, work interval, etc. This is preferable since the wire 86 is oxidized and the contact resistance can be increased.

[0110] As described above, the conductive wire 82 has a flat rectangular cross section and is arranged in a line in the radial direction. For example, the self-bonding coating including the fusion layer and the insulating layer is provided. The shape is maintained by fusing a plurality of wires covered with wires 86 in a burning state and fusing the fusing layers together. In addition, it is also possible to form a wire having no fusion layer or a self-fusion-bonded wire in a twisted state and fixing it to a desired shape with a synthetic resin or the like. If the thickness of the insulating coating 82 in the conductor 8 2 is set to, for example, 80 to 100, and the thickness is thicker than the film thickness (5 to 40) of the commonly used conductor, it is fixed to the conductor 8 2. Even if no insulating paper or the like is interposed between the child core 52 and the child core 52, the insulation between them can be ensured.

[0111] Further, it is desirable that the insulating coating 82 has a higher insulating performance than the insulating layer of the wire 86 and is configured to be able to insulate between the phases. For example, when the thickness of the polymer insulating layer of the wire 8 6 is set to about 5, for example, the thickness of the insulating coating 8 2 of the conductor 8 2 is

It is desirable to be able to suitably perform the insulation between the phases.

[0112] Further, the conductor wire 82 may have a structure in which a plurality of element wires 86 are bundled without being twisted. In other words, the conducting wire 8 2 has a configuration in which a plurality of strands 8 6 are twisted in its entire length, a configuration in which a plurality of strands 8 6 are twisted in a part of its entire length, and a plurality of strands 8 6 in its entire length. It may be either of the configurations in which the bunches are bundled without being twisted. In summary, each conductor wire 8 2 constituting the conductor wire portion is composed of a plurality of wires 8 6 bundled together, and the resistance value between the bundled wires is larger than the resistance value of the wire wire 8 6 itself. It is an aggregate.

[01 13] The conductors 8 2 are arranged in a predetermined arrangement pattern in the circumferential direction of the stator winding 5 1. 〇 2020/175333 35 (:171? 2020/006903

Thus, the phase windings of each phase are formed as the stator windings 51. As shown in Fig. 12, in the stator winding 51, the coil side portion 5 3 is formed by the straight portion 8 3 of each conductor 8 2 that extends linearly in the axial direction, and the coil side portion 5 3 is formed in the axial direction. Coil ends 5 4 and 5 5 are formed by the evening portion 8 4 projecting outward from both sides. Each of the conductors 8 2 is configured as a series of corrugated conductors by alternately repeating straight portions 8 3 and turn portions 8 4. The straight line portion 8 3 is arranged at a position that faces the magnet unit 4 2 in the radial direction, and is a straight line of the same phase that is arranged at a predetermined interval at a position on the outer side in the axial direction of the magnet unit 4 2. Sections 8 3 are connected to each other by evening sections 8 4. The straight part 83 corresponds to the "magnet facing part".

[0114] In the present embodiment, the stator winding 51 is formed by distributed winding in an annular shape. In this case, in the coil side section 53, straight sections 8 3 are arranged in the circumferential direction at an interval corresponding to one pole pair of the magnet unit 4 2 for each phase, and in the coil ends 5 4, 5 5 each phase is arranged for each phase. The respective straight line portions 8 3 are connected to each other by a turn portion 8 4 formed in a substantially V shape. The respective straight line portions 83 corresponding to one pole pair have current directions opposite to each other. In addition, one coil end 5 4 and the other coil end 55 have different combinations of the pair of straight line portions 8 3 connected by the evening portion 8 4, and the coil ends 5 4 and 5 5 By repeating the connection at 5 in the circumferential direction, the stator winding 51 is formed in a substantially cylindrical shape.

[0115] More specifically, the stator winding 5 1 constitutes a winding for each phase using two pairs of conductors 8 2 for each phase, and one of the stator windings 5 1 3 phase line (II phase,

The V phase and phase) and the other three-phase winding (X phase, negative phase, 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 5 1 is 3 (6 in the practical example) and the number per phase of the conductor 8 2 is 2,

Individual conductors 8 2 will be formed. In this embodiment, the number of phases is 6, the number is 4, and the rotating electrical machine has 8 pole pairs (16 poles). 〇 2020/175 333 36 卩 (: 171? 2020 /006903

, 6X4X8= 1 92 conductors 82 are arranged circumferentially around the stator core 52.

[0116] In the stator winding 51 shown in Fig. 12, in the coil side portion 53, the linear portions 83 are overlapped in two layers adjacent to each other in the radial direction, and at the coil ends 5 4 and 55, the diameter is reduced. From each straight line portion 83 that overlaps in the direction, a dun portion 84 extends in the circumferential direction in the directions opposite to each other in the circumferential direction. That is, in the conductor wires 82 adjacent to each other in the radial direction, the directions of the turn portions 84 are opposite to each other except for the end portion of the stator winding 51.

[0117] 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 corrugation are provided in a plurality of layers (for example, two layers) that are radially adjacent to each other. Figure 15 ( ₃ ) and Figure 15 (deposit) show the form of each conductor 82 in the n-th layer, and Figure 15 (a) shows the side view of the stator winding 51. The shape of the conducting wire 82 is shown in Fig. 15(b), and the shape of the conducting wire 82 as seen from one side in the axial direction of the stator winding 51 is shown. In addition, in FIG. 15 (3) and FIG. 15 (匕), the positions where the conductor wire group 81 is arranged are shown as ports 1, 02, 03, respectively. Further, for convenience of explanation, only three conductors 82 are shown, which are referred to as a first conductor 82_8, a second conductor 82_mi, and a third conductor 82_○.

[0118] In each of the conductors 82_8 to 82_○, the straight line portions 83 are arranged at the position of the nth layer, that is, at the same position in the radial direction, and are separated by 6 positions (3X01 pairs) in the circumferential direction. The straight portions 83 are connected to each other by the evening portion 84. In other words, each of the conductors 82_8 to 82_〇 has seven straight lines that are arranged adjacent to each other in the circumferential direction of the stator winding 5 1 on the same circle centered on the axis of the rotor 40. The two ends of section 83 are connected to each other by one turn section 84. For example, in the first conducting wire 828, a pair of straight line portions 83 are arranged at 01 and 07, respectively, and the pair of straight line portions 83 are connected by the inverted V-shaped turn portion 84. In addition, the other conductors 82_M and 82_○ are arranged in the same n-th layer by shifting the position in the circumferential direction one by one. in this case, 〇 2020/175333 37 卩 (：171? 2020 /006903

Since all the conductors 82_8 to 82_○ are arranged in the same layer, it is considered that the turn portions 84 interfere with each other. Therefore, in the present embodiment, an interference avoiding portion, which is offset in the radial direction, is formed in the evening portion 84 of each of the conducting wires 828 to 82_O.

[0119] Specifically, the evening part 84 of each conducting wire 82_8~82_〇 has the same circle (

(One circle) One inclined portion 843 that is a portion that extends in the circumferential direction on the upper side and one side that shifts from the inclined portion 843 radially inward of the same circle (upper side in Fig. 15 (b)) and separates. Has a crest 84 that reaches the circle (second circle), an inclined portion 84 that extends in the circumferential direction on the second circle, and a return portion 84 that returns from the first circle to the second circle. .. The apex 84, the inclined part 84 and the return part 84 correspond to the interference avoidance part. The inclined portion 840 may be configured to shift radially outward with respect to the inclined portion 843.

[0120] That is, the turn portions 84 of each lead 82_ eight-82_〇 are on both sides of the top portion 84 is a central position in the circumferential direction, whereas the inclined portion 84 ₃ of the side and the other side of the inclined slope portion 84 〇 and each of these slopes 84

84 〇 radial position

(The position in the front-back direction of the paper in Fig. 15 (3) and the position in the vertical direction in Fig. 15 (13)) are different from each other. For example, the evening part 84 of the first conductor 82_8 extends along the circumferential direction starting from the 01 position of the layer and extends radially (for example, radially inward) at the top part 84, which is the center position in the circumferential direction. After bending, it bends again in the circumferential direction to extend in the circumferential direction again, and then bends again in the radial direction (for example, the radial outer side) at the return portion 84, so that the end position of the 1! It is configured to reach 07 position.

[0121] According to the above configuration, the conductive wires 82_ eight-82_〇, one of each inclined portion 84 _3, from the top of the first conductor 82 _ eight ® second conductor 82 _ Snake ® third conductor 82 0 The conductors 82_8 to 82_〇 are swapped up and down at the top 84, and the other slanted portion 84〇 is the third conductor 82_〇® second conductor 82 The structure is such that 1 conductor 828 is lined up and down. Therefore, each of the conductors 828 to 82 can be arranged in the circumferential direction without interfering with each other. 〇 2020/175333 38 卩 (：171? 2020 /006903

It has become.

[0122] Here, in a configuration in which a plurality of conductors 8 2 are radially overlapped to form a conductor group 8 1, a turn portion connected to a radially inner straight portion 8 3 of the plurality of straight portions 8 3 8 4 and the turn portion 8 4 connected to the linear portion 8 3 on the outer side in the radial direction are preferably arranged at a distance from each other in the radial direction. In addition, when the conductors 8 2 of multiple layers are bent to the same side in the radial direction at the end of the evening portion 8 4, that is, near the boundary with the straight portion 8 3, the conductors 8 2 of the adjacent layers are It is advisable not to damage the insulation due to interference between them.

[0123] For example, in Fig. 15 (3) and Fig. 15 (slung), 07 to 09, the radial overlapping conductors 8 2 are bent in the radial direction at the return section 8 4 of the turn section 8 4 respectively. To be In this case, as shown in FIG. 16, it is preferable that the radius of curvature of the bent portion be different between the conductor wire 8 2 of the first layer and the conductor wire 8 2 of the +1st layer. Specifically, the radius of curvature 1 of the conductor wire 8 2 on the radially inner side (the 0th layer) is made smaller than the radius of curvature 2 of the conductor wire 8 2 on the radially outer side (n + 1st layer).

[0124] Further, it is preferable that the conducting wire 82 of the first layer and the conducting wire 82 of the +1st layer have different radial shift amounts. Specifically, the shift amount 3 1 of the conductor wire 8 2 on the radially inner side (11th layer) is made larger than the shift amount 3 2 of the conductor wire 8 2 on the radially outer side (n + 1st layer).

[0125] With the above configuration, mutual interference between the conductors 8 2 can be preferably avoided even when the conductors 8 2 overlapping in the radial direction are bent in the same direction. As a result, good insulation can be obtained.

[0126] Next, the structure of the magnet unit 42 in the rotor 40 will be described. In the present embodiment, the magnet unit 42 is made of a permanent magnet, and the residual magnetic flux density is “=1.0 [c], intrinsic coercive force 1 ^to 10 ”=400 [1<8/〇1] or more. It is assumed that In short, the permanent magnet used in the present embodiment is a sintered magnet obtained by sintering a granular magnetic material and molding and solidifying it, and the “individual coercive force 1 ^to 10 on the 1 ^to 1 curve” is 400 [1<8/○1] or more and the residual magnetic flux density "" is 1.0 [c] or more. 5 0 0 0 to 1 0 0 0 0 [8 c] is applied by interphase excitation, 1 Pole pair 〇 2020/175 333 39 卩 (: 171? 2020 /006903

In other words, if you use a permanent magnet with a magnetic length of 1\1 pole and 3 poles, in other words, in the path of the magnetic flux between the 1\1 pole and 3 poles, the length passing through the magnet is 25 [] ,

"

= 10000 [eight], which indicates that demagnetization is not performed.

[0127] In other words, in the magnet unit 42, when the saturation magnetic flux density "3 is 1.2 [c] or more and the crystal grain size is 10 [] or less and the orientation ratio is <<,

0 [D] It is above.

[0128] The following supplements the magnet unit 42. Magnet unit 42 (magnet) is 2. 15 [Ding]

2 [Ding] is a feature. In other words, the magnets used in the magnet unit 42 include do 611 _||\1, 2 do 6148, ◯! 2 do 617, and 61^ magnet having a 1_10 type crystal. In addition, 31^0-5, which is usually called Samakoba,

Which configuration cannot be used. Note that compounds of the same type, such as 2d6148 and 2d6148, typically use the heavy rare earth dsprosium to increase the neodymium content.

3 Even if the magnet with the high coercive force of 〇 is lost while slightly losing its characteristics, 2 .15

2 [Cho] may be met, and this case can also be adopted. In such a case, for example, it will be called ([1 10 乂] 2d 6148). Furthermore, it is possible to achieve two or more types of magnets having different compositions, for example, a magnet made of two or more types of materials, such as Do 61\1丨plus 31112 and Do 617, for example, `` 3 = 1. Achieved even with a mixed magnet with an increased coercive force, such as ₆ magnets, and 2 magnets 6148, which has a large margin of 3, and a small amount of, for example, 0 2 magnet ₆ 148, of 3”1”. It is possible.

[0129] In addition, a rotating electric machine that is operated at a temperature outside the range of human activity, for example, 60 ^° 〇 or more, which exceeds the temperature of the desert, for example, for vehicles where the temperature inside the vehicle approaches 80 ^° 〇 in summer. Especially for motor applications, the temperature dependence coefficient is small, 61^

, 31112 and 617 are desirable. This is a motor from the temperature range of 40° 〇 in Northern Europe, which is within the range of human activity, to 60° 〇 or more, which exceeds the desert temperature mentioned above, or the heat-resistant temperature of the coil enamel coating is about 180 to 240° 〇. Since the motor characteristics differ greatly depending on the temperature dependence coefficient during operation, the same model — This is because it becomes difficult for the driver to perform optimal control. When FeN i having the L10 type crystal, Sm2Fe17N3, or the like is used, the motor dry/load can be suitably reduced due to its characteristic of possessing a temperature dependence coefficient of less than half that of Nd2Fe14B.

[0130] In addition, the magnet unit 42 is characterized in that, by using the above-mentioned magnet mixture, the particle size of the fine powder state before orientation is 10 Mm or less and the single domain particle size or more. There is. In magnets, coercive force is increased by reducing the size of powder particles to the order of several hundred nm, so in recent years powders that have been made as small as possible have been used. However, if it is made too fine, the B H product of the magnet will drop due to oxidation and the like, so a single domain particle size or more is preferable. It is known that coercive force increases with size reduction if the particle size is up to a single domain particle size. The particle size described here is the particle size in the fine powder state during the orientation process, which is the manufacturing process of the magnet.

[0131] Furthermore, 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, in which magnetic powder is baked and solidified at a high temperature. In this sintering, the saturation magnetization J s of the magnet unit 42 is 1.2 T or more, the crystal grain size of the first magnet 91 and the second magnet 92 is 10 Mm or less, and the orientation ratio is Is defined as a, J s X a is performed so as to satisfy the condition of 1. OT (Tesla) or more. Further, each of the first magnet 91 and the second magnet 92 is sintered so as to satisfy the following conditions. Since the orientation is performed in the orientation process in the manufacturing process, the orientation ratio (or i entat i on rat io) is different from the definition of the magnetic force direction in the magnetization process of the isotropic magnet. The saturation magnetization J s of the magnet unit 42 of this embodiment is 1.2 T or more, and the orientation ratio a of the first magnet 9 1 and the second magnet 9 2 is J r ³ J s X a ³ 1. The high orientation rate is set so that it becomes 0 [T]. Note that the orientation ratio a referred to here is, for example, in each of the first magnet 91 and the second magnet 92, for example, there are six easy axes of magnetization, and five of them are oriented in the same direction A10. , If the other one faces the direction B 1 0 which is tilted 90 degrees to the direction A 10 then a = 5/6 and the other one is 45 degrees to the direction A 10 〇 2020/175333 41 卩 (：171? 2020 /006903

In the case where the direction is tilted to the direction 10, the remaining component facing the direction 8 10 is 0 0 3 4 5 ° = 0.77 7, so 《= (5 + 0. 7 0 7)/6. In this example, 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 can be formed by another method. It may be molded. For example, a method of forming a 1\/103 magnet or the like can be adopted.

[0132] In the present embodiment, since a permanent magnet in which the easy axis of magnetization is controlled by orientation is used, the magnetic circuit length inside the magnet is conventionally set to be 1.0 [c] or more linearly oriented magnet. It can be made longer than the magnetic circuit length of. That is, the magnetic circuit length per pole pair can be achieved with a small amount of magnets, and even when exposed to harsh high heat conditions, its irreversible demagnetization can be achieved compared to the conventional design using linearly oriented magnets. You can keep the range. Further, the present inventor has found a configuration that can obtain characteristics close to those of a polar anisotropic magnet even when using a conventional magnet.

[0133] The easy axis refers to a crystal orientation that is easily magnetized in the magnet. The direction of the easy axis of magnetization in the magnet is the direction in which the orientation rate, which indicates the degree of alignment of the easy axis of magnetization, is 50% or more, or the direction in which the orientation of the magnet is averaged.

[0134] 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 has a first magnet 91 and a second magnet 92 which are polar anisotropic magnets and have polarities different from each other. The first magnet 91 and the second magnet 92 are arranged alternately in the circumferential direction. The first magnet 91 is a magnet that forms !\! poles in the portion close to the stator winding 5 1, and the second magnet 9 2 forms 3 poles in the portion close to the stator winding 5 1. It is a magnet. The first magnet 91 and the second magnet 92 are permanent magnets made of a rare earth magnet such as a neodymium magnet.

[0135] As shown in Fig. 9, in each magnet 9 1 and 9 2, the ◯! axis (“60 1; −3_13”) which is the magnetic pole center in the known ¢1-coordinate system and !\1 It is the magnetic pole boundary between the pole and the three poles (in other words 〇 2020/175333 42 卩 (：171? 2020 /006903

If so, the magnetic flux density is 0 Tesla.) The magnetizing direction extends in an arc shape between the axis (9113 0 1"31; 11"6-3_13). Each magnet 9 1, 9 2 In each of these, the magnetization direction is the radial direction of the annular magnet unit 42 on the axis side, and the magnetization direction of the annular magnet unit 42 is the circumferential direction on the 9-axis side. Each of the magnets 9 1 and 9 2 is located on both sides of the first portion 2 50 and the first portion 2 50 in the circumferential direction of the magnet unit 4 2 as shown in FIG. It has two second parts 2 60 and, in other words, the first part 2 50 is closer to the axis than the second part 2 60 and the second part 2 6 0 is closer to the axis than the 1st part 2 50. It is close to the axis, and the direction of the easy axis 300 of the first part 250 is more parallel to the axis than the direction of the easy axis 3100 of the second part 260. The magnet unit 4 2 is constructed, in other words, the angle 0 1 1 formed by the easy magnetization axis 300 of the first portion 250 and the axis is the easy axis 3 1 0 of the second portion 2 60. The magnet unit 42 is configured so that the angle formed by the axis is smaller than 0 12.

[0136] More specifically, the angle 0 1 1 is such that when the direction from the stator 5 0 (armature) to the magnet unit 4 2 is positive in the axis, the axis and the easy axis of magnetization 300 are It is an angle.

This is the angle formed by the 9 axis and the easy axis of magnetization 3 10 when the direction from the stator 50 (armature) to the magnet unit 4 2 in the 9 axis is positive. Both the angle 0 1 1 and the angle 0 1 2 are 90° or less in this embodiment. Here, each of the easy magnetization axes 300 and 310 is defined as follows. In each part of the magnets 9 1 and 9 2, if one easy axis is oriented in the direction 8 11 and the other easy axis is oriented in the direction 11 1, the direction 1 1 and the direction 9 1 The absolute value of the cosine of the angle 0 formed by 1 1 (| 〇 〇 3 0 |) is defined as the easy axis of magnetization 300 or the easy axis of magnetization 3 10.

[0137] That is, each of the magnets 9 1 and 9 2 is connected to the shaft side (portion near the axis)

The direction of the easy magnetization axis differs from that on the 9-axis side (the portion near the 9-axis). The easy-axis direction on the axis side is close to the direction parallel to the ¢1 axis, and the easy-axis direction on the axis side The direction of the axis is close to the direction orthogonal to the 9th axis. And this 〇 2020/175333 43 卩 (：171? 2020 /006903

An arc-shaped magnet magnetic path is formed according 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 axis on the axis side, and the easy axis may be oriented orthogonal to the axis on the 9 axis side.

[0138] In addition, in the magnets 9 1 and 9 2, the outer surface of the stator, which is the stator 50 side (lower side in Fig. 9) of the peripheral surface of each of the magnets 9 1 and 9 2, and the 9 axes in the circumferential direction. Side end surface is the magnetic flux acting surface that is the inflow and outflow surface of the magnetic flux, and the magnet magnetic path is formed so as to connect these magnetic flux acting surfaces (the outer surface of the stator side and the end surface of the shaft side). ..

[0139] In the magnet unit 42, since the magnetic flux flows in an arc shape between the adjacent 1\1 and 3 poles by the magnets 9 1 and 9 2, the magnet magnetic path is smaller than that of a radial anisotropic magnet, for example. It's getting longer. Therefore, the magnetic flux density distribution is close to a sine wave, as shown in Fig. 17. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown in FIG. 18 as a comparative example, 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, it can be confirmed that the magnet unit 42 of the present embodiment has a difference in the magnetic flux density distribution as compared with the conventional Halbach array magnet. In FIGS. 17 and 18, the horizontal axis represents the electrical angle and the vertical axis represents the magnetic flux density. Further, in FIGS. 17 and 18, 90° on the horizontal axis indicates the axis (that is, the magnetic pole center), and 0° and 180° on the horizontal axis indicate the 9 axis.

[0140] That is, according to each of the magnets 9 1 and 9 2 having the above-mentioned configuration, the magnetic flux of the magnet on the axis is strengthened and the change of the magnetic flux near the axis is suppressed. As a result, it is possible to preferably realize the magnets 9 1 and 9 2 in which the surface magnetic flux changes gently from axis to axis at each magnetic pole.

[0141] The sine wave matching rate of the magnetic flux density distribution may be set to, for example, a value of 40% or more. By doing so, it is possible to surely improve the magnetic flux amount in the central portion of the waveform, as compared with the case of using a radial oriented magnet or a parallel oriented magnet having a sine wave matching rate of about 30%. Also, if the sine wave matching rate is set to 60% or more, the amount of magnetic flux in the central portion of the waveform can be reliably improved compared to the magnetic flux concentration array such as the Halbach array. 〇 2020/175 333 44 卩 (: 171? 2020 /006903

[0142] In the radial anisotropic magnet shown in Fig. 18, the magnetic flux density changes sharply near the axis. The steeper the change in magnetic flux density, the greater the eddy current generated in the stator winding 51. Also, the change in magnetic flux on the stator winding 51 side 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. Therefore, the change in the magnetic flux density near the axis is smaller than the change in the magnetic flux density of the radial anisotropic magnet. This can suppress the generation of eddy currents.

[0143] In the magnet unit 42, in the vicinity of the axis of each magnet 9 1, 9 2 (that is, the magnetic pole center), a magnetic flux is generated in a direction orthogonal to the magnetic flux acting surface 2 80 on the stator 50 side, and the magnetic flux is generated. Has an arc shape that is farther from the axis as it is farther from the magnetic flux acting surface 280 on the side of the stator 50. Also, the more perpendicular to the magnetic flux acting surface, the stronger the magnetic flux. In this respect, in the rotary electric machine 10 of the present embodiment, since the conductor wire groups 8 1 are thinned in the radial direction as described above, the radial center position of the conductor wire groups 8 1 is the magnetic flux acting surface of the magnet unit 4 2. Therefore, the stator 50 can receive a strong magnetic flux from the rotor 40.

[0144] Further, the stator 5 0 has a cylindrical stator core 5 2 radially inward of the stator winding 5 1, that is, on the opposite side of the rotor 40 with the stator winding 5 1 interposed therebetween. It is provided. Therefore, the magnetic flux extending from the magnetic flux acting surface of each magnet 91, 92 is attracted to the stator core 52, and circulates while using the stator core 52 as a part of the magnetic path. In this case, the direction and path of the magnetic flux of the magnet can be optimized.

[0145] In the following, as a method of manufacturing the rotating electric machine 10, an assembly procedure for the bearing unit 20 shown in Fig. 5, the housing 30, the rotor 40, the stator 50 and the inverter unit 60 is shown. Will be described. The inverter unit 60 has a unit base 61 and an electric component 62 as shown in Fig. 6, and the unit base 61 and the electric component 62 are assembled together. Each work process including steps will be described. In the following description, the assembly consisting of the stator 50 and the inserter unit 60 is the first unit, and the assembly consisting of the bearing unit 20 and the housing 30 and the rotor 40 is the second unit. There is. 〇 2020/175 333 45 卩 (: 171-1? 2020 /006903

[0146] The manufacturing process is

-The first step of mounting the electrical component 62 on the inner side of the unit base 61,

-The second step of manufacturing the first unit by mounting the unit base 61 on the inner side of the stator 50 in the radial direction,

The third step of manufacturing the second unit by inserting the fixed portion 44 of the rotor 40 into the bearing unit 20 assembled in the housing 30 and

-The fourth step of mounting the first unit inside the second unit in the radial direction,

-The fifth step of fastening and fixing the housing 30 and the unit base 6 1 is included. The order of performing these steps is 1st step 2nd step 3rd step 4th step 5th step.

[0147] According to the above manufacturing method, the bearing unit 20, the housing 30 and the rotor 4 are

After assembling 0, stator 50 and inverter unit 60 as multiple assemblies (sub-assemblies) and then assembling these assemblies, easy handling and inspection completion for each unit are achieved. It is possible to construct a rational assembly line. Therefore, it is possible to easily cope with multi-product production.

[0148] In the first step, the radial inside of the unit base 61 and electrical components

A good thermal conductor with good thermal conductivity is attached to at least one of the radial outer sides of 62 by applying a cloth or adhesive, and in that state, the electrical component 6 is attached to the unit base 61. You should wear 2. This makes it possible to effectively transfer the heat generated by the semiconductor module 6 6 to the unit base 6 1.

[0149] In the third step, the rotor 40 may be inserted while maintaining the housing 30 and the rotor 40 coaxial with each other. Specifically, for example, with the inner peripheral surface of the housing 30 as a reference, the outer peripheral surface of the rotor 40 (outer peripheral surface of the magnet holder 41) or the inner peripheral surface of the rotor 40 (inner peripheral surface of the magnet unit 42). Surface), and slide either the housing 30 or rotor 40 along the jig. 〇 2020/175333 46 卩 (: 171? 2020 /006903

While doing so, the assembly of the housing 30 and the rotor 40 is carried out. This makes it possible to assemble heavy parts without imposing an unbalanced load on the bearing unit 20 and improve the reliability of the bearing unit 20.

[0150] In the fourth step, it is advisable to assemble the first unit and the second unit while maintaining the same axis. 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 fixed portion 44 of the rotor 40 is used, and the first Assemble each of these units while sliding either the unit or the second unit. This makes it possible to assemble the rotor 40 and stator 50 while preventing them from interfering with each other in the minimal gap, resulting in damage to the stator winding 5 1 and lack of permanent magnets. It is possible to eliminate defective products due to assembly.

[0151] The order of each of the above steps may be set as the second step, the third step, the fourth step, the fifth step, the first step. In this case, the delicate electrical component 62 is assembled last, and the stress on the electrical component 62 during the assembly process can be minimized.

[0152] Next, the configuration of the control system for controlling the rotary electric machine 10 will be described. Figure

Reference numeral 19 is an electric circuit diagram of a control system of the rotary electric machine 10, and FIG. 20 is a functional block diagram showing control processing by the control device 110.

[0153] In Fig. 19, two sets of 3-phase windings 5 1 3 and 5 1 are shown as the stator winding 51, and the 3-phase winding 5 1 3 is the II-phase winding and the V-phase winding. It consists of a winding wire and a phase winding, and the three-phase winding wire 5 1 13 consists of an X-phase winding, a normal winding wire and a phase winding. A first inverter 10 1 and a second inverter 10 2 corresponding to a power converter are provided for each of the three-phase windings 5 1 3 and 5 1 13. The inverters 10 1 and 10 2 are composed of a full bridge circuit that has the same number of upper and lower arms as the number of phases of the phase winding, and is fixed by turning on and off the switch (semiconductor switching element) provided in each arm. The energizing current is adjusted in each phase winding of the child winding 51.

[0154] Each inverter 1 0 1 and 1 0 2 has a DC power supply 1 0 3 and a smoothing capacitor.

10 4 and 10 are connected in parallel. The DC power supply 103 is, for example, a plurality of single batteries. 〇 2020/175 333 47 卩 (: 171-1? 2020 /006903

Are composed of assembled batteries connected in series. Each switch of the inverters 10 1 and 10 2 corresponds to the semiconductor module 66 shown in FIG. 1 etc., and the capacitor 10 4 corresponds to the capacitor module 68 shown in FIG. 1 etc.

[0155] The control device 110 is equipped with a microcomputer consisting of 〇II and various memories, and based on various detection information of the rotating electric machine10 and requests for power running drive and power generation, the inverter 1101,1 The energization is controlled by turning on/off each switch in 02. The control device 110 corresponds to the control device 77 shown in FIG. The detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 40 detected by an angle detector such as a resolver or the power supply voltage (inverter input voltage) detected by a voltage sensor. , Includes the energizing current of each phase detected by the current sensor. The control device 110 generates and outputs an operation signal for operating each switch of the inverters 10 1 and 10 2. The request for power generation is a request for regenerative driving when, for example, the revolving electric machine 10 is used as a power source for vehicles.

[0156] The first inverter 101 is provided with a series connection body of the upper arm switch 3 and the lower arm switch 3 in each of the three phases of II phase, V phase and phase. The high potential side terminal of the upper arm switch 3 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 3 of each phase is connected to the negative terminal (ground) of the DC power supply 103. It is connected. At the intermediate connection points between the upper arm switch 3 and the lower arm switch 3 n of each phase, the _ ends of the II phase winding, the V phase winding, and the phase winding are connected. Each of these phase lines is connected in a star shape (cable connection), and the other ends of each phase line are connected to each other at a neutral point.

[0157] The second inverter 1002 has the same configuration as that of the first inverter 101, and the upper arm switch 3 and the lower arm switch 3 are provided in the three phases of the X phase, the negative phase, and the phase. And a series connection body with each. The high potential side terminal of the upper arm switch 3 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 3 n of each phase is the negative terminal (ground) of the DC power supply 103. ) It is connected to the. At the intermediate connection point between the upper arm switch 3 and the lower arm switch 3 n of each phase, the X-phase winding, the zero-phase winding, and one end of the phase winding Are connected. Each of these phase windings is star-connected (Y-connected), and the other ends of each phase winding are connected to each other at a neutral point.

[0158] Fig. 20 shows a current feedback control process for controlling the U, V, W phase currents and a current feedback control process for controlling the X, Y, z phase currents. .. First, the control processing on the U, V, and W phase side will be described.

[0159] In Fig. 20, the current command value setting unit 1 1 1 uses the torque-dq map to obtain the power running torque command value or the power generation torque command value for the rotating electric machine 10 or the electrical angle 0 obtained by time differentiation. Set the d-axis current command value and the q-axis current command value based on the angular velocity of £. In addition, the current command value setting unit 1 1 1

Commonly provided on the W-phase side and the X-, Y-, and Z-phase sides. The power generation torque command value is, for example, a regenerative torque command value when the rotary electric machine 10 is used as a vehicle power source.

[0160] The d q converter 1 1 2 has a current detection value (

D phase current, which is a component of an orthogonal two-dimensional rotational coordinate system whose d axis is the magnetic field direction (di rect i on of an axis of a magnetic field, .r field di rect i on). And q-axis current.

[0161] The d-axis current feedback control unit 113 calculates a d-axis command voltage as an operation amount for feedback controlling the d-axis current to the d-axis current command value. In addition, the q-axis current feedback control unit 1 1 1 1 4 calculates the q-axis command voltage as an operation amount for feedback controlling the q-axis current to the q-axis current command value. In each of these feedback control units 113, 114, the command voltage is calculated using the P feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.

[0162] The three-phase conversion unit 115 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Note that each of the above sections 1 1 1 to 1 1 1 5 is a feedback control section that performs feedback control of the fundamental current based on the dq conversion theory, and the command voltage of the U phase, V phase, and W phase is the feedback control value. Is. 〇 2020/175 333 49 卩 (：171? 2020 /006903

[0163] Then, the operation signal generation unit 1 16 uses the well-known triangular wave carrier comparison method to generate the operation signal of the first inverter 1 0 1 based on the command voltages of the three phases. Specifically, the operation signal generator 1116 controls \^/1\/1 based on the magnitude comparison between the signal obtained by normalizing the three-phase command voltage with the power supply voltage and the carrier signal such as the triangular wave signal. Generates a switch operation signal (duty signal) for the upper and lower arms in each phase.

[0164] Further, the X side, the side, and the phase side have the same configuration,

Converter 1

2 2 is the component of the orthogonal two-dimensional rotational coordinate system with the field direction as the ¢1 axis, which is the detected current value (three phase currents) by the current sensor provided for each phase ¢1 Axis current and Axis current And convert to.

[0165] The 1-axis current feedback control section 1 2 3 calculates the 1-axis command voltage, and the 1-axis current feedback control section 1 2 4 calculates the 9-axis command voltage. The 3-phase converter 1 2 5 converts the command voltages for the axes 9 and 9 into command voltages for the X phase, the negative phase, and the phase. Then, the operation signal generation unit 1 26 generates the operation signal of the second inverter 1 0 2 based on the three-phase command voltage. Specifically, the operation signal generator 1 2 6 controls \^/1\/1 based on the magnitude comparison between the signal obtained by normalizing the three-phase command voltage with the power supply voltage and the carrier signal such as the triangular wave signal. Generates a switch operation signal (duty signal) for the upper and lower arms in each phase.

[0166] Based on the switch operation signals generated by the operation signal generators 1 1 6 and 1 2 6, the driver 1 1 7 switches the 3-phase switches in each inverter 1 0 1 and 1 0 2. Turn 3, 3 on and off.

[0167] Next, the torque feedback control process will be described. This process is mainly for the purpose of increasing the output of the rotating electric machine 10 and reducing the loss under operating conditions where the output voltage of each inverter 10 1, 10 2 is large, such as in the high rotation area and high output area. Used. 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 rotary electric machine 100.

[0168] Fig. 21 shows the torque feedback control process corresponding to the II, V, and phases. \¥0 2020/175333 50 (: 17 2020 /006903

Torque feedback control processing corresponding to X, H, and phase is shown. Note that, in FIG. 21, the same components as those in FIG. 20 are given the same reference numerals and the description thereof will be omitted. Here, first, the control processing on the II, V, \/\/ phase side will be explained.

[0169] The voltage amplitude calculation unit 1 2 7 determines the voltage based on the power running torque command value or the power generation torque command value for the rotary electric machine 10 and the electrical angular velocity 0) obtained by time differentiating the electrical angle 0. A voltage amplitude command, which is a command value of the vector size, is calculated.

[0170] The torque estimation unit 1 2 8 3 and the ¢1 axis current converted by the ¢1 conversion unit 1 1 2

Based on the 9-axis current, the estimated torque value corresponding to the R, V, and phase is calculated. It should be noted that the torque estimator 1 283 may calculate the voltage amplitude command based on the map information in which the shaft current, the shaft current and the voltage amplitude command are associated.

[0171] The torque feedback control unit 1 2 9 3 is a voltage phase which is a command value of the phase of the voltage vector as an operation amount for feedback controlling the estimated torque value to the power running torque command value or the power generation torque command value. Calculate the command. In the torque feedback controller 1293, the voltage phase command is calculated using the feedback method based on the deviation of the estimated torque value with respect to the power running torque command value or the power generation torque command value.

[0172] Operation signal generation unit 1 3 0 _3, the voltage amplitude command, based on the voltage phase command and the electrical angle 0, and generates a first operation signal of the inverter 1 0 1. Specifically, the operation signal generating unit 1 3 0 _3, standard voltage amplitude command, and calculates a command voltage of 3-phase based on the voltage phase command and the electrical angle 0, the power supply voltage command voltage calculated 3-phase The switch operation signals of the upper and lower arms in each phase are generated by \^/1\/1 control based on the magnitude comparison of the converted signal and the carrier signal such as the triangular wave signal.

[0173] By the way, the operation signal generation unit 133 is a pulse amplitude information, a voltage amplitude command, a voltage amplitude command, a voltage phase command, a voltage phase command, a voltage angle command, and a voltage amplitude command, which are map information associated with the switch operation signal. The switch operation signal may be generated based on the phase command and the electrical angle 0.

[0174] In addition, the X, 丫, and phase side have the same configuration, and the torque estimation unit 〇 2020/175333 51 卩 (: 171? 2020 /006903

The 1 2 8 13 calculates the estimated torque value corresponding to the X, phase, and phase based on the 1-axis current and the 1-axis current converted by the 1-converting section 1 2 2.

[0175] The torque feedback control unit 129 calculates the voltage phase command as an operation amount for feedback controlling the estimated torque value to the power running torque command value or the power generation torque command value. In the torque feedback control unit 129, the voltage phase command is calculated using the I feedback method based on the deviation of the estimated torque value from the power running torque command value or the power generation torque command value.

[0176] The operation signal generation unit 1300 generates an operation signal for the second inverter 1O 2 based on the voltage amplitude command, the voltage phase command, and the electrical angle 0. Specifically, the operation signal generator 1300 calculates the three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electrical angle 0, and the calculated three-phase command voltage is specified as the power supply voltage. The switch operation signals of the upper and lower arms in each phase are generated by \^/1\/1 control based on the magnitude comparison of the converted signal and the carrier signal such as the triangular wave signal. Based on the switch operation signal generated by the operation signal generation unit 1330, 1330, the driver 1177 determines the three-phase switches 3 and 3 in each inverter 1101 and 102. Turn on and off.

[0177] By the way, the operation signal generation unit 1300 is configured to include the voltage amplitude command, the voltage phase command, the pulse angle information which is the map information in which the electric angle 0 and the switch operation signal are related, the voltage amplitude command, and the voltage phase. The switch operation signal may be generated based on the command and the electrical angle 0.

[0178] By the way, in the rotary electric machine 10, it is feared that the electrolytic corrosion of the bearings 2 1 and 2 2 may occur due to the generation of the axial current. For example, when the energization of the stator winding 5 1 is switched by switching, the magnetic flux is distorted due to a minute shift in switching timing (switching imbalance), which causes the bearing that supports the rotating shaft 1 1. There is concern that electrolytic corrosion may occur in 2 1 and 2 2. The distortion of the magnetic flux occurs according to the inductance of the stator 50, and the electromotive force in the axial direction caused by the distortion of the magnetic flux causes dielectric breakdown in the bearings 21 and 22 to promote electrolytic corrosion. 〇 2020/175333 52 卩 (: 171-1? 2020 /006903

[0179] In this regard, the present embodiment takes the following three countermeasures as countermeasures against electrolytic corrosion. The first countermeasure against electrolytic corrosion is to reduce the inductance as the stator 50 is made coreless and to reduce the magnetic flux of the magnet unit 42 so as to suppress electrolytic corrosion. The second countermeasure against electrolytic corrosion is a countermeasure against electrolytic corrosion by using a cantilever structure with bearings 2 1 and 2 2 for the rotating shaft. The third countermeasure against electrolytic corrosion is a countermeasure against electrolytic corrosion by molding the annular stator winding 5 1 together with the stator core 52 with a molding material. The details of each of these measures are explained below.

[0180] First, in the first countermeasure against electrolytic corrosion, in the stator 50, each conductor wire group in the circumferential direction

The space between the 81's is made toothless, and a sealing member 57 made of a non-magnetic material is provided between the conductor groups 81 in place of the teeth (iron core) (see Fig. 10). This makes it possible to reduce the inductance of the stator 50. By reducing the inductance of the stator 50, even if there is a deviation in the switching timing when the stator winding 5 1 is energized, the magnetic flux distortion due to the deviation in the switching timing is suppressed, and the bearing It is possible to suppress the electrolytic corrosion of 2 1 and 2 2. It is preferable that the inductance of the 1st axis is equal to or less than the inductance of the 1st axis.

[0181] In addition, the magnets 9 1 and 9 2 were oriented so that the easy axis of magnetization on the axis side was parallel to the axis as compared to the 9 axis side (see Fig. 9).

.. As a result, the magnetic flux in the axis is strengthened, and the change in the surface magnetic flux (increase/decrease in magnetic flux) from axis to axis becomes gentle at each magnetic pole. Therefore, abrupt voltage changes due to switching imbalance are suppressed, which in turn contributes to suppression of electrolytic corrosion.

[0182] In the second countermeasure against electrolytic corrosion, in the rotating electric machine 10, the bearings 2 1 and 2 2 are arranged so as to be deviated to one side in the axial direction with respect to the axial center of the rotor 40. (See Figure 2). As a result, the influence of electrolytic corrosion can be reduced compared to a configuration in which a plurality of bearings are provided on both sides of the rotor in the axial direction with the rotor interposed therebetween. In other words, in a configuration in which the rotor is supported by multiple bearings on both sides, high frequency magnetic flux is generated. 〇 2020/175 333 53 卩 (: 171? 2020 /006903

A closed circuit is formed that passes through the rotor, the stator, and the bearings (that is, the bearings on both sides in the axial direction with the rotor sandwiched between them), and there is concern about electrolytic corrosion of the bearing due to the axial current. On the other hand, in the 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.

[0183] Further, the rotary electric machine 10 has the following configuration in relation to the configuration in which the bearings 21 and 22 are arranged on one side. In the magnet holder 41, a contact avoidance portion that extends in the axial direction and avoids contact with the stator 50 is provided in the 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 axial current is formed via the magnet holder 41, it is possible to lengthen the closed circuit and increase its circuit resistance. As a result, the electrolytic corrosion of the bearings 21 and 22 can be suppressed.

[0184] While holding the rotor 40, the holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction, and the housing 30 and the unit base are fixed on the other side. The screws 6 1 (stator holder) are connected to each other (see Fig. 2). According to this configuration, it is possible to preferably realize a configuration in which the bearings 2 1 and 2 2 are arranged eccentrically on one side in the axial direction of the rotating shaft 11. Further, in this configuration, the unit base 6 1 is connected to the rotary shaft 11 via the housing 30 so that the unit base 6 1 is electrically separated from the rotary shaft 11. Can be placed in different positions. If an insulating member such as resin is interposed between the unit base 61 and the housing 30, the unit base 61 and the rotating shaft 11 will be electrically separated from each other. Becomes As a result, the bearing 2 1,

22 It is possible to properly suppress the electrolytic corrosion.

In the rotary electric machine 10 of the present embodiment, the shaft voltage acting on the bearings 21 and 22 is reduced by the one-sided arrangement of the bearings 21 and 22 and 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 conductive grease generally contains fine particles such as carbon, noise may occur. In this respect, in the present embodiment, 〇 2020/175 333 54 卩 (: 171? 2020 /006903

The bearings 21 and 22 are configured to use non-conductive grease. Therefore, it is possible to suppress the inconvenience that noise is generated in the bearings 21 and 22. For example, when applied to an electric vehicle such as an electric vehicle, it is considered necessary to take noise countermeasures for the rotating electric machine 10. However, it is possible to appropriately implement the noise countermeasures.

[0186] In the third countermeasure against electrolytic corrosion, the stator winding 5 1 and the stator core 5 2 are molded with a molding material to suppress the positional deviation of the stator winding 5 1 in the stator 50. (See Figure 11). In particular, in the rotating electric machine 100 of the present embodiment, since there is no inter-conductor member (teeth) between each conductor group 8 1 in the circumferential direction of the stator winding 5 1, the stator winding 5 1 Although there is a concern that misalignment may occur, by molding the stator winding 5 1 together with the stator core 52, the displacement of the conductor wire of the stator winding 5 1 is suppressed. Therefore, it is possible to suppress the distortion of the magnetic flux due to the positional deviation of the stator winding 51 and the occurrence of electrolytic corrosion of the bearings 21 and 22 caused by the distortion.

[0187] A unit base as a housing member for fixing the stator core 52 is provided.

6 1 for carbon fiber reinforced plastic

Since it is composed of, the discharge to the unit base 61 is suppressed compared with the case of, for example, aluminum and the like, and it is possible to take a suitable countermeasure against electrolytic corrosion.

[0188] In addition, as a countermeasure against electrolytic corrosion of the bearings 21 and 22, 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, etc. It is also possible to use the above configuration.

[0189] In the following, another embodiment will be described focusing on the differences from the first embodiment.

[0190] (Second Embodiment)

In the present embodiment, the polar anisotropic structure of the magnet unit 42 in the rotor 40 is changed, which will be described in detail below.

[0191] As shown in Figs. 22 and 23, the magnet unit 42 is configured using a magnet arrangement called a Halbach arrangement. That is, the magnet unit 4 2 is composed of a first magnet 1 3 1 whose radial direction is the magnetization direction (direction of the magnetization vector), and 〇 2020/175333 55 卩 (: 171? 2020 /006903

It has a second magnet 1 3 2 having a direction (direction of the magnetization vector) as a circumferential direction, and the first magnets 1 3 1 are arranged at a predetermined interval in the circumferential direction, and the first magnets 1 3 1 are arranged adjacent to each other in the circumferential direction. The second magnet 1 3 2 is located at a position between the 1 magnet 1 3 1. The first magnet 1 3 1 and the second magnet 1 3 2 are permanent magnets made of rare earth magnets such as neodymium magnets.

[0192] The first magnet 1 3 1 has alternating poles on the side facing the stator 50 (inward in the radial direction).

They are arranged so as to be separated from each other in the circumferential direction so as to have 1\1 pole and 3 poles. The second magnets 1 3 2 are arranged next to the first magnets 1 3 1 so that the polarities alternate in the circumferential direction. The cylindrical portion 43 provided so as to surround each of these magnets 1 3 1, 1 3 2 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 as the axis or the easy axis of magnetization with respect to the 9-axis in the 19-coordinate system as in the first embodiment.

[0193] In addition, the first magnet 1 31 is radially outside, that is, the cylindrical portion 4 of the magnet holder 41.

On the 3 side, a magnetic body 1 3 3 made of a soft magnetic material is arranged. For example, the magnetic body 133 may be made of electromagnetic steel plate, soft iron, or powdered iron core material. In this case, the circumferential length of the magnetic body 1 3 3 is the same as the circumferential length of the first magnet 1 3 1 (in particular, the circumferential length of the outer peripheral portion of the first magnet 1 3 1 ). The radial thickness of the first magnet 1 3 1 and the magnetic body 1 3 3 in the integrated state is the same as the radial thickness of the second magnet 1 3 2. In other words, the first magnet 1 3 1 is thinner than the second magnet 1 3 2 in the radial direction by the amount of the magnetic body 1 3 3. The magnets 1 3 1, 1 3 2 and the magnetic body 1 3 3 are fixed to each other by, for example, an adhesive. The outer side in the radial direction of the first magnet 1 3 1 in the magnet unit 4 2 is the side opposite to the stator 50, and the magnetic body 1 3 3 is one of the two sides of the first magnet 1 3 1 in the radial direction. It is provided on the opposite side of the stator 50 (opposite side of the stator).

A key 1 3 4 is formed on the outer peripheral portion of the magnetic body 1 3 3 as a convex portion that projects radially outward, that is, to the side of the cylindrical portion 4 3 of the magnet holder 4 1. Also, yen 〇 2020/175 333 56 卩 (: 171? 2020 /006903

A keyway 1 3 5 is formed on the inner peripheral surface of the cylindrical portion 4 3 as a recess for accommodating the key 1 3 4 of the magnetic body 1 3 3. The protruding shape of the keys 1 3 4 and the groove shape of the key grooves 1 3 5 are the same, and the same number of keys as the keys 1 3 4 correspond to the keys 1 3 4 formed on each magnetic substance 1 3 3. Grooves 1 3 5 are formed. Due to the engagement of the keys 1 3 4 and the key grooves 1 3 5, the positional deviation of the first magnet 1 3 1 and the second magnet 1 3 2 and the magnet holder 4 1 in the circumferential direction (rotational direction) is suppressed. It should be noted that the key 1 3 4 and the key groove 1 3 5 (convex portion and concave portion) may be provided on either the cylindrical portion 4 3 of the magnet holder 4 1 or the magnetic body 1 3 3 as desired. In addition, it is possible to provide the key groove 1 3 5 on the outer peripheral portion of the magnetic body 1 3 3 and the key _ 1 3 4 on the inner peripheral portion of the cylindrical portion 4 3 of the magnet holder 41.

[0195] Here, in the magnet unit 42, the magnetic flux density in the first magnet 1 3 1 is increased by alternately arranging the first magnet 1 3 1 and the second magnet 1 3 2. Is possible. Therefore, in the magnet unit 42, the magnetic flux can be concentrated on one side, and the magnetic flux can be strengthened on the side closer to the stator 50.

[0196] Further, since the magnetic body 1 3 3 is arranged on the outer side in the radial direction of the first magnet 1 3 1, that is, on the side opposite to the stator, partial magnetic saturation on the outer side in the radial direction of the first magnet 1 3 1 is achieved. Can be suppressed, and by extension, demagnetization of the first magnet 1 3 1 caused by magnetic saturation can be suppressed. As a result, it is possible to increase the magnetic force of the magnet unit 42. The magnet unit 42 of the present embodiment is, so to speak, configured such that the portion of the first magnet 1 3 1 where demagnetization is likely to occur is replaced with a magnetic body 1 3 3.

[0197] Fig. 24(3) and Fig. 24(匕) are diagrams specifically showing the flow of magnetic flux in the magnet unit 4 2. Fig. 24(3) shows that in the magnet unit 4 2. The case where the conventional configuration without the magnetic body 1 3 3 is used is shown, and FIG. 24 (distance) shows the configuration of the present embodiment having the magnetic body 1 3 3 in the magnet unit 4 2. The case is shown. In addition, in Fig. 24 (3) and Fig. 24 (匕), the cylindrical part 4 3 and the magnet unit 4 2 of the magnet holder 4 1 are shown in a linear form, and the lower side of the figure shows the stator side. The upper side is the side opposite the stator. 〇 2020/175333 57 卩(: 171-1? 2020/006903

In the configuration of FIG. 24 (3), the magnetic flux acting surface of the first magnet 1 31 and the side surface of the second magnet 1 3 2 are in contact with the inner peripheral surface of the cylindrical portion 4 3, respectively. The magnetic flux acting surface of the second magnet 1 3 2 is in contact with the side surface of the first magnet 1 3 1. In this case, the magnetic flux 1 entering the contact surface with the first magnet 1 3 1 through the outer path of the second magnet 1 3 2 in the cylindrical portion 4 3 is substantially parallel to the cylindrical portion 4 3 and 2 A combined magnetic flux with the magnetic flux that attracts the magnetic flux 2 of the magnet 1 3 2 is generated. Therefore, there is a concern that a magnetic saturation may partially occur in the cylindrical portion 4 3 near the contact surface between the first magnet 1 3 1 and the second magnet 1 3 2.

[0199] On the other hand, in the configuration of Fig. 24 (匕), the magnetic flux acting surface of the first magnet 1 3 1 and the cylindrical portion 4 3 on the side opposite to the stator 50 of the first magnet 1 3 1 Since the magnetic body 133 is provided between the magnetic body 133 and the peripheral surface, the magnetic body 133 is allowed to pass the magnetic flux. Therefore, the magnetic saturation in the cylindrical portion 43 can be suppressed, and the resistance to demagnetization is improved.

[0200] Further, unlike the configuration of Fig. 24 ( ₃ ), the configuration of Fig. 24 (distance) can eliminate 2 which promotes magnetic saturation. As a result, 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 heat conditions.

[0201] Further, the magnetic path of the magnet passing through the inside of the magnet becomes longer than that of the radial magnet in the conventional 3 1\/1 rotor. Therefore, the magnet permeance can be increased, the magnetic force can be increased, and the torque can be increased. Furthermore, since the magnetic flux concentrates at the center of the 1st axis, the sine wave matching rate can be increased. In particular, if the current waveform is a sine wave or a trapezoidal wave by the control of \^/1\/1, or the switching I 0 of 120° conduction is used, the torque can be more effectively enhanced.

[0202] In the case where the stator core 52 is made of an electromagnetic steel plate, the radial thickness of the stator core 52 is 1/2 of the radial thickness of the magnet unit 42, or 1/. Greater than 2 is good. For example, the radial thickness of the stator core 52 is preferably 1/2 or more of the radial thickness of the first magnet 1 31 provided at the magnetic pole center in the magnet unit 4 2. Also, the radial thickness of the stator core 52 depends on the magnet unit. 〇 2020/175 333 58 卩 (: 171-1? 2020 /006903

It should be smaller than the radial thickness of the plate 42. In this case, the magnetic flux of the magnet is about 1 [D], and the saturation magnetic flux density of the stator core 5 2 is 2 [D], so the radial thickness of the stator core 5 2 is equal to that of the magnet unit 4 2. By setting the thickness in the radial direction to 1/2 or more, magnetic flux leakage to the inner peripheral side of the stator core 52 can be prevented.

[0203] In a Halbach structure or a magnet having a polar anisotropic structure, since the magnetic path is a pseudo arc, 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 in the stator core 52 does not exceed the magnetic flux in the circumferential direction. In other words, when using an iron-based metal with a saturation magnetic flux density of 2 [Cho] to a magnetic flux of 1 [Cho] of the magnet, magnetic saturation will not occur if the thickness of the stator core 52 is more than half the magnet thickness. It is possible to provide a small and lightweight rotating electric machine. Here, since the demagnetizing field from the stator 50 acts on the magnetic flux of the magnet, the magnetic flux of the magnet is generally below 0.9 [C]. Therefore, if the stator core has a thickness half that of the magnet, its magnetic permeability can be suitably kept high.

[0204] Hereinafter, a modified example in which a part of the configuration described above is modified will be described.

[0205] (Modification 1)

In the above embodiment, the outer peripheral surface of the stator core 52 is formed into a curved surface without unevenness, and a plurality of conductor wire groups 8 1 are arranged side by side on the outer peripheral surface at predetermined intervals, but this may be changed. Good. For example, as shown in Fig. 25, the stator core 52 has an annular shape provided on the radial opposite sides of the stator winding 51 on the side opposite to the rotor 40 (lower side in the figure). It has a yoke 1 4 1 and a protrusion 1 4 2 extending from the yoke 1 4 1 so as to protrude between the linear portions 8 3 adjacent to each other in the circumferential direction. The protrusions 1 4 2 are provided on the outer side in the radial direction of the yoke 1 4 1, that is, on the side of the rotor 40, at predetermined intervals. Each conductor wire group 8 1 of the stator winding 5 1 is engaged with the protrusion 1 4 2 in the circumferential direction, and the protrusions 1 4 2 are arranged side by side in the circumferential direction while being used as the positioning portion of the conductor wire group 8 1. Has been done. The protrusions 14 2 correspond to “inter-conductor members”.

[0206] The protrusion 1 4 2 is a radial thickness dimension from the yoke 1 4 1, that is, 〇 2020/175333 59 (:171? 2020/006903 As shown in Fig. 25, in the radial direction of the yoke 1 41, the protrusion from the inner surface 3 2 0 adjacent to the yoke 1 4 1 of the straight portion 8 3 The distance to the apex of 1 4 2 is 1/2 of the radial thickness dimension of the straight line portion 8 3 that is radially adjacent to the yoke 1 4 1 among the multiple straight layer portions 8 3 inside and outside the radial direction. (1 ^to 11 in the figure). In other words, the size of the conductor wire group 8 1 (conductive member) in the radial direction of the stator winding 5 1 (stator core 5 2) ( Thickness) 1 (twice the thickness of the conductor 8 2; in other words, the face of the conductor group 8 1 that contacts the stator core 5 2 3 20 and the face of the conductor group 8 1 that faces the rotor 40. The non-magnetic part (sealing member 57) should occupy a three-quarter range of (the shortest distance from 3 30) The circumferential direction is limited by the thickness limitation of these protrusions 1 4 2. The protrusions 1 4 2 do not function as teeth between the conductor groups 8 1 (that is, the straight portions 8 3) adjacent to each other so that the magnetic path is not formed by the teeth. Do not have to be provided all between the conductor groups 8 1 arranged in the circumferential direction, and may be provided between at least one set of conductor groups 8 1 that are adjacent in the circumferential direction. It is preferable that the portions 1 4 2 are provided at equal intervals in the circumferential direction at a predetermined number between the conductor wire groups 8 1. The shape of the protrusions 1 4 2 can be an arbitrary shape such as a rectangular shape or an arc shape. Good.

[0207] In addition, the outer peripheral surface of the stator core 52 may be provided with a single linear portion 83. Therefore, in a broad sense, the radial thickness of the protrusion 1 4 2 from the yoke 1 4 1 may be smaller than 1/2 of the radial thickness of the straight portion 8 3.

[0208] Assuming an imaginary circle centered on the axis of the rotating shaft 11 and passing through the radial center of the straight portion 8 3 radially adjacent to the yoke 1 41, the protrusion 1 4 It is preferable that 2 has a shape that projects from the yoke 1 41 within the range of the virtual circle, in other words, a shape that does not project radially outward (that is, the rotor 40 side) from the virtual circle.

[0209] According to the above configuration, the protrusions 1 4 2 are limited in the radial thickness dimension and do not function as teeth between the linear portions 8 3 adjacent in the circumferential direction. Compared to the case where teeth are provided between the straight line parts 8 3 〇 2020/175333 60 卩 (：171? 2020 /006903

It is possible to bring the respective straight line portions 8 3 that are close to each other closer together. This makes it possible to increase the cross-sectional area of the conductor 8 2 _3, can be low reducing the heat generated due to the energization of the stator winding 5 1. In such a configuration, magnetic saturation can be canceled by the absence of teeth, and the current flowing through the stator winding 51 can be increased. In this case, it is possible to appropriately deal with the increase in the amount of heat generated as the energizing current increases. Further, in the stator winding 51, the evening section 8 4 is shifted in the radial direction and has an interference avoiding section for avoiding interference with other evening sections 8 4, so that the different evening It is possible to dispose the inner portions 84 apart from each other in the radial direction. As a result, the heat dissipation can be improved even in the evening section 84. From the above, it is possible to optimize the heat dissipation performance of the stator 50.

[0210] If the yoke 1 41 of the stator core 5 2 and the magnet unit 4 2 of the rotor 40 (that is, the magnets 9 1 and 9 2) are separated by a predetermined distance or more, the protrusion 1 The radial thickness dimension of 42 is not restricted to !· I 1 in Figure 25. Specifically, the yoke 1 4 1 and the magnet unit 4 2

If it is more than the distance, the protrusion

The radial thickness dimension of 1 4 2 may be greater than or equal to !· I 1 in FIG. For example, the straight part

And the conductor wire group 8 1 is composed of two layers of conductor wires 8 2 inside and outside in the radial direction, the straight part 8 3 that is not adjacent to the yoke 1 4 1, that is, from the yoke 1 4 1 The projecting portion 1 4 2 may be provided within the range up to the half position of the conducting wire 8 2 in the second layer. In this case, if the radial thickness of the projection 1 4 2 is up to "1 ^to 1 1 3 /2", increasing the conductor cross-sectional area of the conductor wire group 8 1 will not significantly reduce the above effect. You can get it.

[021 1] Further, the stator core 52 may have the configuration shown in FIG. Figure 2

In FIG. 6, the sealing member 57 is omitted, but the sealing member 57 may be provided. In FIG. 26, for convenience, the magnet unit 42 and the stator core 52 are shown in a linear form.

[0212] In the configuration of FIG. 26, the stator 50 has a circumferentially adjacent conductor 8 2 (ie 〇 2020/175333 61 卩 (: 171-1? 2020 /006903

Between the straight portions 8 3), there is a protrusion 1 4 2 as an inter-conductor member. When the stator winding 5 1 is energized, the stator 50 magnetically functions together with one of the magnetic poles of the magnet unit 4 2 (1\1 pole or 3 poles), and the stator 50 It has a portion 350 that extends circumferentially. The length in the circumferential direction of the stator 50 of this part 350 is! Then, this length range! Is the total width of the protrusions 1 4 2 existing in (i.e., the total dimension of the stator 50 in the circumferential direction), and the saturated magnetic flux density of the protrusions 1 4 2 is defined as 5, the magnet unit. If the width of one pole of the rotor 4 2 in the circumferential direction is \/\/ 01 and the residual magnetic flux density of the magnet unit 4 2 is

X X 3 0 1 X X "( 1)

It is made of a magnetic material.

[0213] Incidentally, the range W _n is a plurality of conductors group 8 1 adjacent in the circumferential direction, the excitation time period is set to include a plurality of conductors group 8 1 overlap. At that time, it is preferable to set the center of the gap 5 6 of the conductor wire group 8 1 as a reference (boundary) when setting the range W _n . For example, in the case of the configuration illustrated in FIG. 26, the fourth to the fourth conductor wire group 8 1 corresponds to the plurality of conductor wire groups 8 1 in order from the shortest distance from the magnetic pole center of the pole in the circumferential direction. .. Then, the range w _n is set so as to include the four conductor groups 81. At that time, the ends (starting point and ending point) of the range W _n are the centers of the gaps 56.

[0214] In Fig. 26, since the protrusions 1 4 2 are included in half at both ends of the range n, the range W n includes a total of 4 protrusions 1 4 2. ing. Therefore, if the width of the protrusion 1 4 2 (that is, the dimension of the protrusion 1 4 2 in the circumferential direction of the stator 5 0, in other words, the interval between the adjacent conductor wire groups 8 1) is set to 8, the range W n is The total width of the protrusions 1 4 2 included is

Eight + Eighty-eight + Eight + One-two-eight = Four-eighth.

[0215] Specifically, in the present embodiment, the three-phase winding of the stator winding 5 1 is distributed winding, and the stator winding 5 1 has a protrusion with respect to one pole of the magnet unit 4 2. The number of parts 1 4 2, that is, the number of gaps 5 6 between the conductor wire groups 8 1 is “phase number ◯”. Here, ◯ is the number of one-phase conductors 8 2 that come into contact with the stator core 5 2. Is. When the conductor wire 82 is the conductor wire group 81 laminated in the radial direction of the rotor 40, it can be said that it is the number of the conductor wires 82 on the inner peripheral side of the one-phase conductor wire group 81. In this case, when the three-phase winding of the stator winding 51 is energized in a predetermined order for each phase, the two-phase protrusions 142 in one pole are excited. Therefore, the total width Wt in the circumferential direction of the protrusion 142 that is excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is the protrusion 142 (that is, the gap 56). When the circumferential width is A, the number of excited phases is XQX A = 2 X 2 XA.

[0216] 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 that satisfies the relationship of (1) above. The total width dimension W t is also the circumferential dimension of the part where the relative magnetic permeability can be greater than 1 within one pole. Further, in consideration of the margin, the total width dimension W t may be the circumferential width dimension of the protrusion 142 in one magnetic pole. Specifically, since the number of protrusions 142 for one pole of the magnet unit 42 is “the number of phases XQ”, the circumferential width dimension (total width dimension Wt) of the protrusions 142 for one magnetic pole is , "The number of phases XQXA = 3X2XA = 6 A" may be used.

[0217] The distributed winding mentioned here is one pole pair period (N pole and S pole) of the magnetic pole, and has one pole pair of the stator winding 51. The one pole pair of the stator winding 51 mentioned here is composed of two straight portions 83 and a turn portion 84 in which currents flow in opposite directions and are electrically connected by the turn portion 84. As long as the above conditions are met, even short rolls (Short Pitch Winding) are considered to be equivalent to the distribution rolls of all rolls (Fu 11 Pitch Winding).

[0218] 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, there are three conductor groups 81 for one pole pair, three conductor groups 81 for two pole pairs, and nine conductor groups 81 for four pole pairs. One of them is a group of conductors 81 having five relationships with five pairs of magnetic poles.

[0219] Here, when the stator winding 5 1 is concentrated winding, three phases of the stator winding 5 1 〇 2020/175333 63 卩 (：171? 2020 /006903

When the windings are energized in a predetermined order, the stator windings 51 for two phases are excited. As a result, the two-phase protrusions 1 4 2 are excited. Therefore, in the range of one pole of the magnet unit 4 2, the circumferential width dimension 1: of the protrusion 1 4 2 excited by the energization of the stator winding 5 1 is “8 2 ”. In addition, the width dimension is defined in this way, and the protrusions 1 42 are configured as a magnetic material that satisfies the relationship of (1) above. In the case of concentrated winding shown above, the total width of the protrusions 1 4 2 in the circumferential direction of the stator 50 is set to 8 in the area surrounded by the same-phase wire group 8 1. In the concentrated winding, \ZV rn is equivalent to "the entire circumference of the surface of the magnet unit 4 2 facing the air gap" X "the number of phases" ÷ "the dispersion number of the conductor group 8 1 ".

[0220] By the way, the 1 ^to 1 product of neodymium magnets, samarium-cobalt magnets, and ferrite magnets is 2 0 [1\/1 〇 6

] The above magnets have a force of 1.0 strong, and the iron has a force of 2.0. Therefore, as a high output motor, the stator core 5 2 has a protrusion 1 4 2

Any magnetic material that satisfies the relationship may be used.

[0221] In addition, as will be described later, in the case where the conductor 8 2 has an outer layer coating 1 82, the conductor

The conductor wire 8 2 may be arranged in the circumferential direction of the stator core 5 2 so that the outer layer coatings 18 2 of 8 2 are in contact with each other. In this case, can be regarded as 0 or the thickness of the outer coating 18 2 of both conducting wires 8 2 in contact with each other.

[0222] In the configurations of Figs. 25 and 26, the inter-conductor members (protrusions 1 4 2) that are disproportionately small with respect to the magnet magnetic flux on the rotor 40 side are configured. The rotor 40 is a flat surface magnet type rotor having a low inductance and a flat surface, and does not have salient poles magnetically. With this configuration, the inductance of the stator 50 can be reduced, the generation of magnetic flux distortion due to the deviation of the switching timing of the stator winding 51 can be suppressed, and eventually the bearings 2 1 and 2 2 Electrolytic corrosion is suppressed.

[0223] (Modification 2)

As the stator 50 using the inter-conductor member that satisfies the relationship of the above formula (1), 〇 2020/175333 64 卩 (：171? 2020 /006903

It is also possible to adopt the configuration of. In FIG. 27, tooth-like portions 1 4 3 are provided as inter-conductor members on the outer peripheral surface side (upper surface side in the figure) of the stator core 52. The tooth portions 1 4 3 are provided at predetermined intervals in the circumferential direction so as to project from the yoke 1 4 1, and have the same thickness dimension as the conductor wire group 8 1 in the radial direction. The side surface of the toothed portion 1 4 3 is in contact with each conductor wire 8 2 of the conductor wire group 8 1. However, there may be a gap between the tooth-like portion 14 3 and each conducting wire 8 2.

[0224] The tooth-shaped portions 1 43 are limited in width in the circumferential direction, and are provided with pole teeth (stator teeth) that are disproportionately thin with respect to the magnet amount. With such a configuration, the tooth-shaped portions 1 43 are reliably saturated by the magnetic flux of the magnet in the number of 1.8 or more, and the inductance can be reduced by lowering the permeance.

[0225] Here, in the magnet unit 42, assuming that the surface area per pole of the magnetic flux acting surface on the stator side is 3, and the residual magnetic flux density of the magnet unit 4 2 is Is, for example, "3. The surface area on the rotor side of each toothed portion 1 43 is 3 I, and the number of conductors 8 2 per phase is given by the following equation. If part 1 4 3 is excited, the magnetic flux on the stator side is, for example, "3 I

2 X Sumi 3”. in this case,

(2)

The inductance is reduced by limiting the dimensions of the toothed portions 1 4 3 so that

[0226] If the magnet unit 4 2 and the tooth portion 1 4 3 have the same axial dimension, the circumferential width of one pole of the magnet unit 4 2 is set to \ZVrn, The width of the groove 1 4 3 in the circumferential direction.

Assuming I, equation (2) can be replaced by equation (3).

More specifically, assuming that, for example, 3 = 2 chomes, "1 chome" and 01 = 2, the above formula (3) becomes

It becomes a relationship. This place 〇 2020/175333 65 卩 (: 171-1? 2020 /006903

In this case, the width dimension 31 of the toothed portion 1 43 is made smaller than 1/8 of the width dimension of one pole of the magnet unit 4 2 to reduce the inductance. If the number is 1, the width dimension 3 I of the toothed portion 1 4 3 should be smaller than 1/4 of the width dimension \ZV rn of one pole of the magnet unit 4 2.

[0227] In the above formula (3), "\^/ 3 I 2" is a toothed portion 1 excited by energization of the stator winding 5 1 within the range of one pole of the magnet unit 4 2. Corresponds to the circumferential width of 4 3.

[0228] In the configuration of Fig. 27, similarly to the configurations of Fig. 25 and Fig. 26 described above, the inter-conductor member (tooth-like portion 1 4 3) disproportionally small with respect to the magnetic flux of the rotor 40 side. Has a configuration. With such a configuration, the inductance of the stator 50 can be reduced, the generation of magnetic flux distortion due to the deviation of the switching timing of the stator winding 51 is suppressed, and by extension the bearings 2 1, 2 2 Electrolytic corrosion is suppressed

[0229] (Modification 3)

In the above-described embodiment, the sealing member 57 covering the stator winding 51 is in a range including all the conductor wire groups 81 on the outer side in the radial direction of the stator core 52, that is, the radial thickness dimension is equal to that of each conductor wire. Although it is configured to be provided within a range that is larger than the radial thickness of the group 81, this may be changed. For example, as shown in FIG. 28, the sealing member 57 is provided so that a part of the conducting wire 82 protrudes. More specifically, the sealing member 57 is provided in such a manner that a part of the conductor wire 8 2 which is the outermost radial direction in the conductor wire group 8 1 is exposed radially outward, that is, the stator 50 side. To do. In this case, the radial thickness of the sealing member 57 is preferably the same as or smaller than the radial thickness of each conductor group 81.

[0230] (Modification 4)

As shown in FIG. 29, in the stator 50, each conductor wire group 81 may not be sealed by the sealing member 57. That is, the sealing member 5 7 covering the stator winding 5 1 is not used. In this case, an inter-conductor member is not provided between the conductor groups 81 arranged in the circumferential direction, and a gap is formed. In short, line up in the circumferential direction 〇 2020/175 333 66 卩 (：171? 2020 /006903

No inter-conductor member is provided between each conductor group 81. Note that air may be regarded as a non-magnetic substance or an equivalent of a non-magnetic substance as 3=0, and air may be arranged in this space.

[0231] (Modification 5)

When the inter-conductor member of the stator 50 is made of a non-magnetic material, it is possible to use a material other than resin as the non-magnetic material. For example, a metallic non-magnetic material may be used, such as the use of austenitic stainless steel 3 II 3 304.

[0232] (Modification 6)

The stator 50 may not have the stator core 52. In this case, the stator 50 is composed of the stator winding 5 1 shown in Fig. 12. In the stator 50 that does not include the stator core 52, the stator winding 5 1 may be sealed with a sealing material. Alternatively, the stator 50 may include an annular winding holding portion made of a non-magnetic material such as synthetic resin, instead of the stator core 52 made of a soft magnetic material.

[0233] (Modification 7)

In the first embodiment described above, a plurality of magnets 9 1 and 9 2 arranged in the circumferential direction are used as the magnet unit 4 2 of the rotor 40, but this is changed and the magnet unit 4 2 Alternatively, an annular magnet, which is an annular permanent magnet, may be used. Specifically, as shown in FIG. 30, an annular magnet 95 is fixed inside the cylindrical portion 43 of the magnet holder 41 in the radial direction. The annular magnet 95 is provided with a plurality of magnetic poles whose polarities alternate in the circumferential direction, and the magnets are integrally formed on both the axis and the nine axes. The annular magnet 95 is formed with an arc-shaped magnet magnetic path in which the orientation direction is radial in the axis of each magnetic pole and the orientation is circumferential in the axis between the magnetic poles.

[0234] Note that in the annular magnet 95, the easy magnetization axis is oriented in a direction parallel to the axis or parallel to the axis in the portion closer to the axis, and the easy magnetization axis is orthogonal to the axis or orthogonal to the axis in the portion closer to the axis. An arc-shaped magnet magnetic path that is oriented close to It suffices if the orientation is set so that

[0235] (Modification 8)

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

[0236] First, with reference to Fig. 31, the processing in the operation signal generation units 1 16 and 1 26 shown in Fig. 20 and the operation signal generation units 1 30 a and 1 30 b shown in Fig. 21 will be described. explain. The processing in each operation signal generator 1 1 6, 1 26, 1 30 a, 1 3 O b is basically the same. Therefore, the processing of the operation signal generation unit 1 16 will be described below as an example.

[0237] The operation signal generation unit 1 16 includes a carrier generation unit 1 16 a and U, V, W phase comparators 1 16 bU, 1 16 bV, 1 16 bW. .. In the present embodiment, the carrier generation unit 1 16 a generates and outputs a triangular wave signal as the carrier signal S i g C.

[0238] U, V, W phase comparators 1 1 6 b U, 1 1 6 b V, 1 1 6 bW have a carrier signal S ig C generated by the carrier generator 1 1 6 a and a 3-phase The U, V, and W phase command voltages calculated by the converter 1 15 are input. The U, V, and W phase command voltages are, for example, sinusoidal waveforms, and their phases are shifted by 120 ^{° in} terms of electrical angle.

[0239] U, V, W phase comparator 1 1 6 b U, 1 1 6 b V, 1 16 bW is a PWM based on the magnitude comparison of U, V, W phase command voltage and carrier signal S ig C. By (PWM: pulse width modulation) control, the operation signal of each switch S p, S n of the upper arm and lower arm of the U, V, W phases in the first inverter 101 is generated. Specifically, the operation signal generation unit 1 16 uses U, V, and W by performing PWM control based on the magnitude comparison between the signal in which the U, V, and W phase command voltages are normalized by the power supply voltage and the carrier signal. , Generates operation signals for the W-phase switches S p and S n. The driver 1 17 turns on and off the U, V, and W-phase switches S p and S n in the first inverter 101 on the basis of the operation signal generated by the operation signal generation unit 1 16. 〇 2020/175 333 68 卩 (: 171? 2020 /006903

Let it go.

[0240] The control device 110 performs a process of changing the carrier signal 3, the carrier frequency, that is, the switching frequency of each switch 3, 3 n. The carrier frequency is set high in the low torque region or high rotation region of the rotary electric machine 10 and set low in the high torque region of the rotary electric machine 10. This setting is made in order to suppress the deterioration of the controllability of the current flowing through each winding.

[0241] That is, as the stator 50 becomes coreless, the inductance of the stator 50 can be reduced. Here, when the inductance becomes low, the electrical time constant of the rotating electric machine 10 becomes small. As a result, the ripple of the current flowing in each phase winding increases, the controllability of the current flowing in the winding deteriorates, and there is concern that current control may diverge. The influence of this decrease in controllability can be more pronounced when the current flowing in 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 deal with this problem, in this modification, the control device 110 changes the carrier frequency.

[0242] A process of changing the carrier frequency will be described with reference to FIG.

This processing is repeatedly executed by the control device 110, for example, at a predetermined control cycle as the processing of the operation signal generation unit 116.

[0243] At step 310, it is determined whether or not the current flowing through the winding 5 13 of each phase is included in the low current region. This process is a process for determining that the current torque of the rotary electric machine 10 is in the low torque region. The following first and second methods can be given as examples of methods for determining whether or not the current is included in the low current region.

[0244] <First method>

○ 1 Calculate the estimated torque value of the rotating electric machine 10 based on the axis current and 9-axis current converted by the converter 1 1 2. Then, when it is determined that the calculated estimated torque value is less than the torque threshold value, it is determined that the current flowing through the winding 5 13 is included in the low current region, and the estimated torque value is equal to or greater than the torque threshold value. If it is determined, it is determined to be included in the high current region. Where the torque threshold is 〇 2020/175 333 69 卩 (: 171-1? 2020 /006903

For example, it may be set to 1/2 of the starting torque (also called the restraint torque) of the rotating electric machine 10.

[0245] <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 value, the current flowing through the winding 5 13 is included in the low current region, that is, in the high rotation region. Judge that there is. Here, the speed threshold may be set to, for example, the rotation speed when the maximum torque of the rotary electric machine 10 becomes the torque threshold.

[0246] When a negative determination is made in step 3110, it is determined to be in the high current region, and the process proceeds to step 311. In step 3 1 1, the carrier frequency is changed to the first frequency! Set to _.

[0247] When the affirmative judgment is made in Step 310, the process proceeds to Step 312, and the carrier frequency is set to the first frequency! Set to the second frequency higher than _!

According to the present modification described above, the carrier frequency T is set higher when the current flowing in each phase winding is included in the low current region than in the high current region. Therefore, the switching frequency of switches 3 and 3 can be increased in the low current region, and the increase of current ripple can be suppressed. As a result, a decrease in current controllability can be suppressed.

[0249] On the other hand, when the current flowing through each phase wire is included in the high current region, the carrier frequency is set to be lower than when it 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 the increase in the current ripple due to the lower inductance has less effect on the current controllability. .. Therefore, in the high current region, the carrier frequency can be set lower than in the low current region, and the switching loss of each of the inverters 10 1 and 10 2 can be reduced.

[0250] In this modification, the following modes can be implemented.

[0251] Carrier frequency is the first frequency! When set to _, When the affirmative determination is made in step S10 of FIG. 32, the carrier frequency fc may be gradually changed from the first frequency fL toward the second frequency fH.

[0252] Also, when the carrier frequency fc is set to the second frequency fH and the negative determination is made in step S10, the carrier frequency fc is changed from the second frequency fH to the first frequency fL. May be gradually changed toward.

[0253] Instead of the PWM control, the operation signal of the switch may be generated by space vector modulation (SVM: space vector modulation) control. Even in this case, the change of the switching frequency described above can be applied.

[0254] (Modification 9)

In each of the above-described embodiments, two pairs of conductors of each phase forming the conductor wire group 81 are connected in parallel as shown in FIG. 33(a). FIG. 33(a) is a diagram showing the electrical connection between the first and second conductors 88a and 88b, which are two pairs of conductors. Here, instead of the configuration shown in FIG. 33(a), the first and second conducting wires 88a, 88b may be connected in series as shown in FIG. 33(b).

[0255] Further, three or more pairs of multi-layer conductors may be laminated in the radial direction. Figure 34 shows a configuration in which four pairs of conductors, first to fourth conductors 88a to 88d, are stacked. The 1st to 4th conductors 88a to 88d are arranged in the radial direction in the order of the 1st, 2nd, 3rd and 4th conductors 88a, 88b, 88c, 88d from the side closer to the stator core 52. Are arranged side by side.

[0256] Here, as shown in Fig. 33 (c), the third and fourth conductors 88c and 88d are connected in parallel, and the first conductor 88a is connected to one end of the parallel connection body. The second conducting wire 88 b may be connected to the other end. When connected in parallel, the current density of the parallel-connected conductors can be reduced, and heat generation during energization can be suppressed. Therefore, in the configuration where the cylindrical stator winding is assembled in the housing (unit base 61) in which the cooling water passage 74 is formed, the first and second conductors 88a, 88b that are not connected in parallel are The third and fourth conductors 88 c, 88 d, which are arranged on the side of the stator core 52 that abuts on the unit base 61 and connected in parallel, are arranged on the side of the non-stator core. This gives a multi-layer conductor structure 〇 2020/175333 71 卩(: 171? 2020/006903

It is possible to equalize the cooling performance of each of the conducting wires 883 to 8801.

[0257] Note that the radial thickness dimension of the conductor wire group 8 1 composed of the first to fourth conductor wires 8 8 3 to 8 8 is smaller than the circumferential width dimension of one phase in one magnetic pole. It should have been done.

[0258] (Modification 10)

The rotating electric machine 10 may have an inner rotor structure (inner rotation structure). In this case, for example, in the housing 30, it is preferable that the stator 50 is provided on the outer side in the radial direction and the rotor 40 is provided on the inner side in the radial direction. Further, the inverter unit 60 may be provided on one side or both sides of both 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. is there.

[0259] The configurations of Figs. 35 and 36 assuming the inner rotor structure are different from the configurations of Figs. 8 and 9 assuming the outer rotor structure in that the rotor 40 and the stator 50 are radially inner and outer. It has the same configuration except that it is reversed in. Briefly, the stator 50 has a stator winding 5 1 having a flat conductor structure and a stator core 5 2 having no teeth. The stator winding 51 is assembled inside the stator core 52 in the radial direction. The stator core 52 has one of the following configurations, as in the case of the outer rotor structure.

(8) On the stator 50, provide inter-conductor members between each conductor in the circumferential direction, and as the inter-conductor members, set the circumferential width dimension of the inter-conductor member for one magnetic pole to 1, If the saturation magnetic flux density of the member is 3, and the circumferential width of the magnet unit in one magnetic pole is ◯!, and the residual magnetic flux density of the magnet unit is ‘

"A magnetic material having a relationship of "is used.

(Mitsumi) 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.

(◯) In the stator 50, the inter-conductor members are not provided between the conductor portions in the circumferential direction. 〇 2020/175333 72 卩 (：171? 2020 /006903

[0260] The same applies to the magnets 9 1 and 9 2 of the magnet unit 42. In other words, the magnet unit 42 is oriented so that the direction of the easy axis of magnetization is parallel to the axis on the Axis 1 side, which is the center of the magnetic pole, compared to the axis 9 side, which is the magnetic pole boundary. The magnets 9 1 and 9 2 are used. The details of the magnetization direction of each magnet 9 1, 9 2 are as described above. It is also possible to use an annular magnet 95 (see Fig. 30) in the magnet unit 42.

[0261] Fig. 37 is a vertical cross-sectional view of the rotating electric machine 10 in the case of the inner rotor type, which corresponds to Fig. 2 described above. Differences from the configuration of FIG. 2 will be briefly described. In FIG. 37, an annular stator 50 is fixed inside the housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap in between. ing. Similar to Fig. 2, the bearings 21 and 22 are arranged so as to be offset to either side in the axial direction with respect to the center of the rotor 40 in the axial direction. Has been supported. Further, the inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.

[0262] Fig. 38 shows another configuration of the rotary electric machine 10 having an inner rotor structure. Figure

In the housing 38, the rotating shaft 11 is rotatably supported by the bearings 21 and 22 in the housing 30 and the rotor 40 is fixed to the rotating shaft 11. Similar to the configuration shown in FIG. 2 and the like, 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. The rotor 40 has a magnet holder 41 and a magnet unit 42.

[0263] The rotating electric machine 10 of Fig. 38 differs from the rotating electric machine 10 of Fig. 37 in that the rotor unit 40 is not provided with the inverter unit 60 inside the radial direction. ing. The magnet holder 41 is connected to the rotary shaft 11 at a position radially inward of the magnet unit 42. The stator 50 has a stator winding 5 1 and a stator core 52, and is attached to the housing 30.

[0264] (Modification 1 1) 〇 2020/175333 73 卩(: 171-1? 2020/006903

Another configuration of the rotating electric machine having the inner rotor structure will be described below. FIG. 39 is an exploded perspective view of the rotary electric machine 200, and FIG. 40 is a side sectional view of the rotary electric machine 200. Here, the vertical direction is shown based on the states of FIGS. 39 and 40.

[0265] As shown in FIGS. 39 and 40, the rotary electric machine 200 has an annular stator core 2

0 1 and a stator 20 3 having a multi-phase stator winding 20 2, and a rotor 20 4 rotatably arranged inside the stator core 20 1. The stator 203 corresponds to an armature, and the rotor 2044 corresponds to a field element. The stator core 20 1 is configured by laminating a large number of silicon steel plates, and the stator windings 20 2 are attached to the stator core 20 1. Although not shown, the rotor 204 has a rotor core and a plurality of permanent magnets as a magnet unit. The rotor core is provided with a plurality of magnet insertion holes at equal intervals in the circumferential direction. A permanent magnet magnetized so that the magnetizing direction is alternately changed for each adjacent magnetic pole is attached to each of the magnet insertion holes. The permanent magnet of the magnet unit may have the Halbach array as described in Fig. 23 or a similar structure. Alternatively, in the permanent magnet of the magnet unit, the orientation direction (magnetization direction) extends in an arc shape between the axis that is the magnetic pole center and the axis that is the magnetic pole boundary as described in FIGS. 9 and 30. It is preferable to have polar anisotropy characteristics.

[0266] Here, the stator 203 may have any of the following configurations.

(8) In the stator 203, an inter-conductor member is provided between each conductor portion in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the inter-conductor member in one magnetic pole is 1, and the inter-conductor member is Where the saturation magnetic flux density of the magnet unit is 3, and the width of the magnet unit in the circumferential direction in one magnetic pole is defined as, and the residual magnetic flux density of the magnet unit is defined as

"A magnetic material having a relationship of "is used.

(Mimi) 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.

(〇) In the stator 203, an inter-conductor member is placed between the conductor parts in the circumferential direction. 〇 2020/175333 74 卩(: 171-1? 2020/006903

It is not provided.

[0267] Further, in the rotor 204, the magnet unit is oriented so that the direction of the easy magnetization axis is parallel to the axis on the side of the axis that is the center of the magnetic pole, compared to the side of the axis that is the magnetic pole boundary. It is composed of a plurality of magnets.

[0268] An annular inverter case 211 is provided on one end side of the rotary electric machine 200 in the axial direction. The inverter case 2 11 is arranged such that the lower surface of the case is in contact with the upper surface of the stator core 2 0 1. Inside the inverter case 2 11 are a plurality of power modules 2 12 that make up the inverter circuit, and a smoothing capacitor 2 1 3 that suppresses the ripples of voltage and current generated by the switching operation of the semiconductor switching elements. A control board 2 14 having a control unit, a current sensor 2 15 for detecting a phase current, and a resolver stator 2 16 which is a rotation speed sensor of the rotor 20 4 are provided. The power module 2 1 2 has a semi-conducting switching element, such as a knife and a diode.

[0269] A power connector 2 17 connected to the DC circuit of the battery mounted on the vehicle and the rotary electric machine 200 0 side and the vehicle side control device are provided on the periphery of the inverter case 2 11. A signal connector 2 18 used to transfer various signals is provided. The inverter case 2 1 1 1 is covered with a top cover 2 1 9. DC power from the on-vehicle battery is input via the power connector 2 17 and is converted to AC by the switching of the power module 2 1 2 and sent to the stator winding 20 2 of each phase.

[0270] On both sides in the axial direction of the stator core 201, on the side opposite to the inverter case 211, a bearing unit 2221 for rotatably holding the rotating shaft of the rotor 204 and its An annular rear case 2 2 2 which houses the bearing unit 2 2 1 is provided. The bearing unit 2 21 has, for example, a pair of bearings, and is arranged so as to be deviated to either one side in the axial direction with respect to the axial center of the rotor 204. However, a plurality of bearings in the bearing unit 2 21 may be provided dispersedly on both sides in the axial direction of the stator core 2 0 1, and the bearing may support both ends of the rotary shaft. The rear case 2 2 2 is used to mount the gear case and transmission of the vehicle. 〇 2020/175333 75 卩(: 171-1? 2020/006903

The rotary electric machine 200 can be mounted on the vehicle side by being bolted and fixed to the attachment part.

[0271] Inside the inverter case 211, a cooling channel 211 for flowing a refrigerant is formed. The cooling flow path 2 1 1 1 3 is formed by closing a space that is annularly recessed from the lower surface of the inverter case 2 1 1 with the upper surface of the stator core 2 0 1. The cooling channel 2 11 3 is formed so as to surround the coil end of the stator winding 2 0 2. The module case 2 1 2 ₃ of the power module 2 1 2 is put into the cooling passage 2 1 1 3. Also in the rear case 2 22, a cooling flow path 2 2 2 3 is formed so as to surround the coil end of the stator winding 2 0 2. The cooling channel 2 2 2 ₃ is formed by closing a space, which is annularly recessed from the upper surface of the rear case 2 2 2, with the lower surface of the stator core 2 0 1.

[0272] (Modification 12)

Up to now, the configuration embodied in the rotating field type rotating electric machine has been described, but it is also possible to change this and realize the rotating armature type rotating electric machine. Figure 4 1 shows the structure of a rotating armature-type rotating electric machine 230.

[0273] In the rotary electric machine 230 shown in Fig. 41, the housing

A bearing 2 3 2 is fixed to each of the 2 3 1 bearings, and the rotating shaft 2 3 3 is rotatably supported by the bearing 2 3 2. The bearing 23 2 is, for example, an oil-impregnated bearing made of porous metal containing oil. The rotor 2 3 4 as an armature is fixed to the rotary shaft 2 3 3. The rotor 2 3 4 has a rotor core 2 3 5 and a multiphase rotor winding line 2 3 6 fixed to the outer periphery of the rotor core 2 3 5. In the rotor 2 3 4, the rotor core 2 3 5 has a slotless structure, and the rotor winding wire 2 3 6 has a flat conductor structure. In other words, the rotor winding line 2 36 has a flat structure in which the region for each phase is longer in the circumferential direction than in the radial direction.

[0274] Further, a stator 237 serving as a field element is provided on the outer side in the radial direction of the rotor 234. The stator 2 3 7 has a stator core 2 3 8 fixed to the housing 2 3 1 3 and a magnet unit 2 3 9 fixed to the inner peripheral side of the stator core 2 3 8. ing. Magnet unit 2 3 9 has multiple magnets with alternating polarity in the circumferential direction. 〇 2020/175 333 76 卩 (：171? 2020 /006903

As in the previously described magnet unit 42, etc., on the side of the axis that is the center of the magnetic pole, the direction of the easy axis of magnetization is closer to the axis that is the magnetic pole boundary than the side of the axis that is the magnetic pole boundary. It is configured so that it is oriented parallel to. The magnet unit 2339 has an oriented sintered neodymium magnet, and its intrinsic coercive force is more than 400 [1 </○!] and the residual magnetic flux density is 1.0 [ It's over.

[0275] The rotary electric machine 230 of this example is a 2-pole 3-coil brushless coreless motor, the rotor winding 2 36 is divided into 3 parts, and the magnet unit 2 3 9 is 2-pole. .. The number of poles and the number of coils of the brushed motor varies depending on the application, such as 2:3, 4:1 0, and 4:1.

[0276] A commutator 2 4 1 is fixed to the rotating shaft 2 3 3, and a plurality of brushes 2 4 2 are arranged on the radially outer side of the commutator 2 4 1. The commutator 2 4 1 is electrically connected to the rotor winding 2 3 6 via a conductor 2 4 3 embedded in the rotating shaft 2 3 3. A direct current flows in and out of the rotor winding 2 3 6 through these commutator 2 4 1, brush 2 4 2, and conductor 2 4 3. The commutator 2 4 1 is appropriately divided in the circumferential direction according to the number of phases of the rotor winding line 2 3 6. The brush 2 42 may be directly connected to a DC power source such as a storage battery via electric wiring, or may be connected to a DC power source via a terminal block or the like.

[0277] The rotating shaft 2 3 3 is provided with a resin washer 2 4 4 as a seal material between the bearing 2 3 2 and the commutator 2 4 1. The resin washer 2 4 4 prevents the oil exuding from the oil-impregnated bearing 2 3 2 from flowing out to the commutator 2 4 1 side.

[0278] (Modification 13)

In the stator winding 5 1 of the rotating electric machine 10, each conductor wire 82 may have a plurality of insulating coatings inside and outside. For example, it is advisable to bundle a plurality of conductive wires (elementary wires) with an insulating coating and to cover them with an outer coating to form the conductive wire 82. In this case, the insulation coating of the wires constitutes the inner insulation coating, and the outer coating is the outer insulation coating. 〇 2020/175333 77 卩(: 171-1? 2020/006903

It constitutes an insulating film. Further, it is particularly preferable that the insulating ability of the outer insulating coating of the plurality of insulating coatings of the conductor 82 is higher than that of the inner insulating coating. Specifically, the thickness of the outer insulating coating is made thicker than the thickness of the inner insulating coating. For example, the thickness of the outer insulating coating is 100, and the thickness of the inner insulating coating is 40. 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 of wire may be configured as an aggregate of a plurality of conductive materials.

[0279] By strengthening the insulation of the outermost layer of the conductive wire 82 as described above, it becomes suitable for use in a vehicle system with high voltage. Further, the rotating electric machine 10 can be properly driven even in a high place where the atmospheric pressure is low.

[0280] (Modification 14)

In the conductor 82 having a plurality of insulating coatings inside and outside, at least one of the linear expansion coefficient (coefficient of linear expansion) and the adhesive strength may be different between the outer insulating coating and the inner insulating coating. Figure 4 2 shows the structure of the conducting wire 82 in this modification.

[0281] In Fig. 42, a conductor wire 8 2 is composed of a plurality of (four in the figure) element wires 1 81 and an outer layer film 1 82 2 made of, for example, resin surrounding the plurality of element wires 1 8 1 (outer insulation Coating) and an intermediate layer 183 (intermediate insulating coating) filled around each element wire 1 81 in the outer coating 182. The element wire 1 81 has a conductive portion 181 3 made of a copper material and a conductor film 181 (inner insulating film) made of an insulating material. When viewed as a stator winding, the outer layer coating 182 insulates the phases. In addition, it is preferable that the wire 181 is configured as an aggregate of a plurality of conductive materials.

[0282] The intermediate layer 183 has a linear expansion coefficient higher than that of the conductor coating 181 of the element wire 181 and lower than that of the outer coating 182. In other words, the conductor 82 has a higher linear expansion coefficient toward the outer side. In general, the outer coating 1 82 has a higher linear expansion coefficient than the conductor coating 1 81, but by providing an intermediate layer 1 8 3 having a linear expansion coefficient between them, Layer 1 8 3 〇 2020/175 333 78 卩 (: 171? 2020 /006903

It functions as a cushion material and can prevent simultaneous cracks on the outer and inner layers.

[0283] In addition, in the case of the conductor wire 8 2, the conductive portion 1 8 1 ₃ and the conductor film 1 8 1

1 Stain is adhered, and conductor coating 1 8 1 Stain and intermediate layer 1 8 3 are bonded, and intermediate layer 1 8 3 and outer coating 1 8 2 are also bonded. The adhesive strength is weaker toward the outside. In other words, the adhesive strength of the conductive part 181 ₃ and the conductor film 181 is the adhesive strength of the conductor film 181 and the intermediate layer 183, and the adhesive strength of the intermediate layer 183 and the outer layer 182. It is getting weaker than that. Also, comparing the adhesive strength of the conductor coating 1 81 and the intermediate layer 1 83 with the adhesive strength of the intermediate layer 1 8 3 and the outer coating 1 82, the latter (outer) is weaker? Or it is good to be equivalent. The magnitude of the adhesive strength between the coatings can be grasped, for example, from the tensile strength required to peel off the two coating layers. By setting the adhesive strength of the conducting 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 there is a difference in temperature between the inside and outside due to heat generation or cooling. You can

[0284] Here, the heat generation and temperature change of the rotating electric machine mainly occur as copper loss generated from the conductive portion 181 ₃ of the wire 181 and iron loss generated from the inside of the iron core. The type of loss is

Alternatively, the heat is transmitted from the outside of the conducting wire 82, and the intermediate layer 183 does not have a heat source. In this case, the intermediate layer 183 has an adhesive force capable of acting as a cushion for both, so that the simultaneous cracking can be prevented. Therefore, it can be suitably used even in the field of high withstand voltage or large temperature change such as vehicle application.

[0285] The following is supplemented. The strand 1 8 1 may be, for example, an enameled wire, and in such a case, it has a resin coating layer of I, I, etc. (conductor coating 18 1 匕). Further, it is desirable that the outer layer coating 1 82 outside the element wire 1 81 be made of the same material, such as 丨 and 縨, and be thick. As a result, the destruction of the coating film due to the difference in linear expansion coefficient is suppressed. In addition, as the outer layer coating 1 82, apart from those corresponding to the above materials such as 8, I, and 8 I by thickening them, 〇 2020/175333 79 卩(: 171-1?2020/006903

3, Mimi, Fluorine, Polycarbonate, Silicone, Epoxy, Polyethylene naphthalate,! It is also desirable to use a material with a dielectric constant such as __ that is smaller than 8 or 8 in order to increase the conductor density of the rotating machine. With these resins, even if they are thinner than the equivalent conductor film 1 81 1 \, PA \ film, or have the same thickness as the conductor film 1 8 1 13, the insulation ability can be increased. As a result, it becomes possible to increase the occupation ratio of the conductive portion. Generally, the above-mentioned resin has a better dielectric constant than the insulating coating of the enamel wire. Of course, there are some cases where the dielectric constant deteriorates depending on the molding conditions and the mixture. Among them, 3, the coefficient of linear expansion is generally larger than that of the enamel coating, but the coefficient of thermal expansion is smaller than that of the other resins, and therefore, 3, is suitable as the outer layer coating of the second layer.

[0286] Further, the adhesive strength between the two kinds of coatings (intermediate insulation coating and outer insulation coating) on the outside of the strand 1 81 and the enamel coating of the strand 1 8 1 is the copper strength of the strand 1 8 1. It is desirable that it be weaker than the bond strength between the and enamel coating. This suppresses the phenomenon that the enamel coating and the above two types of coatings are destroyed at once.

[0287] 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 from the outer layer coating 182. However, even if the insulating layer of the wire 181 and the two types of coatings are different from each other, the thermal stress and impact stress can be reduced by providing a part that does not bond the coatings. it can. That is, a gap is formed between the element wire (enamel wire) and fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate,! By disposing _ ◯, the insulating structure is formed. In this case, it is desirable to bond the outer layer coating and the inner layer coating with an adhesive material such as epoxy having a low dielectric constant and a low linear expansion coefficient. By doing so, not only the mechanical strength but also the destruction of the coating due to the friction due to the vibration of the conductive portion or the destruction of the outer coating due to the difference in the linear expansion coefficient can be suppressed.

[0288] With respect to the conductor wire 8 2 having the above-mentioned configuration, epoxy, 3, 〇 2020/175333 80 卩 (: 171-1? 2020 /006903

It is preferable to use a resin having good moldability such as Mimi 1_○ and having properties such as dielectric constant and linear expansion coefficient similar to those of an enamel coating.

[0289] —Usually, resin potting with urethane or silicon is generally used. However, the linear expansion coefficient of the resin is nearly double that of other resins, and the thermal stress that can shear the resin is appear. Therefore, it is not suitable for applications above 60 V where strict insulation regulations are used internationally. In this respect, epoxy, 3, Mami,! According to the final insulation process that can be easily made by injection molding or the like with _ 0 or the like, each of the above requirements can be achieved.

[0290] Modifications other than the above will be listed below.

[0291] The distance port 1\/1 in the radial direction between the surface of the magnet unit 4 2 on the armature side in the radial direction and the rotor shaft center is 50

The above may be mentioned. Specifically, for example, the inner surface in the radial direction of the magnet unit 4 2 (specifically, the first and second magnets 9 1 and 9 2) shown in FIG. 4 and the axial center of the rotor 40. In the radial direction of and

The above may be mentioned.

[0292] As a rotating electric machine with a slotless structure, a small-scale one whose output is used for a model of several tens to several hundreds of classes is known. In addition, the present inventors do not understand a case in which a slotless structure is adopted in a large industrial rotary electric machine that generally exceeds 10. The reason for this was clarified by the present inventor.

[0293] In recent years, mainstream rotating electrical machines are roughly classified into the following four types. These rotating electrical machines are brushed motors, cage induction motors, permanent magnet synchronous motors, and reluctance motors.

[0294] An exciting current is supplied to the brushed motor via the brush. For this reason, in the case of a brushed motor of a large machine, the brush becomes large and maintenance becomes complicated. As a result, with the remarkable development of semiconductor technology, it has been replaced by brushless motors such as induction motors. On the other hand, in the world of small motors, coreless motors have been supplied to the majority due to their advantages of low inertia and economy. 〇 2020/175333 81 卩 (: 171-1? 2020 /006903

[0295] In the basket-type induction motor, the magnetic field generated in the stator winding on the primary side is received by the iron core of the rotor on the secondary side, and the induced current is concentrated in the cage-type conductor to form a reaction magnetic field. This is the principle of generating torque. For this reason, it is not necessarily a good idea to eliminate the iron cores on both the stator side and rotor side from the viewpoint of the small size and high efficiency of the equipment.

[0296] Reluctance motors are motors that utilize reluctance changes in the iron core, and it is not desirable to eliminate the iron core in principle.

[0297] In the permanent magnet type synchronous motor, I 1\/1 (that is, embedded magnet type rotor) has been predominant in recent years, and especially in a large machine, it is often the IV! unless there are special circumstances.

[0298] I 1\/1 has a characteristic that it has both magnet torque and reluctance torque, and is operated by the inverter control while the ratio of those torques is adjusted in a timely manner. For this reason, the 丨 IV! is a small motor with excellent controllability.

[0299] According to the analysis of the present disclosure, the torque of the rotor surface that generates the magnet torque and the reluctance torque is measured in the radial direction of the surface of the magnet unit on the armature side in the radial direction and the axial center of the rotor. Distance IV!, that is, the radius of the stator core of a typical Innaro-Yu is plotted along the horizontal axis as shown in Fig. 43.

[0300] The magnet torque is determined by the magnetic field strength generated by the permanent magnet as shown in the following equation (6 9 1), while the reluctance torque is shown in the following equation (6 2). Thus, the magnitude of the inductance, especially the axial inductance, determines its potential.

[0301] Magnet torque

1 ??? ((ø

9 1)

Reluctance torque = !<

.1 .1 ○ 1 .( 6

9 2)

Here, I compared the magnetic field strength of the permanent magnet and the magnitude of the inductance of the winding with mouth IV!. The magnetic field strength 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. If a cylindrical rotor, 〇 2020/175333 82 卩(: 171-1? 2020/006903

Becomes the surface area. Strictly speaking, there are 1\1 poles and 3 poles, so it is proportional to the occupied area of 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 cylinder length is constant, it is proportional to the radius of the cylinder.

[0302] —On the other hand, the inductance 1_9 of the winding depends on the shape of the iron core, but the sensitivity is low. Rather, it is proportional to the square of the number of turns of the stator winding, and thus the number of turns is highly dependent. Where is the permeability of the magnetic circuit,

Inductance 1_ = 1\1 2 \3/5, where is the number of turns, 3 is the cross-sectional area of the magnetic circuit, and 3 is the effective length of the magnetic circuit. Since the number of turns of the winding depends on the size of the winding space, in the case of a cylindrical motor, it depends on the winding space of the stator, that is, the slot area. As shown in Fig. 44, the slot area is proportional to the product of the circumferential length dimension 3 and the radial length dimension 3 3 x 3 because the slot shape is approximately square. ..

[0303] The length of the slot in the circumferential direction increases as the diameter of the cylinder increases, and is proportional to the diameter of the cylinder. The radial dimension of the slot is in proportion to the diameter of the cylinder. So the slot area is proportional to the square of the diameter of the cylinder. Further, as can be seen from the above equation (62), the reluctance torque is proportional to the square of the stator current, so the performance of the rotating electrical machine is determined by how large the current can flow, and the performance is determined by the stator slot. It depends on the area. 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. With this in mind, Fig. 43 shows a plot of the relationship between magnet torque and reluctance torque and mouth IV!.

[0304] As shown in Fig. 43, the magnet torque increases linearly with the mouth IV!, and the reluctance torque increases quadratically with the mouth IV!. It can be seen that when the mouth IV! is relatively small, the magnet torque is dominant, and the reluctance torque is dominant as the stator core radius increases. The present applicant 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 = 500!!! That is, the stator core radius is 5

Which is well over 1 0

In a class motor, 〇 2020/175 333 83 卩 (: 171-1? 2020 /006903

It is difficult to eliminate the iron core because it is currently the mainstream to utilize reluctance torque, and this is considered to be one of the reasons why the slotless structure is not adopted in the field of large machines.

[0305] In the case of a rotating electric machine in which an iron core is used for the stator, magnetic saturation of the iron core is always an issue. Particularly in radial gap type rotating electrical machines, the vertical cross-sectional shape of the rotating shaft is fan-shaped per magnetic pole, and the magnetic path width becomes narrower toward the inner peripheral side of the equipment, and the inner diameter of the teeth forming the slot rotates. Determine the performance limit of the electric machine. No matter how high-performance permanent magnets are used, if magnetic saturation occurs in this part, the performance of permanent magnets cannot be fully exploited. In order to prevent magnetic saturation from occurring in this part, the inner diameter must be designed to be large, resulting in an increase in the size of the equipment.

[0306] For example, in a distributed winding rotary electric machine, in the case of a three-phase winding, magnetic flux is distributed by three to six teeth per magnetic pole, but the magnetic flux is concentrated in the teeth in the front in the circumferential direction. Therefore, the magnetic flux does not flow evenly in the three to six teeth. In this case, the magnetic flux concentrates on some of the teeth (for example, one or two), while the teeth that are magnetically saturated also move in the circumferential direction as the rotor rotates. This is also a factor in producing a slotle pill.

[0307] From the above, mouth 1\/1 is 5

To eliminate magnetic saturation in a slotless rotating electric machine, which has the following problem, we would like to eliminate teeth. 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. The reason for the increase in magnetic resistance is, for example, that the air gap between the rotor and the stator becomes large. Therefore, the above-mentioned mouth 1\/1 is 5

In the above-mentioned slotless rotating electrical machine

, There is room for improvement in increasing torque. Therefore, as mentioned above

There is a great advantage in applying the above-mentioned configuration capable of increasing the torque to the slotless rotating electric machine described above.

[0308] Not only the rotating electric machine having the outer rotor structure but also the rotating electric machine having the inner rotor structure, the surface of the magnet unit on the armature side in the radial direction and the rotor are 〇 2020/175 333 84 卩 (: 171? 2020 /006903

Radial distance from the axis of

[0309] In the stator winding 5 1 of the rotating electric machine 10, the linear portion 8 3 of the conducting wire 8 2 may be provided in a single layer in the radial direction. Further, when the straight line portion 83 is arranged in a plurality of layers inside and outside in the radial direction, the number of layers may be arbitrary, and may be three layers, four layers, five layers, six layers or the like.

[0310] For example, in the configuration of FIG. 2, the rotary shaft 11 is provided so as to project in both the one end side and the other end side of the rotary electric machine 10 in the axial direction. However, this is changed to only one end side. It may be configured to project. In this case, the rotary shaft 11 may be provided so as to extend outward in the axial direction with the end portion being a portion that is cantilevered by the bearing unit 20. In this configuration, since the rotary shaft 11 does not project inside 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. Becomes

[031 1] In the rotating electric machine 10 having the above configuration, the bearings 2 1 and 2 2 use the non-conductive grease, but this is changed, and the bearings 2 1 and 2 2 use the conductive grease. It may be configured. For example, the conductive grease containing metal particles and carbon particles is used.

[0312] As a structure for rotatably supporting the rotating shaft 11, bearings may be provided at two power points on the axially one end side and the other end side of the rotor 40. In this case, in terms of the configuration of FIG. 1, bearings may be provided at two power points on one end side and the other end side with the inverter unit 60 interposed therebetween.

[0313] In the rotary electric machine 1 0 having the above structure, but between 4 5 within the magnet holder 4 1 In the rotor 4 0 is configured to have an outer shoulder 4 9 spoon interior shoulder 4 9 ₃ and emotions, These shoulders 4 9

It is also possible to eliminate the gap and to have a flat surface.

[0314] In the rotary electric machine 10 configured as described above, a conductor is provided in the conductor wire 8 2 of the stator winding 5 1.

8 23 is configured as an assembly of a plurality of element wires 8 6, but this may be modified to use a rectangular conductive wire having a rectangular cross section as the conductive wire 8 2. Alternatively, a circular conductor having a circular cross section or an elliptical cross section may be used as the conductor 82. 〇 2020/175333 85 卩 (: 171? 2020 /006903

[0315] In the rotating electric machine 10 having the above-described configuration, the imper unit 60 is provided inside the stator 50 in the radial direction. However, instead of this, an inverter unit is provided inside the stator 50 in the radial direction. A configuration without 60 may be adopted. In this case, it is possible to set a space inside the inner region of the stator 50 in the radial direction. In addition, it is possible to place components different from the inverter unit 60 in the internal area.

[0316] The rotary electric machine 10 having the above configuration may not have the housing 30. In this case, for example, in ^_ part of the wheel and other vehicle components, rotating rotor 4 0, it may be configured such that the stator 5 0 and the like are retained.

[0317] (Embodiment as in-wheel motor for vehicle)

Next, an embodiment in which the rotary electric machine is provided as an in-wheel motor integrally with a vehicle wheel will be described. FIG. 45 is a perspective view showing a wheel 400 of the 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. 4 is an exploded perspective view of a wheel 400. FIG. 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 this embodiment can be applied to various types of vehicles.For example, in the case of a vehicle having two wheels on the front and rear sides of the vehicle, the two wheels on the front side of the vehicle It is possible to apply the in-wheel motor structure of the present embodiment to the two rear wheels or the four front and rear wheels of the vehicle. However, it can be applied to a vehicle in which at least one of the front and rear of the vehicle has one wheel. The in-wheel motor is an example of application as a vehicle drive unit.

[0318] As shown in FIGS. 45 to 47, the wheels 400 include, for example, a tire 4001 that is a well-known pneumatic tire, and a wheel 4 that is fixed to the inner circumferential side of the tire 4101. 0 2 and a rotating electric machine 5 00 fixed to the inner peripheral side of the wheel 4 02. The rotating electric machine 500 has a fixed portion that is a portion that includes a stator (stator) and a rotating portion that is a portion that includes a rotor (rotor). The fixed portion is fixed to the vehicle body side and The part is fixed to the wheel 4 02, and the tire 4 01 and the wheel 4 02 rotate due to the rotation of the rotating part. The rotary electric machine 500 〇 2020/175 333 86 卩 (：171? 2020 /006903

The detailed configuration including the fixed portion and the rotating portion will be described later.

[0319] Further, the wheel 400 includes, as peripheral devices, a suspension device that holds the wheel 400 with respect to a vehicle body (not shown), a steering device that can change the direction of the wheel 400, and a wheel. A brake device for braking 400 is installed.

[0320] The suspension device is an independent suspension type suspension, and any type such as a trailing arm type, a strut type, a wishbone type, or a multi-link type can be applied. In the present embodiment, as the suspension device, the lower arm 4 11 is provided so as to extend toward the center side of the vehicle body, and the suspension arm 4 1 2 and the spring 4 1 3 are provided so as to extend upward and downward. The suspension arm 4 1 2 may be configured as a shock absorber, for example. However, its detailed illustration is omitted. The lower arm 4 11 and the suspension arm 4 12 are both connected to the vehicle body side and also connected to a disk-shaped base plate 4 05 fixed to a fixed portion of the rotating electric machine 500. As shown in Fig. 46, on the rotary electric machine 500 side (base plate 450 side), the lower arm 4 11 and the suspension arm 4 1 2 are coaxial with each other by the support shafts 4 1 4 and 4 1 5. Supported by.

[0321] As the steering device, for example, a rack and pinion structure, a ball and nut structure, a hydraulic power steering system, or an electric power steering system can be applied. In the present embodiment, a rack device 4 2 1 and a tie rod 4 2 2 are provided as steering devices, and the rack device 4 21 is mounted on the rotary electric machine 5 00 side via the tie rod 4 2 2. Connected to plate 405. In this case, when the rack device 4 2 1 is operated in accordance with the rotation of the steering shaft (not shown), the tie rod 4 2 2 moves to the left and right of the vehicle. As a result, the wheel 400 rotates about the support shafts 4 1 4 and 4 15 of the lower arm 4 11 and the suspension arm 4 12 and the wheel direction is changed.

[0322] As the braking device, it is preferable to apply a disc brake or a drum brake. 〇 2020/175 333 87 卩 (: 171? 2020 /006903

Is. In the present embodiment, as a brake device, a disk rotor 431 fixed to a rotary shaft 5001 of a rotating electric machine 500 and a brake carriage fixed to a base plate 405 on the rotating electric machine 500 side. 4 3 2 is provided. The brake pad of the brake bar 4 32 is actuated by hydraulic pressure, etc., and the brake pad is pressed against the disc rotor 4 31 to generate a braking force due to friction, and the wheel 4 0 0 rotation is stopped.

[0323] Further, the wheel 400 is provided with a housing duct 440 for housing the electric wiring !I 1 and the cooling pipe !2 extending from the rotary electric machine 500. The accommodating duct 440 extends along the end surface of the rotating electric machine 500 from the end of the rotating electric machine 500 on the fixed side, and is provided so as to avoid the suspension arm 412, and in that state, the suspension duct It is fixed to arm 4 1 2. As a result, the connection position of the accommodating duct 440 in the suspension arm 412 is fixed relative to the base plate 405. Therefore, it is possible to suppress the stress caused by the vibration of the vehicle in the electric wiring !I 1 and the cooling pipe !2. The electric wiring! I 1 is connected to an on-vehicle power supply unit and an on-vehicle MII II which are not shown, and the cooling pipe! I 2 is connected to a radiator which is not shown.

[0324] Next, the configuration of the rotary electric machine 500 used as an in-wheel motor will be described in detail. In this embodiment, an example in which the rotary electric machine 500 is applied to an in-wheel motor is shown. The rotary electric machine 500 has excellent operating efficiency and output as compared with a motor of a vehicle drive unit having a speed reducer as in the related art. In other words, if the rotary electric machine 500 is used in applications where it is possible to achieve a practical price by reducing costs compared to the conventional technology, it may be used as a motor for applications other than vehicle drive units. Even in such a case, the same excellent performance as when applied to the in-wheel mode is exhibited. The operating efficiency refers to the index used during the test in the driving mode that derives the fuel consumption of the vehicle.

[0325] The outline of the rotating electric machine 500 is shown in Figs. 48 to 51. Fig. 48 shows the rotary electric machine 50

Fig. 4 is a side view of 0 viewed from the protruding side (inside of the vehicle) of the rotating shaft 501, and Fig. 49 is a vertical cross-sectional view of the rotating electric machine 550 (cross-sectional view taken along line 4 9-4 9 in Fig. 48). And Figure 50 〇 2020/175 333 88 卩 (：171? 2020 /006903

FIG. 5 is a cross-sectional view of the rotary electric machine 500 (a cross-sectional view taken along the line 50-500 in FIG. 49), and FIG. 51 is an exploded cross-sectional view of the components of the rotary electric machine 500. In the following description, the direction of the rotary shaft 50 1 extending in the outer direction of the vehicle body is the axial direction in FIG. 51, and the direction extending radially from the rotary shaft 50 1 is the radial direction. The center of the axis of rotation 5 0 1, in other words, the center of rotation of the rotating part, is drawn on the center line drawn to make the cross-section 4 9 passing through, and from any point other than the center of rotation of the rotating part Each of the two extending directions is the circumferential direction. In other words, the circumferential direction may be either a clockwise direction starting from an arbitrary point on the cross section 49 or a counterclockwise direction. Further, in the state of being mounted on the vehicle, the right side is the vehicle outside and the left side is the vehicle inside in FIG. In other words, from the state of being mounted on the vehicle, the rotor 510 described later is arranged more to the outside of the vehicle body than the rotor force bar_670.

[0326] 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 is roughly divided into a rotor 510, a stator 520, an inverter unit 5300, a bearing 560, and a rotor cover 670. Each of these members is coaxially arranged with respect to a rotating shaft 501, which is integrally provided in the rotor 5100, and is assembled in a predetermined order in the axial direction to form the rotating electric machine 500. There is.

[0327] In the rotating electric machine 500, the rotor 510 and the stator 520 each have a cylindrical shape, and are arranged to face each other across an air gap. The rotor 5 10 rotates integrally with the rotating shaft 5 0 1, so that the rotor 5 10 rotates on the radially outer side of the stator 5 20. The rotor 5 1 0 corresponds to the "field element" and the stator 5 2 0 corresponds to the "armature".

[0328] The rotor 5110 has a substantially cylindrical rotor carrier 511 and an annular magnet unit 512 fixed to the rotor carrier 511. The rotating shaft 5 0 1 is fixed to the rotor carrier 5 1 1.

[0329] The rotor carrier 5 11 has a cylindrical portion 5 13. A magnet unit 5 12 is fixed to the inner peripheral surface of the cylindrical portion 5 13. In other words, magnet unit 5 1 〇 2020/175333 89 卩 (: 171-1? 2020 /006903

2 is provided in a state of being surrounded by the cylindrical portion 5 13 of the rotor carrier 5 11 from the outside in the radial direction. Further, the cylindrical portion 5 13 has a first end and a second end that face each other in the axial direction. The first end is located outside the vehicle body and the second end is located in the direction in which the base plate 405 exists. In the rotor carrier 511, an end plate 514 is continuously provided at the first end of the cylindrical portion 513. That is, the cylindrical portion 5 13 and the end plate 5 14 are integrated. The second end of the cylindrical portion 5 13 is open. The rotor carrier 5 11 is, for example, a cold-rolled steel plate with sufficient mechanical strength (thickness 3 1 ^to 10 thicker than 3 0 0 or 3 0 0 0, forging steel, carbon fiber reinforced plastic).

It is formed by.

[0330] The axial length of the rotary shaft 5 01 is longer than the axial dimension of the rotor carrier 5 11. In other words, the rotary shaft 50 1 projects toward the open end side (inward direction of the vehicle) of the rotor carrier 5 11 and the above-mentioned brake device etc. can be attached to the projecting end. There is.

[0331] A through hole 5 1 4 ₃ is formed in the center of the end plate 5 1 4 of the rotor carrier 5 1 1. The rotating shaft 5 01 is fixed to the rotor carrier 5 1 1 in a state of being passed through the through hole 5 1 4 3 of the end plate 5 1 4. The rotating shaft 5 01 has a flange 5 0 2 extending in a direction intersecting (orthogonal to) the axial direction at a portion where the rotor carrier 5 11 is fixed, and the flange and the end plate 5 1 4 The rotary shaft 5 0 1 is fixed to the rotor carrier 5 1 1 in a state where the outer surface of the vehicle is surface-joined. In addition, in the wheel 400, the wheel 400 is fixed by using a fastener such as a bolt erected from the flange 502 of the rotary shaft 501 in the vehicle outer direction.

[0332] Further, the magnet unit 5 12 is composed of a plurality of permanent magnets arranged so that the polarities thereof alternate along the circumferential direction of the rotor 5 10. As a result, the magnet unit 5 12 has a plurality of magnetic poles in the circumferential direction. The permanent magnet is fixed to the rotor carrier 5 1 1, for example by gluing. The magnet unit 5 12 has the configuration described as the magnet unit 4 2 in FIGS. 8 and 9 of the first embodiment, and as a permanent magnet, its intrinsic coercive force is 40 0 [1<8/ ] that's all 〇 2020/175333 90 卩 (: 171-1? 2020 /006903

And a residual neodymium magnet having a residual magnetic flux density of "1.0" or more.

[0333] The magnet unit 5 1 2 is a polar anisotropic magnet and has a first magnet 9 1 and a second magnet 9 2 having different polarities, as in the magnet unit 4 2 of FIG. doing. As explained in Fig. 8 and Fig. 9, the magnets 9 1 and 9 2 each have an easy magnetization axis on the ¢1 axis side (the part near the 0 axis) and the 9 axis side (the part near the axis). On the axis side, the direction of the easy axis of magnetization is close to the direction parallel to the axis, and on the side of the axis, the direction of the easy axis of magnetization is close to the direction orthogonal to the axis. An arc-shaped magnet magnetic path is formed with an orientation corresponding to the direction of this easy axis of magnetization. In addition, in each magnet 91, 92, the easy axis may be oriented parallel to the axis on the axis side, and the easy axis may be oriented directly on the 9 axis side. In short, the magnet unit 5 12 is configured such that the direction of the easy magnetization axis is parallel to the axis, which is the magnetic pole center, compared to the axis, which is the magnetic pole boundary. Has been done.

[0334] According to each of the magnets 9 1 and 9 2, the magnetic flux of the magnet on the axis is strengthened, and the change of the magnetic flux near the axis is suppressed. As a result, the magnets 9 1 and 9 2 in which the surface magnetic flux changes gently from axis to axis in each magnetic pole can be suitably realized. As the magnet unit 5 12 it is also possible to use the structure of the magnet unit 4 2 shown in FIGS. 22 and 23 or the structure of the magnet unit 4 2 shown in FIG.

[0335] It should be noted that the magnet unit 5 12 is a rotation unit formed by axially laminating a plurality of magnetic steel sheets on the side of the cylindrical portion 5 13 of the rotor carrier 5 11 that is, on the outer peripheral surface side. It may have a child core (back yoke). That is, the rotor core is provided on the radially inner side of the cylindrical portion 5 13 of the rotor carrier 5 11 and the permanent magnets (magnets 9 1 and 9 2) are provided on the radially inner side of the rotor core. It is also possible.

[0336] As shown in FIG. 47, the cylindrical portion 5 13 of the rotor carrier 5 11 is provided with recesses 5 1 3 3 at predetermined intervals in the circumferential direction and extending in the axial direction. .. This 〇 2020/175333 91 卩(: 171-1? 2020/006903

The concave portion 5 1 3 3 of the concave portion 5 1 3 3 is formed by, for example, press working, and as shown in FIG. 5 1 3 Sinks are formed. On the other hand, a concave portion 5 1 2 3 is formed on the outer peripheral surface side of the magnet unit 5 1 2 so as to match the convex portion 5 1 3 of the cylindrical portion 5 1 3 and is formed in the concave portion 5 1 2 3. When the convex portion 5 13 of the cylindrical portion 5 13 enters, the positional displacement of the magnet unit 5 12 in the circumferential direction is suppressed. In other words, the convex portion 5 13 on the rotator carrier 5 11 side functions as a detent portion for the magnet unit 5 1 2. The method for forming the convex portion 5 13 sack may be any method other than press working.

[0337] In Fig. 52, the directions of the magnet magnetic paths in the magnet unit 5 12 are indicated by arrows. The magnet magnetic path extends in an arc shape so as to straddle the axis that is the magnetic pole boundary, and the 0 axis, which is the center of the magnetic pole, is oriented parallel or nearly parallel to the axis. The magnet unit 5 12 is provided with recesses 5 12 on its inner peripheral surface side at each position corresponding to the axis. In this case, in the magnet unit 5 1 2, the length of the magnetic path differs between the side closer to the stator 5 20 (lower side in the figure) and the side farther (upper side in the figure). The magnet magnetic path length is shorter on the closer side, and a concave portion 5 1 2 is formed at a position where the magnet magnetic path length is the shortest. In other words, considering that it is difficult for the magnet unit 5 1 2 to generate a sufficient magnetic flux in the place where the magnetic path length is short, the magnet should be deleted in the place where the magnetic flux is weak. There is.

[0338] Here, the effective magnetic flux density value of the magnet increases as the length of the magnetic circuit passing through the interior of the magnet increases. Moreover, the permeance coefficient ◯ and the effective magnetic flux density of the magnet are in a relationship that when 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 ◯, which is an index of the height of the effective magnetic flux density of the magnet. In the 1st ^to 1st coordinates, the operating point is the intersection of the demagnetization curve and the permeance line corresponding to the shape of the magnet, and the magnetic flux density at that operating point is the effective magnetic flux density of the magnet. The rotating electrical machine 500 of this embodiment has a structure in which the amount of iron in the stator 520 is reduced. 〇 2020/175 333 92 卩 (: 171? 2020 /006903

Therefore, in such a configuration, the method of setting the magnetic circuit across the axes is extremely effective.

[0339] Further, the concave portion 5 12 of the magnet unit 5 12 can be used as an air passage extending in the axial direction. Therefore, it is possible to improve the air cooling performance.

[0340] Next, the structure of the stator 520 will be described. The stator 5 2 0 is the stator winding 5 2

1 and a stator core 5 22. FIG. 53 is an exploded perspective view of the stator winding 5 21 and the stator core 5 22.

[0341] The stator winding 5 2 1 is composed of a plurality of phase windings that are wound in a substantially tubular shape (annular shape), and is fixed inside the stator winding 5 2 1 as a base member in the radial direction. Child core 5 2 2 is assembled. In the present embodiment, the stator winding 5 21 is configured as a three-phase phase winding by using phase windings of II phase, V phase, and phase. Each winding wire is composed of inner and outer two-layer conductors 5 2 3 in the radial direction. The stator 52 0 is characterized by having a slotless structure and a flat conductor structure of the stator winding 5 21 as in the case of the above-mentioned stator 50, and is shown in Figs. 8 to 16. The stator 50 has the same or similar structure as the stator 50.

[0342] The structure of the stator core 52 2 will be described. The stator core 52 2 has a cylindrical shape in which a plurality of magnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction, like the stator core 52 described above. The stator winding 5 21 is assembled on the outer side of the core 5 22 on the rotor 5 10 side in the radial direction. The outer peripheral surface of the stator core 5 2 2 has a curved surface without unevenness, and when the stator winding 5 2 1 is assembled, the outer surface of the stator core 5 2 2 is Conductive wires 5 2 3 forming 2 1 are arranged side by side in the circumferential direction. The stator core 5 22 functions as a back core.

[0343] The stator 520 may use any one of the following (8) to (○).

(8) In the stator 520, an inter-conductor wire member is provided between each conductor 523 in the circumferential direction, and as the inter-conductor member, the circumferential width dimension of the inter-conductor member in one magnetic pole is I, The saturation magnetic flux density of the inter-conductor member is calculated by 〇 2020/175333 93 卩 (: 171? 2020 /006903

When the circumferential width of the nit 5 1 2 is \ZV rn and the residual magnetic flux density of the magnet unit 5 1 2 is defined as "," a magnetic material having a relation of "X" is used.

(Mitsumi) In the stator 520, an inter-conductor wire member is provided between each conductor 523 in the circumferential direction, and a non-magnetic material is used as the inter-conductor member.

(◯) In the stator 520, no inter-conductor material is provided between each conductor 523 in the circumferential direction.

[0344] According to such a configuration of the stator 520, a rotary electric machine having a general tooth structure in which teeth (iron core) for establishing a magnetic path are provided between the conductor wire portions as the stator windings. Inductance is reduced compared to. Specifically, it is possible to reduce the inductance to 1/10 or less. In this case, since the impedance decreases as the inductance decreases, it is possible to increase the output power with respect to the input power in the rotary electric machine 500 and thus contribute to the torque increase. Further, it is possible to provide a rotating electric machine with a large output as compared with a rotating electric machine using an embedded magnet type rotor that outputs torque using the voltage of the impedance component (in other words, uses reluctance torque). Has become.

[0345] In the present embodiment, the stator winding 5 2 1, resin or Ranaru molding material with the stator core 5 2 2 are molded ^_ body by (insulating member), each conductor arranged in the circumferential direction A molding material is interposed between the 5 2 3 and the 5 3 2 3 According to this configuration, the stator 520 of this embodiment corresponds to the configurations of (8) to (○) (Mitsumi) described above. The end faces in the circumferential direction are in contact with each other, or are arranged close to each other with a minute gap therebetween, and in view of this configuration, the configuration of (0) above may be adopted. When adopting the configuration, the outer circumference of the stator core 5 2 2 is adjusted according to the direction of the conductor wire 5 2 3 in the axial direction, that is, according to the skew angle in the case of the stator winding 5 2 1 having a skew structure, for example. The surface may be provided with a protrusion.

[0346] Next, the configuration of the stator winding 5 21 will be described with reference to Fig. 54. Figure 54 shows 〇 2020/175 333 94 卩 (: 171-1? 2020 /006903

FIG. 5 is a front view showing the stator winding 5 2 1 in a flattened state.Fig. 5 4 (a) shows the conductors 5 2 3 located on the outer layer in the radial direction, and Fig. 5 4 (b) shows Indicates the conductors 52 3 located in the inner layer in the radial direction.

[0347] The stator windings 5 2 1 are formed by distributed winding in an annular shape. In the stator winding 5 21, the conductive wire material is wound in two layers inside and outside in the radial direction, and the inner and outer conductors 5 2 3 are skewed in different directions (Fig. 5 4 ( ₃ ), see Figure 54 (b)). The conductors 5 2 3 are insulated from each other. The conducting wire 5 23 is preferably configured as an assembly of a plurality of element wires 8 6 (see Fig. 13). In addition, for example, two conducting wires 523 having the same phase and the same energizing direction are arranged side by side in the circumferential direction. In the stator winding 5 2 1, two conductors in the radial direction and 2 conductors in the circumferential direction (that is, a total of 4 conductors) constitute one conductor part of the same phase, and each conductor part has one magnetic pole. There is one inside each.

[0348] In the conductor portion, the radial thickness dimension is set to be smaller than the circumferential width dimension for one phase in one magnetic pole, whereby the stator winding 5 2 1 is formed into a flat conductor structure. It is desirable to do. Specifically, for example, in the stator winding 5 2 1, if two conductors in the radial direction and 4 conductors in the circumferential direction (that is, 8 conductors in total) 5 2 3 constitute one conductor part of the same phase. Good. Alternatively, in the conductor wire cross section of the stator winding 5 21 shown in FIG. 50, the width dimension in the circumferential direction may be larger than the thickness dimension in the radial direction. It is also possible to use the stator winding 5 1 shown in Fig. 12 as the stator winding 5 21. However, in this case, it is necessary to secure a space for housing the coil end of the stator winding in the rotor carrier 5 11.

[0349] In the stator winding 5 21, the conductors 5 2 3 are arranged side by side in the circumferential direction by inclining at a predetermined angle in the coil side 5 2 5 that overlaps with the stator core 5 2 2 in the radial direction. At the same time, the coil ends 526 on both sides, which are axially outside of the stator core 52, are turned inward (folded back) inward in the axial direction to form a continuous wire connection. Figure 5 4 (a) shows the range of coil side 5 25 and the range of coil end 5 26, respectively. Inner conductor 5 〇 2020/175 333 95 卩 (: 171? 2020 /006903

2 3 and the conductor 5 2 3 on the outer layer side are connected to each other at the coil end 5 26, so that every time the conductor 5 2 3 is axially inverted at the coil end 5 2 6 (folded back). Each time), the conductors 5 2 3 are alternately switched between the inner layer side and the outer layer side. In short, the stator winding 5 21 has a structure in which the inner and outer layers are switched in accordance with the reversal of the direction of the current in each of the conducting wires 5 23 that are continuous in the circumferential direction.

[0350] Further, the stator winding 5 21 is provided with two types of skews having different skew angles in the end regions at both ends in the axial direction and the central region sandwiched by the end regions. .. That is, as shown in Fig. 55, in the conductive wire 5 23, the skew angle 0 3 1 in the central region is different from the skew angle 0 3 2 in the end region, and the skew angle 0 3 1 is the skew angle 0 3 1. It is smaller than 2. In the axial direction, the end region is defined in the range including the coil side 5 25. The skew angle 0 3 1 and the skew angle 0 3 2 are the tilt angles at which the conductors 5 23 are tilted with respect to the axial direction. The skew angle 0 3 1 in the central region is preferably set within an appropriate angle range for reducing the harmonic components of the magnetic flux generated by the energization of the stator winding 5 21.

[0351] The skew angle of each conductor 5 2 3 in the stator winding 5 2 1 is made different between the central region and the end region, and the skew angle 0 3 1 in the central region is set to the skew angle 0 3 2 in the end region. By making it smaller than this, it is possible to increase the winding line coefficient of the stator winding 5 21 while reducing the coil end 5 26. In other words, it is possible to shorten the length of the coil end 5 26, that is, the length of the conductor wire extending axially from the stator core 5 22 while securing a desired winding coefficient. This makes it possible to improve the torque while reducing the size of the rotary electric machine 500.

[0352] Here, an appropriate range as the skew angle 0 3 1 of the central area will be described. When X conductors 5 2 3 are arranged in one magnetic pole in the stator winding 5 2 1, it is considered that the Xth harmonic component is generated by the energization of the stator winding 5 21. .. If the number of phases is 3 and the logarithm is 111, then = 2 3 111. Discloser of the application 〇 2020/175 333 96 卩 (：171? 2020 /006903

Is the component that forms the composite wave of the X— 1st-order harmonic component and the + 1st-order harmonic component, so the X— 1st-order harmonic component or + We focused on reducing the X-order harmonic component by reducing at least one of the first-order harmonic components. Based on this attention, the present disclosure sets the skew angle 03 1 within the angular range of “360 ^° / (侂+1) ~ 360 ^° / (乂1 1)” in electrical angle, and We have found that harmonic components can be reduced.

[0353] For example, if 3 = 3 and = 2, then = 1 In order to reduce the 2nd order harmonic component, the skew angle 03 1 within the angle range of "360° / 1 3 to 360° / 1 1" To set. That is, the skew angle 031 should be set within the range of 27.7° to 32.7°.

[0354] By setting the skew angle 031 of the central area as described above, three alternating magnet magnetic fluxes can be positively interlinked in the central area, and the stator winding 52 1 The roll coefficient can be increased.

[0355] The skew angle 032 in the end area is equal to the skew angle 03 in the center area described above.

The angle is greater than 1. In this case, the angle range of the skew angle 032 is “03 1 <032<90° ”.

[0356] Also, in the stator winding 52 1, the inner layer side conductor wire 523 and the outer layer side conductor wire 5

The 23 is preferably welded or bonded between the end portions of the respective conductive wires 523 or is preferably bent by bending. In the stator winding 521, one end of each coil end 526 on both sides in the axial direction (that is, one end in the axial direction) has the end of each winding wire connected to a power converter (imperter) via a bus bar or the like. It is configured to be electrically connected. Therefore, here, a configuration will be described in which the conductors are connected to each other in the coil end 526 while distinguishing between the coil end 526 on the bus bar connection side and the coil end 526 on the opposite side.

[0357] As a first configuration, each wire 523 is welded at the coil end 526 on the bus bar connection side, and each wire 523 is connected to other means at the coil end 526 on the opposite side by welding. It will be constructed in a conducive manner. Means other than welding 〇 2020/175333 97 卩(: 171-1? 2020/006903

For example, it is considered that the wire is bent by bending the conductor. At the coil end 526 on the bus bar connection side, it is assumed that the bus bar will be welded to the end of each phase line. Therefore, by configuring each wire 5 23 to be welded at the same coil end 5 26, each weld can be performed in a series of steps, improving work efficiency. You can

[0358] As a second configuration, in the coil end 5 2 6 on the bus bar connection side, each conductor 5 2 3 is connected by a means other than welding, and at the coil end 5 2 6 on the opposite side, each conductor is connected. 5 2 3 is constructed by welding. In this case, if the conductors 5 2 3 are connected by welding at the coil end 5 2 6 on the bus bar connection side, the bus bar and coil end 5 2 6 should be prevented in order to avoid contact between the weld and the bus bar. Although it is necessary to secure a sufficient separation distance between the bus bar and the coil end 5 26, it is possible to reduce the separation distance between the bus bar and the coil end 5 26. As a result, it is possible to loosen the restriction on the length of the stator winding 5 21 in the axial direction and/or the crossbar.

[0359] In the third configuration, the coil ends 5 2 6 on both sides in the axial direction have the conductors 5

2 and 3 are welded together. In this case, the conductor wire prepared before welding may have a short wire length, and the work efficiency can be improved by reducing the bending process.

[0360] As a fourth configuration, the coil ends 5 2 6 on both sides in the axial direction are connected to each conductor 5

2 3 is constructed by a method other than welding. In this case, the portion of the stator winding 5 21 where welding is performed can be reduced as much as possible, and it is possible to reduce the concern that insulation separation will occur in the welding process.

[0361] Further, in the process of manufacturing the annular stator winding 5 21, it is preferable to manufacture a band-shaped winding arranged in a plane and then shape the band-shaped winding into a ring. In this case, it is advisable to weld the conductor wires at the coil ends 52 6 as needed in the state of the flat band-shaped winding wire. When forming a flat strip winding into an annular shape, use a cylindrical jig having the same diameter as the stator core 52 to wind the strip winding into an annular shape. Good. Or, fix the strip winding \¥0 2020/175 333 98 卩 (: 17 2020 /006903

It may be wound directly around the determinate core 522.

[0362] Note that the configuration of the stator winding 5 21 can be changed as follows.

[0363] For example, in the stator winding 5 21 shown in Fig. 54 (a) and (匕), the skew angles of the central region and the end region may be the same.

[0364] In addition, in the stator winding 5 2 1 shown in Figs. 5 4 (a) and (10), the ends of in-phase conductors 5 2 3 adjacent to each other in the circumferential direction are oriented in the direction orthogonal to the axial direction. It may be configured to be connected by a crossover portion extending to.

[0365] The number of layers of the stator winding 5 2 1, 2 c _n layer _(n is a natural number) may be any, the stator卷線5 2 1, 4-layer in addition to two layers, to 6 layers, etc. It is also possible.

[0366] Next, the inverter unit 5300, which is a power conversion unit, will be described. Here, the configuration of the inverter unit 5300 will be described with reference to FIGS. 56 and 57, which are exploded cross-sectional views of the inverter unit 5300. In FIG. 57, each member shown in FIG. 56 is shown as two subassemblies.

[0367] The inverter unit 530 electrically connects the inverter housing 531, a plurality of electrical modules 532 assembled in the inverter housing 531, and each of the electrical modules 532. It has a busbar module 5 3 3.

[0368] The inverter housing 531 has a cylindrical outer wall member 541, and a cylindrical shape having an outer peripheral diameter smaller than that of the outer wall member 541, and is arranged radially inward of the outer wall member 541. Inner wall member 5 42 and a boss forming member 5 4 3 fixed to one axial end of the inner wall member 5 4 2. Each of these members 5 41 to 5 4 3 is preferably made of a conductive material, for example, carbon fiber reinforced plastic (. The inverter housing 5 3 1 and the outer wall member 5 4 1 The inner wall member 5 4 2 and the inner wall member 5 4 2 are overlapped with each other in the radial direction, and the boss forming member 5 4 3 is attached to one end side of the inner wall member 5 4 2 in the axial direction. The state is shown in FIG.

[0369] A stator coil is placed on the outer side of the outer wall member 541 of the inverter housing 531. 〇 2020/175 333 99 卩 (: 171? 2020 /006903

A 5 2 2 is fixed. As a result, the stator 520 and the inverter unit 520 are

It is designed to be integrated with 30.

[0370] As shown in FIG. 56, the outer wall member 541 has a plurality of recesses 541 on its inner peripheral surface.

1 3 ,5 4 1 13 ,5 4 1 ○ is formed, and the inner wall member 5 4 2 has a plurality of recesses 5 4 2 on its outer peripheral surface.

5 4 2 13 and 5 4 2 0 are formed. The outer wall member 5 4 1 and the inner wall member 5 4 2 are assembled to each other so that there is a space between them.

5 4 4 13 and 5 4 4 0 are formed (see Fig. 5 7). Of these, the central hollow portion 5454 is used as a cooling water passage 5445 through which cooling water as a refrigerant flows. In addition, the hollow part on both sides of the hollow part (cooling water passage 5445) is sandwiched.

Sealing material 5 46 is contained in 544. This sealing material 5 4 6 allows the hollow part 5

The spillway (cooling water passage 5 445) is sealed. The cooling water passage 5 4 5 will be described in detail later.

[0371] Further, the boss forming member 543 includes a disc ring-shaped end plate 547 and the end plate 547.

Bosses 5 48 protruding from 5 47 toward the inside of the housing are provided. The bosses 548 are provided in the shape of a hollow cylinder. For example, as shown in Fig. 51, the boss forming member 543 is arranged such that the first end of the inner wall member 542 in the axial direction and the second end on the protruding side (that is, the vehicle inner side) of the rotating shaft 5011 facing it. It is fixed at the second end of the ends. In the wheels 400 shown in FIGS. 45 to 47, the base plate 450 is fixed to the inverter housing 531 (more specifically, the end plate 547 of the boss forming member 543). It is like this.

[0372] The inverter housing 5 3 1 is configured to have a double peripheral wall in the radial direction around the axis, and the outer peripheral wall of the double peripheral wall is the outer wall member 5 41 and the inner wall member 5 3. 42, and the inner peripheral wall is formed by the boss portion 5 48. In the following description, the outer peripheral wall formed by the outer wall member 5 4 1 and the inner wall member 5 4 2 is referred to as “outer peripheral wall \ZV A 1 ”, and the inner peripheral wall formed by the boss portion 5 4 8 is referred to as “ Inner peripheral wall \ZV A 2".

[0373] The inverter housing 5 3 1 has an outer peripheral wall 8 1 and an inner peripheral wall 8 2 〇 2020/175333 100 units (：171? 2020 /006903

An annular space is formed between them, and a plurality of electric modules 5 32 are arranged in the annular space in the circumferential direction. The electric module 5 3 2 is fixed to the inner peripheral surface of the inner wall member 5 4 2 by gluing, screwing or the like. In the present embodiment, the inverter housing 5 3 1 corresponds to the “housing member” and the electric module 5 3 2 corresponds to the “electric component”.

[0374] A bearing 560 is housed inside the inner peripheral wall \ZV A 2 (boss 548), and the bearing 560 rotatably supports the rotary shaft 501. The bearing 560 is a hub bearing that rotatably supports the wheel 400 at the center of the wheel. The bearing 560 is composed of a rotor 520, a stator 520, and an inverter unit.

It is provided at a position overlapping axially with respect to 5 30. In the rotating electric machine 500 of this embodiment, it is possible to reduce the thickness of the magnet unit 5 12 in the rotor 5 10 according to the orientation, and the stator 5 20 has a slotless structure or a flat conductor structure. By adopting this, it is possible to reduce the radial thickness of the magnetic circuit part and expand the hollow space inside the magnetic circuit part in the radial direction. This makes it possible to arrange the magnetic circuit part, the inserter unit 530, and the bearing 560 in a laminated state in the radial direction. The boss portion 548 is a bearing holding portion that holds the bearing 560 inside thereof.

[0375] The bearing 5600 is, for example, a radial ball bearing, and has a cylindrical inner ring 561 and a cylindrical shape having a diameter larger than that of the inner ring 561, and is arranged radially outside the inner ring 561. The outer ring 5 62 is provided with a plurality of balls 5 63 arranged between the inner ring 5 61 and the outer ring 5 62. The bearing 5 6 0 is fixed to the inverter housing 5 3 1 by assembling the outer ring 5 6 2 to the boss forming member 5 4 3 and the inner ring 5 6 1 is fixed to the rotating shaft 5 0 1. These inner ring 5 6 1, outer ring 5

Both 6 2 and balls 5 6 3 are made of a metal material such as carbon steel.

[0376] Further, the inner ring 561 of the bearing 5600 has an axial portion that intersects with the tubular portion 561-3 that houses the rotary shaft 501 and one axial end of the tubular portion 561. It has a flange 5 6 1 swath extending in the (orthogonal) direction. The flange 5 61 is the part that comes into contact with the end plate 5 14 of the rotor carrier 5 11 from the inside. 〇 2020/175333 101 卩(：171? 2020/006903

When the bearing 5600 is assembled, the rotor carrier 5111 is held while being sandwiched between the flange 5202 of the rotating shaft 501 and the flange 5611 of the inner ring 561. It has become so. In this case, the flanges 50 2 of the rotating shaft 50 1 and the flanges 5 61 of the inner ring 5 61 have the same angle of intersection with the axial direction (both are right angles in this embodiment), The rotor carrier 5 11 is held in a state of being sandwiched between these flanges 50 2 and 5 61.

[0377] According to the structure in which the inner ring 5 61 of the bearing 5 60 supports the rotor carrier 5 11 from the inside, the angle of the rotor carrier 5 1 1 with respect to the rotating shaft 5 0 1 can be maintained at an appropriate angle, As a result, the parallelism of the magnet unit 5 1 2 with respect to the rotation axis 5 0 1 can be kept good. As a result, even in the configuration in which the rotor carrier 5 11 is expanded in the radial direction, it is possible to enhance resistance to vibration and the like.

[0378] Next, the electric module 5 3 2 housed in the inverter housing 5 3 1 will be described.

[0379] The plurality of electric modules 5 3 2 is a module in which electric components such as a semiconductor switching element and a smoothing capacitor that compose the power converter are divided into a plurality of modules and the modules are individually modularized. 532 includes a switch module 532 having a semiconductor switching element which is a power element and a capacitor module 532 having a smoothing capacitor.

[0380] As shown in Fig. 49 and Fig. 50, the inner peripheral surface of the inner wall member 5 42 is provided with a plurality of spacers 5 49 having a flat surface for mounting the electric module 5 32. Fixed and the electrical module 5 3 2 is attached to its spacer 5 4 9. In other words, the inner peripheral surface of the inner wall member 5 4 2 is a curved surface, while the mounting surface of the electric module 5 32 is a flat surface. A flat surface is formed on the surface side, and the electric module 5 32 is fixed on the flat surface.

[0381] Note that the structure in which the spacer 549 is interposed between the inner wall member 542 and the electric module 532 is not essential, and the inner peripheral surface of the inner wall member 542 is flat. 〇 2020/175333 102 卩(：171? 2020/006903

Alternatively, the electric module 5 3 2 can be directly attached to the inner wall member 5 4 2 by making the mounting surface of the electric module 5 3 2 a curved surface. It is also possible to fix the electric module 5 3 2 to the inverter housing 5 3 1 without contacting the inner peripheral surface of the inner wall member 5 4 2. For example, the electric module 5 32 is fixed to the end plate 5 47 of the boss forming member 5 43. The switch module 5 3 2 8 is fixed to the inner peripheral surface of the inner wall member 5 4 2 in contact with it, and the capacitor module 5 3 2 is fixed to the inner peripheral surface of the inner wall member 5 4 2 in a non-contact state. It is also possible to do so.

[0382] When the spacer 549 is provided on the inner peripheral surface of the inner wall member 542, the outer peripheral wall 81 and the spacer 549 correspond to the "cylindrical portion". When the spacer 549 is not used, the outer peripheral wall 1 corresponds to the "cylindrical portion".

[0383] As described above, the outer peripheral wall 8 1 of the inverter housing 5 3 1 is formed with the cooling water passage 5 45 for circulating the cooling water as the refrigerant, and the cooling water passage 5 4 5 flowing through the cooling water passage 5 4 5 is formed. This allows each electric module 5 32 to be cooled. It is also possible to use cooling oil instead of cooling water as the refrigerant. The cooling water passages 5 4 5 are annularly installed along the outer peripheral wall 1, and the cooling water flowing in the cooling water passages 5 4 5 flows from the upstream side to the downstream side while passing through each electric module 5 3 2. Distribute to. In the present embodiment, the cooling water passages 5 45 are provided in an annular shape so as to overlap the electric modules 5 32 in the radial direction and to surround the electric modules 5 32.

[0384] The inner wall member 5 42 has an inlet passage 5 for allowing cooling water to flow into the cooling water passage 5 45.

7 1 and an outlet passage 5 72 for letting the cooling water flow out from the cooling water passage 5 45 are provided. As described above, a plurality of electric modules 5 32 are fixed to the inner peripheral surface of the inner wall member 5 42, and in such a configuration, there is only one force point between the electric modules adjacent in the circumferential direction. The inner wall member 5 4 2 is further expanded, and a part of the inner wall member 5 4 2 is projected inward in the radial direction to form a protruding portion 5 7 3. The projecting portion 573 is provided with an inlet passage 571 and an outlet passage 572 in a side-by-side arrangement along the radial direction. [0385] Fig. 58 shows the arrangement of the electric modules 532 in the inverter housing 531. Note that FIG. 58 is the same vertical cross-sectional view as FIG.

[0386] As shown in Fig. 58, each electric module 5 32 is arranged in the circumferential direction such that the intervals between the electric modules in the circumferential direction are the first interval NT1 or the second interval NT2. Has been done. The second interval NT 2 is wider than the first interval NT 1. The intervals NT 1 and NT 2 are, for example, the distances between the center positions of two electric modules 5 32 adjacent to each other in the circumferential direction. In this case, the interval between the electric modules adjacent to each other in the circumferential direction without sandwiching the protrusion 573 is the first interval INT 1, and the interval between the electric modules adjacent to each other in the circumferential direction with the protrusion 573 interposed therebetween is The second interval is NT 2. That is, the interval between the electric modules adjacent to each other in the circumferential direction is expanded by the part ^_ , and the projecting part 5 73 is provided at the central part of the expanded interval (second interval INT 2 ), for example. ..

[0387] The intervals NT 1 and NT 2 are the arcs between the center positions of two electric modules 5 3 2 that are adjacent to each other in the circumferential direction on the same circle centered on the rotation axis 50 1. It may be a distance. Alternatively, the intervals between the electric modules in the circumferential direction may be defined by the angular intervals 0 i 1 and 0 i 2 about the rotation axis 5 0 1 (0 i 1 <0 i 2) ₀

[0388] Note that in the configuration shown in FIG. 58, each electric module lined up at the first interval NT1

5 3 2 are arranged so as to be separated from each other in the circumferential direction (non-contact state), but instead of this configuration, the electric modules 5 3 2 are arranged so as to be in contact with each other in the circumferential direction. Good.

[0389] As shown in Fig. 48, the end plate 5 47 of the boss forming member 5 4 3 has an inlet passage 5

7 1 and outlet passage 5 7 2 are provided with a waterway port 5 7 4 in which the passage ends are formed. A circulation path 5 75 for circulating cooling water is connected to the inlet path 5 71 and the outlet path 5 72. The circulation route 5 7 5 consists of cooling water piping. The circulation path 5 7 5 is provided with a pump 5 7 6 and a heat dissipation device 5 7 7, and the cooling water circulates through the cooling water passage 5 4 5 and the circulation path 5 7 5 as the pump 5 7 6 is driven. Pump 5 7 6 is an electric pump. The heat dissipation device 5 7 7 〇2020/175333 104 卩(：171? 2020/006903

For example, it is a radiator that releases heat of cooling water to the atmosphere.

[0390] As shown in Fig. 50, since the stator 520 is arranged on the outer side of the outer peripheral wall 81, and the electric module 532 is arranged on the inner side, the outer peripheral wall 81 is compared with the outer peripheral wall 81. As a result, the heat of the stator 520 is transmitted from the outside and the heat of the electric module 532 is transmitted from the inside. In this case, it is possible to cool the stator 5 20 and the electric module 5 32 at the same time by the cooling water flowing through the cooling water passage 5 45, so that the heat generated by the heat-generating components in the rotary electric machine 500 can be efficiently cooled. Can be released well.

[0391] Here, the electrical configuration of the power converter will be described with reference to FIG.

[0392] As shown in Fig. 59, the stator winding 5 21 is composed of a II-phase winding, a V-phase winding and a phase winding, and the inverter 600 is connected to the stator winding 5 21. Has been done. The inverter 600 is composed of a full bridge circuit having the same number of upper and lower arms as the number of phases, and a series connection body consisting of an upper arm switch 60 1 and a lower arm switch 60 2 is provided for each phase. There is. Each of these switches 60 1 and 60 2 is turned on/off by the drive circuit 60 3, and the winding of each phase is energized by the on/off. Each of the switches 60 1 and 60 2 is composed of a semiconductor switching element such as a 1//1 0 3 den or a den. In addition, the upper and lower arms of each phase are connected to a series connection of switches 60 1 and 60 2 in parallel, and a capacitor 6 for supplying charge that supplies the charges required for switching to each switch 60 1 and 60 2. 0 4 is connected.

[0393] The control device 600 is equipped with a microcomputer consisting of 〇II and various memories, and based on various detection information in the rotating electric machine 500 and requests for power running drive and power generation, each switch 60 Energization control is performed by turning on and off 1,600. The control device 60 7 performs on/off control of each switch 60 1 and 60 2 by, for example, \^/1\/1 control at a predetermined switching frequency (carrier frequency) or rectangular wave control. The control device 600 may be a built-in control device built in the rotary electric machine 500, or an external control device provided outside the rotary electric machine 500. 〇 2020/175333 105 卩(: 171-1? 2020/006903

[0394] By the way, in the rotary electric machine 500 of this embodiment, the electrical time constant is small because the inductance of the stator 520 is reduced, and the electrical time constant is small. Under the circumstances, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed. At this point, the capacitor for charge supply 60 4 is connected in parallel to the series connection body of the switches 60 1 and 60 2 of each phase to reduce the wiring inductance and increase the switching speed. Even with the configuration, appropriate surge countermeasures can be taken.

[0395] The high potential side terminal of the inverter 600 is connected to the positive terminal of the DC power source 600, and the low potential side terminal is connected to the negative terminal (ground) of the DC power source 600. A smoothing capacitor 606 is connected in parallel with the DC power supply 605 to the high potential side terminal and the low potential side terminal of the inverter 600.

[0396] The switch module 5 3 2 8 is a heat generating component for each switch 6 0 1, 6 0.

2 (semiconductor switching element), a drive circuit 60 3 (specifically, an electric element forming the drive circuit 60 3 ), and a charge supply capacitor 60 4. Further, the capacitor module 53.2 has a smoothing capacitor 606 as a heat generating component. Figure 60 shows a concrete example of the configuration of the switch module 5 3 2 8.

[0397] As shown in Fig. 60, the switch module 5 3 2 8 has a module case 6 1 1 as a housing case, and the switch 6 0 for one phase housed in the module case 6 1 1. It has 1, 6 02, a drive circuit 6 03, and a capacitor 6 04 for supplying a charge. The drive circuit 60 3 is provided in the switch module 5 32 8 as a dedicated circuit or a circuit board.

[0398] The module case 6 11 is made of, for example, an insulating material such as resin, and its side surface is in contact with the inner peripheral surface of the inner wall member 5 4 2 of the inverter unit 5 30 while the outer peripheral wall 8 1 is formed. It is fixed. Molding material such as resin is filled in the module case 6 11. In the module case 6 1 1, the switches 6 0 1 and 6 0 2 and the drive circuit 6 0 3, the switches 6 0 1 and 6 0 2 and the capacitor 〇 2020/175333 106 卩(：171? 2020/006903

604 are electrically connected by wiring 612. More specifically, the switch module 5 3 2 8 is attached to the outer peripheral wall 8 1 via a spacer 5 49, but the spacer 5 49 is not shown.

[0399] When the switch module 5 3 2 8 is fixed to the outer peripheral wall 81, the cooler the switch module 5 3 2 8 is closer to the outer peripheral wall 81, that is, the closer to the cooling water passage 5 45. Therefore, the order of arrangement of the switches 60 1, 60 2, the drive circuit 60 3 and the capacitor 60 4 is determined according to the cooling performance. Specifically, when comparing the amount of heat generation, the order is the switch 601, 602, the capacitor 604, and the drive circuit 603 in descending order, so according to the order of the amount of heat generation, The switches 60 1, 60 2, capacitors 60 4, and drive circuit 60 3 are arranged in this order from the side close to the outer peripheral wall 1. The contact surface of the switch module 532 is preferably smaller than the contactable surface of the inner peripheral surface of the inner wall member 542.

[0400] Although detailed illustration of the capacitor module 5 3 2 is omitted, in the capacitor module 5 32, the capacitor 6 0 is placed in a module case of the same shape and size as the switch module 5 3 2 8 Six are housed and configured. As with the switch module 5 3 2 8, the capacitor module 5 3 2 has an outer peripheral wall with the side surface of the module case 6 1 1 abutting on the inner peripheral surface of the inner wall member 5 4 2 of the inverter housing 5 3 1. It is fixed at 1.

[0401] The switch module 532 and capacitor module 532 do not necessarily have to be arranged concentrically inside the outer peripheral wall 81 of the inverter housing 531 in the radial direction. For example, the switch module 532 may be arranged radially inward of the capacitor module 532 or vice versa.

[0402] When the rotating electric machine 500 is driven, the inner wall member 5 4 2 of the outer peripheral wall 8 1 is interposed between the switch module 5 3 2 8 and the capacitor module 5 3 2 and the cooling water passage 5 4 5. Heat is exchanged. This allows the switch module 5 〇 2020/175333 107 卩(: 171-1? 2020/006903

32 8 and condenser module 532 are cooled.

[0403] Each electric module 532 may have a configuration in which cooling water is drawn into the inside thereof and cooling is performed by the cooling water inside the module. Here, the water cooling structure of the switch module 5328 is described with reference to FIGS. 61 (a) and (b). Fig. 6 1 (3) is a vertical cross-sectional view showing the cross-sectional structure of the switch module 5328 in the direction crossing the outer peripheral wall 81, and Fig. 61 (匕) is shown in Fig. 61 (a). -6 1 It is a cross-sectional view of the line.

[0404] As shown in Fig. 6 1 (a) and (匕), the switch module

Similar to 60, it has a module case 61 1, switches 601 and 602 for one phase, a drive circuit 603, and a capacitor 604, as well as a pair of pipe parts 62 1 and 622 and a cooler 623. It has a cooling device. In the cooling device, the pair of piping parts 62 1 and 622 are the piping part 62 1 on the inflow side that allows the cooling water to flow from the cooling water passage 545 of the outer peripheral wall 1 to the cooler 623, and the cooling water passage 545 from the cooler 623. It consists of the piping part 6 22 on the outflow side that allows the cooling water to flow out. The cooler 623 is provided according to the object to be cooled, and the cooling device uses one or a plurality of stages of coolers 623. In the configuration shown in Fig. 61 (a) and (匕), a two-stage cooler 623 is installed in the direction away from the cooling water passage 545, that is, in the radial direction of the inverter unit 53 〇, in a state of being separated from each other. Cooling water is supplied to each of the coolers 623 through the pair of piping portions 62 1 and 622. The cooler 623 has, for example, a hollow inside. However, inner fins may be provided inside the cooler 623.

[0405] In the configuration including the two-stage cooler 623, (1) the outer peripheral wall \ZVA 1 side of the first-stage cooler 623, (2) between the first-stage and second-stage coolers 623, (3) The anti-outer peripheral wall side of the second-stage cooler 623 is the place where the electrical parts to be cooled are placed, and these places are from the one with the highest cooling performance in order from (2), (1). , (3). In other words, the place between two coolers 623 has the highest cooling performance, and in the place adjacent to any one cooler 623, the cooling performance is closer to the outer peripheral wall 81 (cooling water passage 545). It's getting higher. 〇 2020/175333 108 卩 (：171? 2020 /006903

Taking this into consideration, in the configuration shown in Fig. 61 (a) and (b), the switches 601 and 6

02 is arranged between the (2) first-stage cooler 623 and the second-stage cooler 623, and the capacitor 604 is (1) arranged on the outer peripheral wall 81 side of the first-stage cooler 623, and the drive circuit 603 is (3) arranged on the side opposite to the outer peripheral wall of the second stage cooler 623. Although not shown, the drive circuit 603 and the capacitor 604 may be arranged in reverse.

[0406] In either case, the switch 6

01, 602 and the drive circuit 603, and the switches 601, 602 and the capacitor 604 are electrically connected by the wiring 6 12 respectively. Further, since the switches 601 and 602 are located between the drive circuit 603 and the capacitor 604, the wiring 6 1 2 extending from the switches 601 and 602 toward the drive circuit 603 and the wiring 612 extending from the switches 601 and 602 toward the capacitor 604. The wirings 6 1 2 have a relationship of extending in mutually opposite directions.

[0407] As shown in Fig. 6 1 (distance), the pair of piping parts 62 1 and 622 are arranged side by side in the circumferential direction, that is, on the upstream side and the downstream side of the cooling water passage 545, and on the upstream side. Cooling water flows into the cooler 623 from the inflow side piping portion 621 located therein, and thereafter, cooling water flows out from the outflow side piping portion 622 located downstream. In order to promote the inflow of cooling water into the cooling device, the cooling water passage 545 is located at a position between the inflow side pipe portion 62 1 and the outflow side pipe portion 62 1 when viewed in the circumferential direction. It is preferable that a regulation unit 624 that regulates the flow of cooling water is provided. The restriction unit 624 may be a blocking unit that blocks the cooling water passage 545, or a throttle unit that reduces the passage area of the cooling water passage 545.

[0408] FIG. 62 shows another cooling structure of the switch module 5328. Fig. 62

(3) is a vertical cross-sectional view showing the cross-sectional structure of the switch module 53,28 in the direction crossing the outer peripheral wall 81, and FIG. Is.

[0409] The configuration of Figs. 62 ( ₃ ) and (b) differs from the configuration of Figs. 61 (a) and (b) described above in that the arrangement of the pair of piping parts 62 1 and 622 in the cooling device is different. 〇 2020/175333 109 卩 (：171? 2020 /006903

They are different, and a pair of piping parts 6 2 1 and 6 2 2 are arranged side by side in the axial direction. Further, as shown in Fig. 6 2 (○), the cooling water passages 5 45 are connected to the inflow side pipe section 6 21 and the outflow side pipe section 6 2 2. And the passages are separated from each other in the axial direction.

It is connected through 6 2 2 and each cooler 6 2 3.

[0410] In addition, the following configurations can be used as the switch module 5328.

[041 1] In the configuration shown in Fig. 6 3 (3 ), the cooler 6 2

3 has been changed from 2 tiers to 1 tier. In this case, the location with the highest cooling performance in the module case 6 11 is different from that in Fig. 6 1 (a), and the outer peripheral wall The cooling performance is highest in the area on the side, followed by the cooling performance in the order of the location on the side opposite to the outer peripheral wall of the cooler 6 2 3 and the location away from the cooler 6 23 3. Taking this into consideration, in the configuration shown in Fig. 6 3 (a ), the switches 60 1 and 60 2 are located on the outer peripheral wall 1 side of both sides of the cooler 6 23 in the radial direction (both sides in the horizontal direction in the figure). , The condenser 60 4 is arranged at a position on the side opposite to the outer peripheral wall of the cooler 6 23, and the drive circuit 60 3 is arranged at a place apart from the cooler 6 23 3.

[0412] In addition, in the switch module 532, a configuration in which the switches 6011 and 602 for one phase, the drive circuit 603, and the capacitor 604 are housed in the module case 611. It is also possible to change. For example, the configuration may be such that the switches 60 1 and 60 2 for one phase and one of the drive circuit 60 3 and the capacitor 60 4 are housed in the module case 6 11.

[0413] In Fig. 6 3 (匕), a pair of piping parts 6 2 1,

6 2 2 and a two-stage cooler 6 2 3 are provided, and switches 6 0 1 and 6 0 2 are placed between the first and second coolers 6 2 3 and the condenser 6 0 4 Alternatively, the drive circuit 60 3 is arranged on the outer peripheral wall 1 side of the first-stage cooler 6 23 3. In addition, the switches 60 1 and 60 2 and the drive circuit 60 3 are integrated into a semiconductor module, and the semiconductor module and the capacitor 60 4 are combined. 〇 2020/175 333 1 10 卩 (：171? 2020 /006903

It is also possible to adopt a configuration in which the module case 6 11 is housed.

[0414] In Fig. 63 (匕), in the switch module 5328, at least one of the coolers 623 arranged on both sides of the switch 601, 602 is sandwiched. It is advisable to place a capacitor on the side opposite to the switches 60 1 and 60 2 in the device 6 23. That is, the condenser 60 4 is arranged on only one of the outer peripheral wall 81 side of the first-stage cooler 6 23 and the opposite peripheral wall side of the second-stage cooler 6 23, or both. A configuration in which the capacitor 604 is arranged is possible.

[0415] In this embodiment, the switch module 5 3 2 8 and the capacitor module 5 3

Only the switch module 5 3 2 8 out of 3 2 m is configured to draw cooling water into the module from the cooling water passage 5 4 5. However, the configuration may be changed so that the cooling water is drawn into the both modules 532, 532 from the cooling water passage 5445.

[0416] Further, it is also possible to cool each electric module 5 3 2 by directly applying cooling water to the outer surface of each electric module 5 32. For example, as shown in FIG. 64, a cooling water is applied to the outer surface of the electric module 5 3 2 by embedding the electric module 5 32 in the outer peripheral wall 81. In this case, a configuration in which a part of the electric module 5 32 is sunk into the cooling water passage 5 45, or the cooling water passage 5 45 is expanded in the radial direction compared to the configuration of FIG. It is conceivable that all of 3 2 are immersed in the cooling water passage 5 4 5. When immersing the electric module 5 3 2 in the cooling water passage 5 4 5, providing cooling fins on the module case 6 1 1 (the immersed part of the module case 6 1 1) further improves the cooling performance. be able to.

[0417] In addition, the electric module 532 includes a switch module 532 and a capacitor module 532, and there is a difference in the amount of heat generated when the two are compared. Considering this point, it is possible to devise the arrangement of each electric module 5 3 2 in the inverter housing 5 3 1.

[0418] For example, as shown in FIG. 〇 2020/175 333 1 1 1 卩 (: 171? 2020 /006903

They are arranged in the circumferential direction without being dispersed and are arranged on the upstream side of the cooling water passage 5 45, that is, on the side close to the inlet passage 5 71. In this case, the cooling water flowing from the inlet passage 5 71 is first used for cooling the three switch modules 5 3 2 8 and then used for cooling the respective capacitor modules 5 3 2. In Fig. 65, the pair of pipe parts 6 2 1 and 6 2 2 are arranged side by side in the axial direction as shown in Fig. 6 2 ( ₃ ) and (b) above. As shown in FIGS. 6 1 (a) and (10) in FIG. 6, a pair of piping parts 6 2 1 and 6 2 2 may be arranged side by side in the circumferential direction.

[0419] Next, a configuration relating 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 6 6-66 of FIG. 49, and FIG. 67 is a sectional view taken along line 6 7-6 7 of FIG. FIG. 68 is a perspective view showing the bus bar module 5 33 as a single unit. Here, the configuration relating to the electrical connection of each electric module 5 3 2 and bus bar module 5 3 3 will be described by using these drawings together.

[0420] As shown in FIG. 6 6, the inverter housing 5 3 1 has a protrusion 5 7 3 provided on the inner wall member 5 4 2 (that is, an inlet passage 5 7 1 leading to the cooling water passage 5 4 5 and Three switch modules 5 3 2 8 are arranged side by side in the circumferential direction at a position adjacent to the projecting portion 5 7 3) provided with the outlet passage 5 7 2 in the circumferential direction, and further adjacent to that, 6 Two capacitor modules 5 3 2 are arranged side by side in the circumferential direction. As an outline of this, in the inverter housing 5 3 1, the inside of the outer peripheral wall 8 1 is divided into 10 areas (that is, the number of modules + 1) in the circumferential direction, and the electric module 5 3 2 are arranged one by one, and a protrusion 5 73 is provided in the remaining one area. Three switch modules ^_ le 5 3 2 eight is re-phase module ^_ Le, V-phase module, a \ / \ / phase module.

[0421] As shown in Fig. 66 and the above-mentioned Fig. 56, Fig. 57, etc., each electric module 5 3 2 (switch module 5 3 2 8 and capacitor module 5 3 2 M) has a module case 6 1 It has a plurality of module terminals 6 15 extending from 1. The module terminals 6 1 5 are the electrical contacts for each electrical module 5 3 2. 〇 2020/175 333 1 12 卩 (: 171? 2020 /006903

It is a module input/output terminal for force. The module terminals 6 15 are provided so as to extend in the axial direction, and more specifically, the module terminals 6 15 are arranged so as to extend from the module case 6 11 toward the inner side of the rotor carrier 5 11 (outside the vehicle). It is provided (see Figure 51).

[0422] The module terminals 6 15 of each electrical module 5 3 2 are connected to the busbar module 5 3 3, respectively. The number of module terminals 6 1 5 is different between the switch module 5 3 2 8 and the capacitor module 5 3 2 8 and the switch module 5 3 2 8 is provided with 4 module terminals 6 1 5 and is a capacitor. The module 5 3 2 is provided with two module terminals 6 1 5.

[0423] Further, as shown in Fig. 68, the bus bar module 533 is an annular portion 631 having an annular shape, and extends from the annular portion 631, and is connected to a power supply device or a semiconductor device 11 (electronic control device). ), etc., and three external connection terminals 6 3 2 that enable connection with external devices, and a winding wire connection terminal 6 3 3 connected to the end of the winding wire of each phase in the stator winding wire 5 2 1. have. Busbar module 5 3 3 corresponds to "terminal module"

[0424] The annular portion 631 is arranged radially inside the outer peripheral wall 81 in the inverter housing 531 and on one side in the axial direction of each electric module 532. The annular portion 631 has, for example, an annular main body formed of an insulating member such as resin, and a plurality of bus bars embedded therein. The plurality of bus bars are connected to the module terminals 6 15 of each electric module 5 3 2, each external connection terminal 6 3 2, and each winding of the stator winding 5 21. The details will be described later.

[0425] The external connection terminals 6 3 2 are the high-potential-side power terminal 6 3 2 8 and the low-potential-side power terminal 6 3 2 which are connected to the power supply device, and the external potential (3 II 1 Each of these external connection terminals 6 3 2 (6 3 2 8 to 6 3 2 0) is arranged in a row in the circumferential direction and is radially inward of the annular portion 6 3 1. It is installed so as to extend in the axial direction at the bus bar module as shown in Fig. 51. 〇 2020/175 333 1 13 卩 (: 171? 2020 /006903

When the ruler 5 3 3 is assembled in the inverter housing 5 3 1 together with each electric module 5 3 2, one end of the external connection terminal 6 3 2 protrudes from the end plate 5 4 7 of the boss forming member 5 4 3. Is configured. Specifically, as shown in FIGS. 56 and 57, the end plate 5 47 of the boss forming member 54 3 is provided with a shed hole 5 47 3 and the shed hole 5 47. A cylindrical grommet 6 3 5 is attached to 4 7 3 and an external connection terminal 6 3 2 is provided with the grommet 6 3 5 being put in a knot. Grommet 6 35 also functions as a sealed connector.

[0426] The winding connection terminal 6 3 3 is a terminal connected to the winding end of each phase of the stator winding 5 21 and is provided so as to extend radially outward from the annular portion 6 3 1. ing. Winding connection terminal 6 3 3 is a winding wire connection terminal 6 3 3 II, which is connected to the end of the II phase winding in the stator winding 5 2 1, and a winding wire that is connected to the end of the V phase winding. It has a connection terminal 6 3 3 V, and a winding wire connection terminal 6 3 3 \^/ that is connected to the connection at each end of the phase winding. It is said that each of these winding wire connection terminals 6 3 3 and a current sensor 6 3 4 for detecting the current (II phase current, V phase current, phase current) flowing in each phase winding wire are provided (Fig. 7 0 See).

[0427] Note that the current sensor 6 34 may be arranged outside the electric module 5 32 and around each wire connecting terminal 6 33, or inside the electric module 5 32. It may be arranged.

[0428] Here, the connection between each electric module 5 3 2 and the bus bar module 5 3 3 will be described in more detail with reference to Figs. 69 and 70. FIG. 69 is a diagram showing each electric module 5 32 in a plan view, and schematically showing the electrical connection state between each electric module 5 32 and the bus bar module 5 33. .. FIG. 70 is a diagram schematically showing the connection between the electric modules 5 3 2 and the bus bar module 5 3 3 when the electric modules 5 32 are arranged in an annular shape. Incidentally, in FIG. 6 9 shows a path for power transmission by the solid line indicates the path of a signal transmission system in ^_ point chain line. In Fig. 70, only the path for power transmission is shown.

[0429] The busbar module 5 3 3 is used as a busbar for power transmission, and is the first busbar module. 〇 2020/175 333 1 14 卩 (: 171? 2020 /006903

-6 41, 2nd busbar 6 4 2 and 3rd busbar 6 4 3. Of these, the first bus bar 6 4 1 is connected to the power terminal 6 3 2 8 on the high potential side, and the second bus bar 6 4 2 is connected to the power terminal 6 3 2 on the low potential side. In addition, the three third busbars 6 4 3 are connected to the II phase winding connection terminal 6 3 3 II, the V phase winding connection terminal 6 3 3 V, and the phase winding connection terminal 6 3 3 \^/ Respectively connected to.

[0430] Further, the winding connection terminal 6 33 and the third bus bar 6 43 are portions that easily generate heat due to the operation of the rotating electric machine 10. For this reason, a terminal block (not shown) is interposed between the winding connection terminal 6 33 and the third bus bar 6 43, and this terminal block is installed in the inverter housing 5 3 1 having the cooling water passages 5 45. You may make it abut. Alternatively, the winding connection terminal 6 3 3 and the third bus bar 6 4 3 are bent in a crank shape so that the winding connection terminal 6 3 3 and the third bus bar 6 4 3 are connected to the inverter housing having the cooling water passages 5 4 5. It may be brought into contact with 5 31.

[0431] With such a configuration, the heat generated in the winding connection terminal 6 3 3 and the third bus bar 6 4 3 can be radiated to the cooling water in the cooling water passage 5 4 5.

[0432] Note that in Fig. 70, the first busbar 6 4 1 and the second busbar 6 4 2 are shown as annular busbars, but these busbars 6 4 1 and 6 4 2 are always circles. It may be ring-shaped and unbroken, or may have a substantially <3 character shape with a partial interruption in the circumferential direction. Also, each wire connection terminal 6 3 3 II, 6 3 3 V, 6 3 3 \^/ need only be individually connected to the switch module 5 3 2 corresponding to each phase, so the busbar module 5 3 3 It may be configured such that it is directly connected to each switch module 5 3 2 8 (actually module terminal 6 15) without going through.

[0433] On the other hand, each switch module 532 has four module terminals 615 consisting of a positive electrode side terminal, a negative electrode side terminal, a winding terminal and a signal terminal. Of these, 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 wire terminal is connected to the third bus bar 643.

[0434] In addition, the bus bar module 5 33 is used as a bus bar for the signal transmission system, and the fourth bar. 〇 2020/175 333 1 15 卩(: 171? 2020/006903

It has a sub bar 644. The signal terminal of each switch module 5 3 2 8 is connected to the fourth bus bar 6 4 4, and the 4 th bus bar 6 4 4 is connected to the signal terminal 6 3 20.

[0435] In the present embodiment, the control signal for each switch module 5 3 2 is configured to be input from the external node 11 via the signal terminal 6 320. That is, the switches 60 1 and 60 2 in each of the switch modules 5 3 2 8 are turned on/off by the control signal input via the signal terminal 6 3 2 0. Therefore, each switch module 5328 is connected to the signal terminal 6320 without passing through the control unit with a built-in rotary electric machine on the way. However, it is also possible to change this configuration so that a control device is built in the rotating electric machine and the control signal from the control device is input to each switch module 5328. Such a configuration is shown in Fig. 71.

[0436] The configuration of Fig. 71 includes a control board 651 on which a control device 652 is mounted, and the control device 652 is connected to each switch module 532. In addition, the signal terminal 6 3 2 (3 is connected to the control device 6 52. In this case, the control device 6 52 is, for example, an external control unit (3 II for power running or power generation from the upper control device). A command signal relating to this is input, and the switches 601, 602 of each switch module 532 are turned on/off as appropriate based on the command signal.

[0437] In the inverter unit 5300, the control board 651 may be arranged on the outer side of the vehicle (the inner side of the rotor carrier 511) than the busbar module 533. Alternatively, the control board 6 51 may be arranged between each electric module 5 32 and the end plate 5 47 of the boss forming member 5 43. The control board 6 51 may be arranged such that at least a part thereof overlaps with each electric module 5 32 in the axial direction.

[0438] Moreover, each capacitor module 5 3 2 has two module terminals 6 1 5 consisting of a positive side terminal and a negative side terminal, and the positive side terminal is connected to the first bus bar 6 4 1. The negative terminal is connected to the second bus bar 6 42.

[0439] As shown in Figs. 49 and 50, the inverter housing 531 has a 〇 2020/175 333 1 16 卩 (: 171? 2020 /006903

A projection 573 having a cooling water inlet passage 571 and an outlet passage 572 is provided at a position juxtaposed with each electric module 532 in the direction, and a radial direction with respect to the projection 573 is provided. The external connection terminal 6 3 2 is provided adjacent to. In other words, the protruding portion 5 73 and the external connection terminal 6 32 are provided at the same angular position in the circumferential direction. In the present embodiment, the external connection terminal 6 32 is provided at a position on the radially inner side of the protrusion 5 73. When viewed from the inside of the inverter housing 531, the end plate 547 of the boss forming member 543 is provided with the waterway port 574 and the external connection terminal 632 arranged side by side in the radial direction. (See Figure 48).

[0440] In this case, the plurality of electric modules 5 3 2 and the protrusions 5 7 3 and the external connection terminals 6 3 2 are arranged side by side in the circumferential direction, thereby reducing the size of the inverter unit 5 30 and eventually the rotating electric machine. It is possible to reduce the size as 500.

[0441] The structure of the wheel 400 is shown in Fig. 45 and Fig. 47. Cooling piping is connected to the waterway port 574! I 2 is connected and the external connection terminal 6 3 2 is electrically connected. !· I 1 is connected, and in that state, electric wiring!· I 1 and piping for cooling! ·I 2 is stored in the storage duct 440.

[0442] In the above configuration, three switch modules 5 3 2 8 are arranged side by side in the circumferential direction in the inverter housing 5 3 1 next to the external connection terminal 6 3 2, and further 6 Although the configuration is such that the three capacitor modules 5 32 are arranged side by side in the circumferential direction, this may be changed. For example, the configuration may be such that the three switch modules 5 32 8 are arranged side by side at the position farthest from the external connection terminal 6 32, that is, at the position on the opposite side of the rotary shaft 50 1. It is also possible to disperse each switch module 5 3 2 8 so that the capacitor modules 5 3 2 8 are arranged on both sides of each switch module 5 3 2 8.

[0443] If each switch module 5 3 2 is arranged at the position farthest from the external connection terminal 6 3 2, that is, at the position on the opposite side of the rotary shaft 5 0 1. 〇 2020/175 333 1 17 卩 (：171? 2020 /006903

, It is possible to suppress malfunction caused by mutual inductance between the external connection terminal 6 32 and each switch module 5 32 8.

[0444] Next, the configuration related to the resolver 660 provided as the rotation angle sensor will be described.

[0445] As shown in FIGS. 49 to 51, the inverter housing 531 is provided with a resolver 660 that detects an electrical angle 0 of the rotary electric machine 500. The resolver 660 is an electromagnetic induction type sensor, and includes a resolver fixed on the rotating shaft 5 01 and a resolver stator 6 6 arranged opposite to the resolver rotor 6 61 in the radial direction. It has 2 and. The resolver rotor 6 61 has a disk ring shape, and is provided coaxially with the rotary shaft 5 01 with the rotary shaft 5 01 being passed through. The resolver stator 6 62 includes an annular stator core 6 63 and a stator coil 6 64 wound around a plurality of teeth formed on the stator core 6 63. The stator coil 6 64 includes a 1-phase excitation coil and a 2-phase output coil.

[0446] The excitation coil of the stator coil 6 64 is excited by the sinusoidal excitation signal, and the magnetic flux generated in the excitation coil by the excitation signal interlinks the ^_ pairs of output coils. At this time, the relative positional relationship between the exciting coil and the pair of output coils changes cyclically according to the rotation angle of the resolver rotor 6 61 (that is, the rotation angle of the rotation shaft 50 1 ). The number of magnetic fluxes that link the output coil changes periodically. In the present embodiment, the pair of output coils and the excitation coil are arranged so that the phases of the voltages generated in the pair of output coils are shifted from each other by /2. As a result, the output voltage of each of the pair of output coils becomes a modulated wave in which the excitation signal is modulated by each of the modulation waves 311 and 030. More specifically, assuming that the excitation signal is “3 1 1 0 1 :”, the modulated waves are “3 I 11 0 X 3 I ◯ 1:” and “0 0 3 0 X 3 1 门 〇”, respectively. 1:”.

[0447] The resolver 660 has a resolver digital converter. The resolver digital converter calculates the electrical angle 0 by detection based on the generated modulated wave and excitation signal. For example, resolver 660 is connected to signal terminal 6320. 〇 2020/175 333 1 18 卩 (: 171? 2020 /006903

The calculation result of the resolver digital converter is output to the external device via the signal terminal 6320. Further, when the rotating electric machine 500 has a built-in control device, the calculation result of the resolver digital converter is input to the control device.

[0448] Here, the assembling structure of the resolver 660 in the inverter housing 531 will be described.

[0449] As shown in FIGS. 4 9 and 5 1, the boss portion 5 4 8 of the boss forming member 5 4 3 forming the inverter housing 5 3 1 has a hollow cylindrical shape, and the boss portion 5 4 8 On the inner peripheral side, a protrusion 5 4 8 3 extending in a direction orthogonal to the axial direction is formed. The resolver stator 6 62 is fixed by a screw or the like in a state where the resolver stator 6 62 is in axial contact with the projecting portion 5 48 3. Inside the boss portion 548, a bearing 5600 is provided on one side in the axial direction with the protruding portion 5448 being sandwiched, and a resolver 6600 is provided coaxially on the other side.

[0450] Further, the hollow portion of the boss portion 548 is provided with a projecting portion 5448 on one side of the resolver 660 in the axial direction, and accommodates the resolver 660 on the other side. A disc ring-shaped housing cover 6 6 6 is attached to close the space. The housing cover 6666 is made of a conductive material such as carbon fiber reinforced plastic (○[¾9)). A hole 6 6 6 3 is formed in the center of the housing cover 6 6 6 to allow the rotary shaft 50 1 to pass through it. A seal member 667 is provided in the hole 6663 to seal the gap between the hole 6166 and the outer peripheral surface of the rotary shaft 501. The resolver accommodating space is sealed by the sealing material 667. The sealing material 667 is preferably a sliding seal made of a resin material, for example.

[0451] The space in which the resolver 660 is housed is surrounded by the boss portion 548 having an annular shape in the boss forming member 543, and the axial direction is defined by the bearing 560 and the housing cover 666. It is a sandwiched space, and the circumference of the resolver 660 is surrounded by a conductive material. As a result, the influence of electromagnetic noise on the resolver 660 can be suppressed.

[0452] Further, as described above, the inverter housing 5 3 1 has a double outer periphery. 〇 2020/175 333 1 19 卩 (：171? 2020 /006903

It has a wall 1 and an inner peripheral wall 2 (see Fig. 57), and a stator 5 20 is arranged on the outer side of the double peripheral wall (outer side of the outer peripheral wall 81). The electric module 5 32 is arranged between the two (8 1, \ZV A 2) and the resolver 6 60 is arranged inside the double peripheral wall (inside the inner peripheral wall 8 2 ). Since the inverter housing 5 3 1 is a conductive member, the stator 5 20 and the resolver 6 60 are arranged with a conductive partition wall (particularly a double conductive partition wall in this embodiment) separated from each other. Thus, the occurrence of magnetic interference between the stator 520 side (magnetic circuit side) and the resolver 660 can be appropriately suppressed.

[0453] Next, the rotor cover 6 provided on the open end side of the rotor carrier 5 1 1

7 0 will be described.

[0454] As shown in Figs. 49 and 51, the rotor carrier 511 is open on one side in the axial direction, and the open end portion thereof has a substantially disc-shaped rotor cover 6 7. 0 is installed. The rotor cover 670 may be fixed to the rotor carrier 511 by any joining method such as welding, adhesion, and screw fixing. It is even more desirable if the rotor cover 670 has a position that is dimensioned to be smaller than the inner circumference of the rotor carrier 511 so as to prevent axial movement of the magnet unit 512. Good. The outer diameter of the rotor cover 6 70 matches that of the rotor carrier 5 11 and the inner diameter is slightly larger than that of the inverter housing 5 31. ing. The outer diameter of the inverter housing 5 3 1 and the inner diameter of the stator 5 20 are the same.

[0455] As described above, the stator 5 2 is located radially outside the inverter housing 5 3 1.

0 is fixed, and at the joint where the stator 5 20 and the inverter housing 5 3 1 are joined to each other, the inverter housing 5 3 1 projects axially with respect to the stator 5 20. .. A rotor cover 670 is attached so as to surround the protruding portion of the inverter housing 531. In this case, seal material 671 is installed between the inner peripheral end surface of the rotor cover 670 and the outer peripheral surface of the inverter housing 531 to seal the gap between them. 〇 2020/175333 120 卩(：171? 2020/006903

Has been. The seal member 671 seals the housing space for the magnet unit 512 and the stator 520. The sealing material 6 71 may be a sliding seal made of, for example, a resin material.

[0456] According to this embodiment described in detail above, the following excellent effects are obtained.

[0457] In the rotating electric machine 500, the outer peripheral wall 8 1 of the inverter housing 5 3 1 is arranged radially inside the magnetic circuit portion consisting of the magnet unit 5 1 2 and the stator winding 5 2 1. Cooling water passages 5 45 were formed in the outer peripheral wall 1. Further, a plurality of electric modules 5 32 are arranged radially inside the outer peripheral wall 1 along the outer peripheral wall 1 in the circumferential direction. As a result, the magnetic circuit section, cooling water passage 5445, and power converter can be arranged so as to be stacked in the radial direction of the rotary electric machine 500, and the efficiency can be reduced while reducing the size in the axial direction. Good parts placement is possible. In addition, it is possible to efficiently cool the plurality of electric modules 5 32 forming the power converter. As a result, in the rotary electric machine 500, high efficiency and downsizing can be realized.

[0458] A state in which an electric module 5 3 2 (a switch module 5 3 2 8 and a capacitor module 5 3 2) having a heat generating component such as a semiconductor switching element or a capacitor is in contact with the inner peripheral surface of the outer peripheral wall 1. The configuration is provided in. Thereby, the heat in each electric module 5 32 is transferred to the outer peripheral wall 1, and the electric module 5 32 is suitably cooled by the heat exchange in the outer peripheral wall 81.

[0459] In the switch module 5328, coolers 623 are arranged on both sides of the switches 6011 and 6022, respectively, and coolers 62 on both sides of the switches 6011 and 60202 are arranged. In at least one of the three coolers, the condenser 60 4 is arranged on the opposite side of the switches 60 1 and 60 2. As a result, the cooling performance for the switches 60 1 and 60 2 can be improved, and at the same time, the cooling performance of the capacitor 60 4 can be improved.

[0460] In the switch module 532, the coolers 623 are arranged on both sides of the switches 601 and 602, respectively, and the coolers 62 on both sides of the switches 601 and 6022 are arranged. Switch 6 0 1, 6 0 2 in the cooler of ^_ 3 out of 3 〇 2020/175333 121 卩(：171? 2020/006903

The drive circuit 60 3 is arranged on the side opposite to the above, and the condenser 60 4 is arranged on the opposite side to the switches 60 1 and 60 2 in the other cooler 6 23. As a result, the cooling performance for the switches 60 1, 60 2 can be improved, and at the same time, the cooling performance for the drive circuit 60 3 and the capacitor 60 4 can also be improved.

[0461] For example, in the switch module 5328, cooling water is introduced from the cooling water passage 5445 into the module, and the cooling water is used to cool the semiconductor switching elements and the like. In this case, the switch module 5328 is cooled by heat exchange by the cooling water inside the module in addition to the heat exchange by the cooling water at the outer peripheral wall 81. As a result, the cooling effect of the switch module 5 3 2 8 can be enhanced.

[0462] In a cooling system in which cooling water flows in from an external circulation path 5 7 5 to the cooling water passage 5 4 5, the switch module 5 3 2 8 is close to the inlet passage 5 7 1 of the cooling water passage 5 4 5. In addition to being arranged on the upstream side, the capacitor module 532 is arranged on the downstream side of the switch module 5328. In this case, assuming that the cooling water flowing through the cooling water passage 5 445 has a lower temperature on the upstream side, it is possible to realize a configuration in which the switch module 5 32 8 is preferentially cooled.

[0463] The distance between the electric modules adjacent to each other in the circumferential direction is partially expanded, and the inlet passages 5 7 1 and the outlet passages 5 7 are provided at the expanded gaps (the second gap 1 \1 2). The structure is such that the protruding portion 5 73 having 2 is provided. As a result, the inlet passage 5 7 1 and the outlet passage 5 72 of the cooling water passage 5 45 can be preferably formed in the radially inner portion of the outer peripheral wall 81. That is, in order to improve the cooling performance, it is necessary to secure the flow rate of the refrigerant, and for that purpose, it is conceivable to increase the opening area of the inlet passage 5 71 and the outlet passage 5 72. In this regard, as described above, by partially expanding the interval between the electric modules to provide the protrusion 5 73, the inlet passage 5 7 1 and the outlet passage 5 7 2 having a desired size are preferably formed. be able to. 〇 2020/175333 122 卩 (: 171-1? 2020 /006903

[0464] The external connection terminals 6 3 2 of the bus bar module 5 3 3 are arranged at positions radially aligned with the protruding portion 5 7 3 on the radially inner side of the outer peripheral wall 1. In other words, the external connection terminals 6 32 are placed together with the protrusions 5 7 3 at the portion where the gap between the electric modules adjacent to each other in the circumferential direction is widened (the portion corresponding to the second interval I!\! I decided to do it. As a result, the external connection terminals 6 32 can be preferably arranged while avoiding interference with the electric modules 5 32.

[0465] In the rotor-rotor electric machine 500, the stator 520 is fixed to the outer side of the outer peripheral wall 81 in the radial direction, and the plurality of electric modules 532 are arranged on the inner side in the radial direction. As a result, the heat of the stator 5 20 is transferred from the outer side in the radial direction to the outer peripheral wall \ZV A 1, and the heat of the electric module 5 3 2 is transferred from the inner side in the radial direction. In this case, the stator 520 and the electric module 532 can be cooled at the same time by the cooling water flowing through the cooling water passage 545, and the heat of the heat generating member in the rotating electric machine 550 can be efficiently released. can do.

[0466] The radially inner electric module 5 3 2 and the radially outer stator winding 5 2 1 with the outer peripheral wall 1 sandwiched therebetween are electrically connected to each other by the winding wire connection terminal 6 3 3 of the bus bar module 5 3 3. It is configured to connect. Further, in this case, the winding connection terminal 6 33 is provided at a position axially separated from the cooling water passage 5 45. As a result, even if the cooling water passages 5 45 are formed in an annular shape on the outer peripheral wall 1, that is, the inside and outside of the outer peripheral wall 81 are divided by the cooling water passages 5 45, the electric module 5 3 2 and the stator winding 5 2 1 can be suitably connected.

[0467] In the rotating electric machine 500 of the present embodiment, by reducing or eliminating the teeth (iron core) between the conductors 5 23 arranged in the stator 5 20 in the circumferential direction, the conductors 5 2 3 In addition to suppressing the torque limit due to magnetic saturation that occurs between the two, the conductor wire 52 3 is made flat and thin to suppress the torque decrease. In this case, even if the outer diameter of the rotary electric machine 500 is the same, it is possible to expand the radially inner region of the magnetic circuit unit by thinning the stator 520. 〇 2020/175333 123 卩 (：171? 2020 /006903

Therefore, by using the inner region, the outer peripheral wall 1 having the cooling water passages 5 45 and the plurality of electric modules 5 32 provided on the radially inner side of the outer peripheral wall 1 can be suitably arranged.

[0468] In the rotary electric machine 500 of the present embodiment, the magnet magnetic flux gathers on the shaft side in the magnet unit 5 12 to strengthen the magnet magnetic flux in the shaft, and the torque can be increased accordingly. .. In this case, the radial thickness of the magnet unit 5 1 2 can be reduced (thinned), and the radial inner area of the magnetic circuit can be expanded. Using the inner region, the outer peripheral wall 1 having the cooling water passages 5 45 and the plurality of electric modules 5 32 provided on the radially inner side of the outer peripheral wall 1 can be suitably arranged.

[0469] Further, not only the magnetic circuit portion, the outer peripheral wall 81, and the plurality of electric modules 532, but also the bearing 5600 and the resolver 660 can be similarly preferably arranged in the radial direction.

[0470] A wheel 400 that uses the rotary electric machine 500 as an in-wheel motor is

— It is mounted on the vehicle body via the base plate 450 fixed to the housing 531 and a mounting mechanism such as a suspension device. Here, since the rotating electrical machine 500 has been downsized, it is possible to save space even if it is supposed to be mounted on the vehicle body. Therefore, it is possible to realize an advantageous configuration in expanding the installation area of a power supply device such as a battery or expanding the vehicle interior space in a vehicle.

[0471] Hereinafter, modifications of the in-wheel motor will be described.

[0472] (Modification 1 of in-wheel motor)

In the rotating electric machine 500, the electric module 532 and the busbar module 533 are arranged radially inward of the outer peripheral wall 81 of the inverter unit 5300, and the outer peripheral wall 1 is separated in the radial direction. An electric module 532, a bus bar module 5333, and a stator 52O are arranged inside and outside the electric motor, respectively. In such a configuration, the position of the bus bar module 533 with respect to the electric module 532 can be set arbitrarily. Also, the outer wall 8 1 〇 2020/175333 124 卩 (：171? 2020 /006903

When connecting each winding of the stator winding 52 1 and the bus bar module 53 3 across the radial direction, the position to guide the winding connection wire (for example, the winding connection terminal 633) used for the connection. Can be set arbitrarily.

[0473] That is, as the position of the busbar module 533 with respect to the electric module 532, (<< 1) the busbar module 533 is arranged on the outer side of the vehicle in the axial direction than the electric module 532, that is, on the inner side of the rotor carrier 5 1 1 side. And the configuration,

It is conceivable that the {(X 2) busbar module 533 is located inside the electric module 532 in the axial direction, that is, on the front side of the rotor carrier 5 11 side.

[0474] Further, as a position for guiding the winding connection line,

((31) A configuration in which the winding connecting wire is guided outside the vehicle in the axial direction, that is, on the back side of the rotor carrier 5 11 side,

(/32) A configuration in which the winding connecting wire is guided inside the vehicle in the axial direction, that is, on the front side of the rotor carrier 5 11 side,

Is possible.

[0475] In the following, four configuration examples regarding the arrangement of the electric module 532, the bus bar module 533, and the winding wire connection line will be described with reference to Figs. 72( ₃ ) to (¢0. Fig. 72( ₃ )). ~ (¢0 is a vertical cross-sectional view showing a simplified structure of the rotary electric machine 500, and the same reference numerals are given to the structures already described in the figure. The winding connecting wire 637 is a stator winding. It is electrical wiring that connects each winding wire of the wire 521 and the bus bar module 533, and for example, the winding connection terminal 633 described above corresponds to this.

[0476] In the configuration of Fig. 72 (a), the above (<< 1) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (/3 1 ) Is adopted. That is, the electric module 532 and the busbar module 533, the stator winding 52 1 and the busbar. 〇 2020/175333 125 卩 (：171? 2020 /006903

All of the modules 5 3 3 are connected outside the vehicle (the inner side of the rotor carrier 5 11 ). Note that this corresponds to the configuration shown in FIG.

[0477] According to this configuration, the cooling water passage 5445 can be provided in the outer peripheral wall 81 without fear of interference with the winding connection wire 637. Further, the winding wire connecting wire 6 3 7 connecting the stator winding 5 21 and the bus bar module 5 3 3 can be easily realized.

[0478] In the configuration of Fig. 7 2 (匕), the above (<< 1) is adopted as the position of the bus bar module 5 3 3 with respect to the electric module 5 3 2 and the position for guiding the winding connecting wire 6 3 7 The above (/3 2) is adopted as. That is, the electric module 5 3 2 and the busbar module 5 3 3 are connected on the outside of the vehicle (the inner side of the rotor carrier 5 11) and the stator winding 5 2 1 and the busbar module 5 3 3 are connected. Are connected inside the vehicle (front side of rotor carrier 5 1 1).

According to this configuration, the cooling water passages 5 45 can be provided in the outer peripheral wall 1 without fear of interference with the winding connection line 6 37.

[0480] In the configuration of Fig. 7 2 (○), the above (<< 2) is adopted as the position of the bus bar module 5 33 with respect to the electric module 5 32, and the position for guiding the winding connecting wire 6 3 7 is adopted. As above, (/3 1) is adopted. That is, the electric module 5 3 2 and the busbar module 5 3 3 are connected inside the vehicle (front side of the rotor carrier 5 11 1), and the stator winding 5 2 1 and the busbar module 5 3 3 are connected. And are connected on the outside of the vehicle (the inner side of the rotor carrier 5 11).

[0481] In the configuration of Fig. 7 2 (), the above (<< 2) is adopted as the position of the bus bar module 5 3 3 with respect to the electric module 5 3 2 and the position for guiding the winding connecting wire 6 3 7 is adopted. The above (/3 2) is adopted. That is, the configuration in which the electric module 5 3 2 and the bus bar module 5 3 3, the stator winding 5 2 1 and the bus bar module 5 3 3 are all connected inside the vehicle (front side of the rotor carrier 5 1 1) Has become. 〇 2020/175 333 126 卩(: 171-1? 2020/006903

[0482] According to the configurations of Fig. 7 2 (○) and Fig. 7 2 (, the bus bar module 5 3 3 is arranged inside the vehicle (front side of the rotor carrier 5 1 1), so that a fan motor or the like is temporarily placed. It is conceivable that the wiring will be easier if an electric component of the busbar module 5 3 3 is placed closer to the resolver 6 6 0 arranged inside the vehicle than the bearing. It will be possible, and wiring to the resolver 660 will be easier.

[0483] (Modification 2 of in-wheel motor)

A modified example of the mounting structure of the resolver rotor 6 61 will be described below. That is, the rotating shaft 501, the rotor carrier 511 and the inner ring 561 of the bearing 5600 are rotating bodies that rotate integrally, and the deformation of the mounting structure of the resolver rotor 661 with respect to the rotating body. An example will be described below.

[0484] Figs. 73 (3) to (○) are configuration diagrams showing an example of the mounting structure of the resolver rotor 6 61 to the rotating body. In either configuration, the resolver 660 is surrounded by the rotor carrier 5 11 and the inverter housing 5 3 1 and is provided in a closed space protected from water and mud from the outside. In Fig. 73 (a) of Fig. 73 (3) to (○), the bearing 560 has the same configuration as that of Fig. 49. In addition, in Fig. 7 3 (slung) and Fig. 7 3 (○), the bearing 5 60 has a different configuration from that of Fig. 49 and is located at a position away from the end plate 5 1 4 of the rotor carrier 5 11. It is arranged. In each of these figures, two force stations are illustrated as the mounting locations of the resolver rotor 6 61. Although the resolver stator 6 62 is not shown, for example, the boss portion 5 48 of the boss forming member 5 4 3 is extended to the outer peripheral side of the resolver rotor 6 61 or its vicinity, and the boss portion 5 4 8 is formed. It suffices that the resolver stator 6 62 be fixed to the.

[0485] In the configuration shown in Fig. 73 (a), the resolver rotor 6 6 is attached to the inner ring 5 6 1 of the bearing 5 60.

1 is installed. Specifically, the resolver rotor 6 61 is provided on the axial end surface of the flange 5 6 1 13 of the inner ring 5 61, or on the axial end surface of the tubular portion 5 6 1 3 of the inner ring 5 61. Has been.

[0486] In the configuration shown in Fig. 7 3 (匕), the resolver rotor 6 6 1 is attached to the rotor carrier 5 1 1. 〇 2020/175333 127 卩(: 171-1? 2020/006903

Is attached. Specifically, the resolver rotor 6 61 is provided on the inner surface of the end plate 5 14 in the rotor carrier 5 11. Alternatively, in the configuration in which the rotor carrier 5 11 has the cylindrical portion 5 15 extending from the inner peripheral edge portion of the end plate 5 14 along the rotation axis 5 0 1, the resolver rotor 6 6 1 includes the rotor carrier 6 1 1. It is provided on the outer peripheral surface of the cylindrical portion 5 1 5 1. In the latter case, the resolver rotor 6 61 is arranged between the end plate 5 14 of the rotor carrier 5 11 and the bearing 5 6 0.

[0487] In the configuration of Fig. 7 3 (○), the resolver rotor 6 61 is attached to the rotating shaft 50 1. Specifically, the resolver rotor 6 61 is provided between the end plate 5 1 4 of the rotor carrier 5 1 1 and the bearing 5 6 0 in the rotary shaft 5 0 1, or the rotary shaft 5 6 1. It is arranged on the opposite side of the rotor carrier 5 1 1 with the bearing 5 6 0 sandwiched in 0 1.

[0488] (Modification 3 of in-wheel motor)

A modification of the inverter housing 531 and the rotor cover 670 will be described below with reference to FIG. Fig. 7 4 ( ₃ ) and Fig. 7 4 (匕) are vertical cross-sectional views showing a simplified structure of the rotating electric machine 500, in which the same reference numerals are assigned to the structures already described. There is. Note that the structure described in FIG. 4 (a) substantially corresponds to the configuration described in FIG. 4 9 such that the configuration shown in FIG. 4 (spoon) is 7 4 Configuring ₍₃₎ ^_ This corresponds to the configuration in which the parts are changed.

[0489] In the configuration shown in Fig. 7 4 ( ₃ ), the rotor cover 6 70 fixed to the open end of the rotor carrier 5 11 surrounds the outer peripheral wall 8 1 of the inverter housing 5 3 1. It is provided in. That is, the end surface on the inner diameter side of the rotor cover 670 is opposed to the outer peripheral surface of the outer peripheral wall 81, and the seal material 671 is provided between them. In addition, a housing cover 666 is attached to the hollow part of the boss 548 of the inverter housing 531, and a sealing material 667 is provided between the housing cover 666 and the rotary shaft 501. Has been. The external connection terminals 6 3 2 that compose the bus bar module 5 3 3 penetrate the inverter housing 5 3 1 and extend to the inside of the vehicle (lower side in the figure). \\0 2020/175 333 128 (: 17 2020 /006903

[0490] Further, the inverter housing 5 3 1 is formed with an inlet passage 5 7 1 and an outlet passage 5 7 2 which communicate with the cooling water passage 5 45, and the inlet passage 5 7 1 and the outlet passage 5 7 A waterway port 5 74 including the passage end of 7 2 is formed.

[0491] On the other hand, in the configuration shown in Fig. 74 (匕), the inverter housing 5 3

1 (specifically, the boss forming member 54 3) is formed with an annular convex portion 6 81 extending to the protruding side (inside the vehicle) of the rotating shaft 5 01, and the rotor cover 6 7 0 It is provided so as to surround the convex portion 681 of the housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 is opposed to the outer peripheral surface of the convex portion 681, and the seal material 671 is provided between them. Also, the external connection terminals 6 3 2 that compose the bus bar module 5 3 3 penetrate the boss portion 5 4 8 of the inverter housing 5 3 1 and extend into the hollow area of the boss portion 5 4 8 and the housing cover 6 6 2. It passes through 6 and extends to the inside of the vehicle (lower side in the figure).

[0492] Further, the inverter housing 531 is formed with an inlet passage 571 and an outlet passage 572 communicating with the cooling water passage 5445, and these inlet passage 571 and the outlet passage 571 are formed. 7 2 extends in the hollow region of the boss portion 5 48 and extends to the inside of the vehicle (lower side in the figure) with respect to the housing cover 6 6 6 via the relay pipe 6 82. In this configuration, the pipe portion extending from the housing cover 6 66 to the inside of the vehicle is the waterway port 5 74.

[0493] According to the configurations shown in Fig. 7 4 ( ₃ ) and Fig. 7 4 (b), the rotor carrier 5 1 1 and the rotor cover 6 7 0 can be rotated while maintaining the internal space tightness. The child carrier 5 11 and the rotor cover 6 70 can be suitably rotated with respect to the inverter housing 5 3 1.

[0494] Particularly, according to the configuration of Fig. 74 (13), the inner diameter of the rotor cover 670 is smaller than that of the configuration of Fig. 74 (a). Therefore, the inverter housing 5 3 1 and the rotor cover 6 70 are doubly provided in the axial direction at a position on the vehicle inner side of the electric module 5 32, which is a concern in the electric module 5 32. The inconvenience caused by the generated electromagnetic noise can be suppressed. Also \\0 2020/175 333 129 卩 (: 17 2020 /006903

, By reducing the inner diameter of the rotor cover 670, the sliding diameter of the seal material 617 is reduced, and the mechanical loss in the rotary sliding portion can be suppressed.

[0495] (Modification 4 of in-wheel motor)

A modification of the stator winding 5 21 will be described below. Figure 75 shows a modification of the stator winding 5 21.

[0496] As shown in Fig. 75, the stator winding 5 21 uses a conductor wire having a rectangular cross section, and is wound by wave winding with the long side of the conductor wire extending in the circumferential direction. It has been turned. In this case, the conductors 5 23 of each phase, which are coil sides in the stator winding 5 21, are arranged at a predetermined pitch interval for each phase and are connected to each other at the coil ends. In the coil side, the conductor wires 52 3, which are adjacent to each other in the circumferential direction, have their end faces in the circumferential direction abut each other, or are arranged in close proximity to each other with a minute gap.

[0497] Further, in the stator winding 521, the conductor wire is bent in the radial direction for each phase at the coil end. More specifically, the stator winding 5 2 1 (conductor wire) is bent inward in the radial direction at different positions for each phase in the axial direction, which results in winding of each phase of II phase, V phase, and phase. Mutual interference in the lines is avoided. In the configuration shown in the figure, the conductor wires are bent inward at a right angle in the radial direction for each phase, with each phase wire differing by the thickness of the conductor wire. It is preferable that the length dimension between both ends in the axial direction of the conductors 5 2 3 arranged in the circumferential direction be the same for each conductor 5 2 3.

[0498] When assembling the stator core 5 2 2 to the stator winding 5 2 1 to manufacture the stator 5 2 0, part of the annular shape of the stator winding 5 2 1 is not connected. The stator windings 5 2 1 in the shape of a circle, and after assembling the stator core 5 2 2 on the inner circumference side of the stator winding 5 2 1, disconnect it. It is advisable to connect the parts to each other and form the stator winding 5 2 1 in an annular shape.

[0499] In addition to the above, the stator core 5 22 is divided into a plurality (for example, three or more) in the circumferential direction, and the stator core 5 , Split into multiple 〇 2020/175333 130 卩 (: 171-1? 2020 /006903

It is also possible to assemble assembled core pieces.

[0500] (Modification 15)

Next, the rotating electric machine 700 according to the present modification will be described. The rotating electric machine 700 is used as a unit for driving a vehicle. An outline of the rotating electric machine 700 is shown in Fig. 76 to Fig. 78. FIG. 76 is a perspective view showing the entire rotating electric machine 700, FIG. 77 is a vertical cross-sectional view of the rotating electric machine 700, and FIG. 78 shows the components of the rotating electric machine 700. It is a disassembled disassembled sectional view.

[0501] The rotary electric machine 700 is an outer rotor type surface magnet type rotary electric machine. The rotating electric machine 700 is roughly classified into a rotating electric machine main body having a rotor 710, a stator 730, an inner unit 770 and a bus bar module 810, and a rotating electric machine main body surrounding the rotating electric machine main body. It is provided with a housing 831 and a cover 832 provided. All of these members are coaxially arranged with respect to a rotary shaft 7 01 provided integrally with the rotor 7 100, and the rotary electric machine 70 0 is configured by being assembled in the axial direction in a predetermined order. Has been done. The rotor 7 10 is cantilevered by a pair of bearings 7 9 1 and 7 9 2 provided inside the inner unit 7 70 in the radial direction, and is rotatable in that state. The rotating shaft 7 01 is integrally provided with a connecting shaft 7 05 which is fixed to an axle or a wheel of a vehicle.

[0502] In the rotary electric machine 700, the rotor 710 and the stator 7300 each have a cylindrical shape, and are arranged to face each other in the radial direction with an air gap therebetween. The rotor 7 1 0 rotates integrally with the rotating shaft 7 0 1, so that the rotor 7 1 0 rotates radially outside the stator 7 3 0.

[0503] As shown in FIG. 79, the rotor 710 is composed of a substantially cylindrical rotor carrier 711 and an annular magnet unit 711 fixed to the rotor carrier 711. And have. The rotor carrier 7 11 has an end plate portion 7 13 and a tubular portion 7 14 extending axially from the outer peripheral portion of the end plate portion 7 13. A through hole 7 1 3 3 is formed in the end plate portion 7 1 3, and the end plate portion 7 1 3 3 is tightened with bolts and other fasteners 7 1 5 in a state where the through hole 7 1 3 3 is kneaded. The rotary shaft 701 is fixed to. The axis of rotation 7 01 is axially aligned with the part where the rotor carrier 7 11 is fixed. 〇 2020/175333 131 卩(: 171-1? 2020/006903

It has a flange 702 that extends in a direction that intersects (orthogonally) with, and in the state where the flange 702 and the end plate 711 are surface-joined, the rotary shaft 701 faces the rotary shaft 701. Then the rotor carrier 7 1 1 is fixed.

[0504] The magnet unit 7 1 2 includes a cylindrical magnet holder 7 2 1 and the magnet holder 7 2 1.

A magnet 7 2 2 fixed on the inner peripheral surface of 2 1 and an annular end plate 7 2 3 fixed on the opposite side to the rotor carrier 7 1 1 on both axial sides of the magnet 7 2 2. doing. The magnet holder 7 2 1 has the same length dimension as the magnet 7 2 2 in the axial direction. The magnet 7 22 is provided in the magnet holder 7 21 so as to be surrounded from the outside in the radial direction. In addition, the magnet holder 7 21 and the magnet 7 22 are fixed with one end of the axial ends contacting the rotor carrier 7 11 and the other end contacting the end plate 7 23. It is fixed at.

[0505] The rotor carrier 7 1 1, the magnet holder 7 2 1 and the end plate 7 2 3 are all made of aluminum or a non-magnetic stainless steel (for example, 3 11 3 3 0 4) which is a non-magnetic material having a smaller specific gravity than iron. ). Each of these members is preferably made of a light metal such as aluminum, but instead of this, it may be made of a synthetic resin. Each of these members may be joined by adhesion or welding. Note that, for example, the magnet holder 721 may be configured by stacking a plurality of non-magnetic core sheets in the axial direction. The core sheet is formed by punching, for example, in the shape of an annular plate. Further, for example, the magnet holder 7 21 may have a helical core structure. The magnet holder 7 21 with a helical core structure uses a strip-shaped core sheet, and the core sheet is formed into an annular wrap and is laminated in the axial direction. Is configured.

[0506] The end plate 7 23 is made of a non-magnetic material having a larger specific gravity than the magnet holder 7 21. As a result, when the end plate 7 23 is cut in the manufacturing process of the rotary electric machine 700, the end plate 7 is balanced when the rotor 7 10 is balanced around the axis of the rotary shaft 7 01. The amount of shaving can be reduced by 23. Therefore, the balancing work can be facilitated. 〇 2020/175333 132 卩 (：171? 2020 /006903

[0507] Fig. 80 is a partial cross-sectional view showing an enlarged cross-sectional structure of the magnet unit 7 1 2. In Fig. 80, the easy axis of magnetization of the magnet 72 2 is indicated by an arrow.

[0508] In the magnet unit 7 12, the magnets 7 22 are arranged side by side so that the polarities thereof alternate along the circumferential direction of the rotor 7 10. As a result, the magnet 72 2 has a plurality of magnetic poles in the circumferential direction. The magnet 72 2 is a polar-anisotropic permanent magnet, has an intrinsic coercive force of at least 400 [1 <8/○ 1] and a residual magnetic flux density of at least 1.0 [D]. It is composed of a sintered neodymium magnet The magnet 7 22 2 is fixed to the inner peripheral surface of the magnet holder 7 21 by, for example, bonding.

[0509] The magnets 72 are provided with two magnetic poles adjacent to each other in the circumferential direction, with one axis being the center of each magnetic pole. In other words, the magnet 722 has one magnetic pole as one magnet, and the center in the circumferential direction is the axis. The radially inner peripheral surface of the magnet 7 22 is a magnetic flux transfer surface 7 2 4 on which magnetic flux is transferred. In the magnet 7 22, the direction of the easy axis of magnetization is different on the axis side (portion closer to the 1st axis) and on the 9th axis side (portion closer to the axis). The orientations are parallel, and on the axis side, the direction of the easy magnetization axis is orthogonal to the axis. In this case, an arc-shaped magnet magnetic path is formed along the direction of the easy axis of magnetization. In short, the magnet 72 is oriented so that the easy axis of magnetization is closer to the axis, which is the center of the magnetic pole, than the axis, which is the magnetic pole boundary.

[0510] The magnets 7 22 arranged in the circumferential direction enhance the magnetic flux of the magnets in the axis.

And, the magnetic flux change near the axis can be suppressed. As a result, it is possible to preferably realize a magnet 72 2 in which the surface magnetic flux changes gently from axis to axis at each magnetic pole. The magnet 72 2 may have a structure having the center in the circumferential direction as the axis, instead of the structure having the center in the circumferential direction as the axis. Further, as the magnets 72, instead of using the same number of magnets as the number of magnetic poles, a magnet having an annular shape may be used.

[051 1] The magnet 7 2 2 preferably has the following configuration. Magnet 7 2 2 〇 2020/175333 133 卩 (: 171-1? 2020 /006903

The thickness in the direction is less than or equal to the arc length of the magnetic flux transfer surface 7 24 between the shafts, and specifically, is smaller than the above arc length. As a result, the thickness of the magnet 72 2 can be reduced, and the amount of the magnet 7 22 used can be reduced.

[0512] Also, as shown in Fig. 81, in the magnet 7 2 2, the intersection of the 9 axis and the magnetic flux transfer surface 7 2 4 is the center point 〇, and the radial thickness of the magnet 7 2 2 is the radius. If the circle is the orientation circle X that defines the easy axis of magnetization of the magnet 7 22, the magnet 7 22 is configured to include a quarter circle of the orientation circle X. In other words, the magnet 7 22 is provided with an arc-shaped easy axis of magnetization so as to cross the axis, and of the easy axis of magnetization, the circumferential surface on the side opposite to the magnetic flux transfer surface 7 24 is located in the radial direction. The strongest magnetic flux is generated by the easy magnetization axis passing through the intersection with the axis, that is, the easy magnetization axis passing through the orientation circle X. In this case, since the magnet 7 22 is configured to include a quarter circle of the orientation circle X, the length of the magnet magnetic path passing through the axis must be secured as the length specified by the orientation circle X. It is possible to generate magnet magnetic flux

[0513] Here, when the thickness dimension in the radial direction of the magnet 7 22 is smaller than the arc length of the magnetic flux transfer surface 7 2 4 between the 19 axes, it is radially outside the magnet 7 22. That is, there is a fear of magnetic flux leakage to the side opposite to the stator. However, in this embodiment, since the magnet holder 7 21 is made of a non-magnetic material, the influence of magnetic flux leakage can be reduced.

[0514] Further, the magnet 7 22 has a recess 7 25 formed on the outer peripheral surface on the radial outer side within a predetermined range including the shaft, and the inner peripheral surface on the radial inner side includes the shaft. Recesses 7 26 are formed within a certain range. In this case, according to the direction of the easy axis of magnetization of the magnet 7 22, the magnet magnetic path becomes shorter near the axis on the outer peripheral surface of the magnet 7 22 and near the 9 axis on the inner peripheral surface of the magnet 7 22. The magnet magnetic path becomes shorter. Therefore, considering that it is difficult to generate a sufficient magnetic flux in the magnet 72 2 where the magnetic path length is short, the magnet is deleted in the place where the magnetic flux is weak.

[0515] The magnet holder 7 2 1 is provided on the outer side in the radial direction of each magnet 7 2 2 arranged in the circumferential direction. 〇 2020/175333 134 卩 (: 171? 2020 /006903

ing. Further, the magnet holder 7 21 may be provided in a range including a space between the magnets 7 22 in the circumferential direction and a radially inner side of the magnets 7 22. That is, the magnet holder 7 21 may be provided so as to surround the magnet 7 22. When the magnet holder 7 2 1 has a radially outer portion and a radially inner portion of each magnet 7 2 2, the radially outer portion has higher strength than the radially inner portion. Good.

[0516] The magnet holder 7 2 1 has a convex portion 7 2 7 that enters the concave portion 7 2 5 of the magnet 7 2 2. In this case, the position shift of the magnet 7 22 in the circumferential direction is suppressed by the engagement of the concave portion 7 25 of the magnet 7 22 and the convex portion 7 27 of the magnet holder 7 21. That is, the convex portion 7 27 of the magnet holder 7 21 functions as a rotation stopping portion for the magnet 7 22 2. If the magnet holder 7 2 1 has a portion that is radially inward of the magnet 7 2 2 (on the side of the stator 7 3 0), the concave portion 7 of the magnet 7 2 2 should be located in that portion. There may be provided a convex portion that enters into the inside of 26.

[0517] In addition, the rotor carrier 7 1 1, the magnet holder 7 2 1 and the end plate 7 2

3 is integrated by welding both sides in the axial direction of the rod (not shown) that is inserted into the holes of the rotor carrier 7 11 and the magnet holder 7 2 1 and the end plate 7 2 3 respectively. Good.

[0518] In Fig. 80, the magnet holder 7 2 is provided between the magnets 7 22 adjacent to each other in the circumferential direction.

1 is provided, but the present invention is not limited to this, and the magnet holder 7 21 may not be provided. In this case, the magnets 72 2 adjacent to each other in the circumferential direction come into contact with each other.

[0519] Next, the configuration of the stator 7300 will be described.

[0520] The stator 730 has a stator winding 731 and a stator core 732.

The stator core 7 32 has a cylindrical shape in which a plurality of core sheets made of magnetic steel sheets, which are magnetic materials, are laminated in the axial direction and has a predetermined thickness in the radial direction. In, the stator winding 7 31 is assembled on the radially outer side of the rotor 7 10 side. The outer peripheral surface of the stator core 7 32 has a curved surface without unevenness. The stator core 7 32 functions as a back yoke. Stator core 〇 2020/175333 135 卩(: 171-1? 2020/006903

7 32 is configured by stacking a plurality of core sheets, which are punched and formed, for example, in an annular plate shape, in the axial direction. However, it may have a helical core structure. In the stator core 7 32 with a helical core structure, a strip-shaped core sheet is used, and this core sheet is wound in a ring shape and laminated in the axial direction, so that the overall stator core 7 has a cylindrical shape. 3 2 are configured.

[0521] The stator 7 30 has a portion corresponding to a coil side radially opposed to the magnet 7 2 2 of the rotor 7 10 in the axial direction and a coil end that is an axial outer side of the coil side. And a corresponding portion. In this case, the stator core 7 32 is provided in the range corresponding to the coil side in the axial direction.

[0522] The stator winding 7 31 has a plurality of phase windings, and the phase windings of each phase are arranged in the circumferential direction in a predetermined order to form a cylindrical shape (annular shape). The stator core 7 3 2 is assembled on the radially inner side of the stator winding 7 3 1. In this example, by using phase windings of II phase, V phase, and phase, the stator winding 7 3 1 has a configuration having a 3-phase winding.

[0523] Next, the inner unit 770 will be described.

[0524] Figs. 82 and 83 are vertical cross-sectional views of the inner unit 770. Note that the figure

8 3 includes a bearing 7 9 1, which supports the rotating shaft 7 01 on the inner unit 7 70.

7 9 2 shows the assembled state. For the sake of convenience, in the following description, the bearing 7 91 is the first bearing 7 91 (corresponding to the “base end bearing”) and the bearing 7 92 is the second bearing 7 92 (corresponding to the “reduction side bearing”) Also called. The first bearing 7 91 is a bearing provided on the base end side in the axial direction of the rotating shaft 7 01, that is, on the connecting shaft 7 05 side, and the second bearing 7 92 is the bearing of the rotating shaft 7 0 1 It is a bearing provided on the tip side.

[0525] The inner unit 770 has an inner housing 771. The inner housing 7 71 has a cylindrical outer cylinder member 7 72 and a cylindrical shape having an outer peripheral diameter smaller than that of the outer cylinder member 7 72, and is arranged inside the outer cylinder member 7 72 in the radial direction. It has an inner cylinder member 773, and a substantially disc-shaped end plate 774 fixed to one end side of the outer cylinder member 772 and the inner cylinder member 773 in the axial direction. Each of these members 7 7 2 〇 2020/175333 136 卩(: 171-1?2020/006903

~ 7 74 should be made of conductive material, such as carbon fiber reinforced plastic

It is composed by. The outer cylinder member 7 72 and the end plate 7 74 have the same outer dimensions, and the inner cylinder member 7 7 3 is placed in the space formed by the outer cylinder member 7 72 and the end plate 7 74. Is provided. The inner tubular member 773 is fixed to the outer tubular member 772 and the end plate 774 by fasteners 775 such as bolts.

[0526] The outer core member 7 7 1 of the inner housing 7 7 1 has a stator core 7 on the outside in the radial direction.

3 2 is fixed. As a result, the stator 7 30 and the inner unit 7 70 are integrated.

[0527] A refrigerant passage 777 through which a refrigerant such as cooling water flows is formed between the outer cylinder member 772 and the inner cylinder member 773. Refrigerant passage 7 7 7 is the inner housing

It is provided annularly in the circumferential direction of 7 71. Although illustration is omitted, a refrigerant pipe is connected to the refrigerant passage 777 so that the refrigerant flowing from the refrigerant pipe exchanges heat in the refrigerant passage 777 and then flows out to the refrigerant pipe again. Has become.

[0528] An annular space is formed inside the inner tubular member 773 in the radial direction, and electrical components forming an inverter as a power converter may be disposed in the annular space. The electric component is, for example, an electric module in which a semiconductor switching element and a capacitor are packaged. By disposing the electric module in a state of being in contact with the inner cylinder member 773, the electric module is cooled by the refrigerant flowing through the refrigerant passage 777.

[0529] The outer cylinder member 7 7 2 has a cylindrical boss portion 7 radially inward of the inner cylinder member 7 7 3.

Has 80. The boss portion 780 is provided in the shape of a hollow cylinder, and the rotary shaft 701 is passed through the hollow portion. The boss portion 780 serves as a bearing holding portion for holding the bearings 791 and 792, and the bearings 791 and 792 are fixed in the hollow portion thereof. In the present embodiment, the bearings 79 1 and 7 92 include a cylindrical inner ring, a cylindrical outer ring arranged radially outside the inner ring, and a plurality of balls arranged between the inner ring and the outer ring. It is a radial ball bearing with and the outer ring is fixed to the boss 780 so that it can be assembled to the inner unit 770. 〇 2020/175 333 137 卩 (: 171? 2020 /006903

There is.

[0530] In the hollow portion of the boss portion 7800, the first fixed portion 781 (corresponding to the "base end side fixed portion") for fixing the first bearing 791 and the second bearing 792 are provided. The second fixing part 7 82 (corresponding to the "reduction side fixing part") for fixing is provided. The first bearing 7 91 and the second bearing 7 92 have different physiques depending on the supporting position on the rotary shaft 7 01, considering the vibration and centrifugal load of the rotor 7 10 and the rotary shaft 7 9 1. The first bearing 7 91 supporting the base end side of 0 1 has a larger size, that is, a bearing with a larger supporting load. Therefore, the first fixing portion 7 81 has a larger diameter than the second fixing portion 7 82.

[0531] Also, comparing the first bearing 7 91 and the second bearing 7 92, the first bearing 7 91 has a larger radial inner clearance, that is, the radial clearance than the second bearing 7 92. It is big. The radial clearance is the amount of axial play between the inner ring, outer ring, and balls of the bearing. Here, the first bearing 7 91 is a bearing that is more susceptible to the vibration and centrifugal load of the rotor 7 10 than the second bearing 7 92, and the radial clearance of the first bearing 7 91 is increased. This enhances the effect of load absorption. As a result, the load acting on the boss portion 780 on the base end side of the rotating shaft 701 is reduced, and the runout on the tip side of the rotating shaft 701 is suppressed.

[0532] The first fixed portion 7 81 is a parallel surface 7 8 1 parallel to the axial direction in the boss portion 7 80.

3 and an orthogonal surface 7 8 1 which is orthogonal to the axial direction, and the first bearing 7 9 1 is fixed in contact with each of these surfaces. Further, the second fixing portion 7 82 is formed by a parallel surface 7 8 2 3 parallel to the axial direction in the boss portion 7 8 0 and an orthogonal surface 7 82 2 orthogonal to the axial direction. The second bearing 7 92 is fixed in the state of abutting against the surface. A panel (not shown) that applies a preload to the second bearing 7 92 is provided between the step between the second fixed portion 7 82 and the third fixed portion 783 and the second bearing 7 92. It may be.

[0533] Further, in the hollow portion of the boss portion 780, a resolver as a rotation sensor is provided on the side of the second fixed portion 782 of the first fixed portion 781 and the second fixed portion 782. 8 00 fixed 〇 2020/175333 138 卩(: 171-1?2020/006903

A fixed third fixed part 783 (corresponding to the "expansion side fixed part") is provided. The third fixing portion 783 is formed by expanding the diameter of the second fixing portion 782 in a stepped shape.

[0534] As shown in Fig. 77, the resolver 800 includes a resolver rotor 8O1 fixed to a rotary shaft 7O1 and a resolver 8A arranged radially outside the resolver rotor 8O1. And a stator 800. The resolver rotor 801 has a disc ring shape and is provided coaxially with the rotating shaft 701 with the rotating shaft 701 being passed through. The resolver stator 802 has a stator core and a stator coil (not shown), and is fixed to the third fixing portion 783 of the boss portion 780.

[0535] As shown in FIG. 82, the hollow portion of the boss portion 780 is located at a position between the first fixed portion 781 and the second fixed portion 782 in the axial direction. Reduced diameter portions 7 84, 7 8 5 having a diameter smaller than that of each fixed portion 7 81, 7 82 are provided. The reduced diameter portion 7 84 is a hole having a smaller diameter than the first fixed portion 7 81, and the reduced diameter portion 7 85 is a hole having a smaller diameter than the second fixed portion 7 8 2. In addition, the third fixing portion 783 for fixing the resolver 800 is located axially outside the second fixing portion 782, in other words, is located at the tip end side of the rotary shaft 7101. It is provided as a portion having a diameter larger than that of the second fixed portion 7 82. The second fixed portion 7 82 and the third fixed portion 7 83 are provided at positions adjacent to each other in the axial direction.

[0536] In this case, when the outer cylinder member 772 is bored by boring or the like, the second fixing portion 782 and the third fixing portion 783 are continuously machined coaxially from the same direction. It is possible to Therefore, the coaxiality between the second bearing 7 9 2 fixed to the second fixed portion 7 8 2 and the resolver stator 8 0 2 fixed to the third fixed portion 7 8 3 is increased, and by extension, the resolver rotor 8 0 1 This will increase the concentricity between the resolver stator and the resolver stator 802. In this case, the shake of the resolver stator 8O2 with respect to the resolver rotor 8O1 is reduced, and by extension, the angle detection error in the resolver 8O00 is reduced.

[0537] Next, the bus bar module 810 will be described. Bus bar module 〇 2020/175333 139 卩(: 171-1? 2020/006903

Reference numeral 810 is a winding wire connecting member for electrically connecting the stator winding 731 of each phase. The bus bar module 810 has an annular shape.

According to the present embodiment described above, the following effects can be obtained.

[0539] The third fixed portion 783 and the second fixed portion 782 are adjacent to each other in the axial direction. According to this structure, the axial distance between the supporting portion of the second bearing 7 92 and the fixed portion of the resolver rotor 8 01 can be shortened in the rotating shaft 7 01, and the rotating shaft 7 01 can be shortened. The shake of 1 can be reduced. As a result, the shake of the resolver rotor 8 01 with respect to the resolver stator 8 02 can be reduced, and the detection accuracy of the rotation position of the rotor 7 10 can be improved.

[0540] In addition, the configuration in which the second fixing portion 7 82 and the third fixing portion 7 8 3 are adjacent to each other in the axial direction is such that the boss portion 7 80 faces the end plate 7 7 4 in the axial direction. The second fixing portion 7 82 and the third fixing portion 7 8 3 can be continuously machined coaxially from the same direction when the hole is machined by boring from the side. Therefore, it is possible to increase the coaxiality between the second bearing 7 92 and the resolver stator 8 02. As a result, the coaxiality between the resolver rotor 8 01 and the resolver stator 8 02 can be increased, and the shake of the resolver rotor 8 01 with respect to the resolver stator 8 02 can be reduced. As a result, the effect of improving the detection accuracy of the rotational position can be further enhanced.

[0541] Cup-shaped rotor on the side of the first bearing 7 91 in the axial direction of the rotating shaft 7 01

7 1 0 is fixed. Therefore, the first bearing 7 91 is more susceptible to rotor vibration and centrifugal load than the second bearing 7 92. Here, radial ball bearings are used as the first bearing 7 91 and the second bearing 7 92, and the radial gap of the first bearing 7 9 1 is larger than that of the second bearing 7 9 2. According to this configuration, the effect of load absorption of the rotor 710 can be enhanced, and the load acting on the first bearing 791 side of the boss portion 780 can be reduced. As a result, the runout of the support portion of the rotary shaft 7101 due to the second bearing 792 can be reduced, and the runout of the resolver rotor 8O1 with respect to the resolver stator 8O2 can be reduced. As a result, the effect of improving the detection accuracy of the rotational position can be further enhanced. 〇 2020/175333 140 (:171? 2020/006903

[0542] The magnet holder 7 21 is made of a non-magnetic material. For this reason, rotor 7

It is possible to reduce the weight of the rotary shaft 70 and reduce the runout of the rotary shaft 70 1. As a result, the shake of the resolver rotor 8 01 with respect to the resolver stator 8 02 can be reduced, and the effect of improving the rotational position detection accuracy can be further enhanced.

[0543] Here, the center of the magnet 7 22 is the intersection of the 9-axis and the magnetic flux transfer surface 7 24, and the circle whose radius is the radial thickness of the magnet 7 22 is the orientation circle X. .. In this case, the magnet 72 2 is configured to include a quarter circle of the orientation circle X. According to this structure, in the magnet 72, the strongest magnet magnetic flux is generated due to the easy axis of magnetization passing through the orientation circle X. It is possible to prevent the magnetic path of the strongest magnetic flux of the magnet from being formed on the side of the magnetic holder 7 2 1, and to enhance the effect of suppressing magnetic flux leakage from the magnet 7 22 to the magnet holder 7 21. As described above, according to the present embodiment, it is possible to improve the detection accuracy of the rotational position while suppressing the decrease in the torque of the rotary electric machine 700.

[0544] (Modification 16)

Hereinafter, Modification 16 will be described focusing on the differences from Modification 15. As shown in Fig. 84, an annular cover member 803 is fixed to the inner peripheral surface of the third fixing portion 783 on the opening side in the axial direction with respect to the resolver stub 802 in the axial direction. ing. According to this structure, one resolver 803 can protect the resolver 800 and the second bearing 79 2 from foreign matter.

[0545] (Other modifications)

-In Modifications 1 5 and 1 6, the resolver stator 8 0 2 may be fixed to the second fixed portion 7 82 and the second bearing 7 9 2 may be fixed to the third fixed portion 7 8 3.

[0546] The magnets in Modifications 15 and 16 are not limited to those shown in Figs. 80 and 81, and Halbach array magnets may be used, for example.

The configurations of Modifications 15 and 16 may be applied to an inner rotor type rotating electric machine instead of the outer rotor type rotating electric machine.

[0548] For example, as shown in FIG. 50, in the rotary electric machine 500, 〇 2020/175333 141 卩 (：171? 2020 /006903

The inlet passage 5 7 1 and the outlet passage 5 7 2 are provided in one place, but this configuration has been modified so that the inlet passage 5 7 1 and the outlet passage 5 7 2 are located at different positions in the circumferential direction. May be provided in each. For example, the inlet passage 5 71 and the outlet passage 5 72 may be provided at positions different by 180 degrees in the circumferential direction, or at least one of the inlet passage 5 71 and the outlet passage 5 72 may be provided in plural. May be.

[0549] In the wheel 400 of the above-described embodiment, the rotating shaft 5O1 is configured to project to one side in the axial direction of the rotating electric machine 500. However, this is modified so that the rotating shaft 5 It may be configured such that 0 1 is projected. As a result, for example, a suitable configuration can be realized in a vehicle in which at least one of the front and rear of the vehicle has one wheel.

[0550] As the rotary electric machine 500 used for the wheel 400, an inner rotor type rotary electric machine can be used.

[0551] The rotary electric machine is not limited to the star connection, but may be the Δ connection.

[0552] The disclosure herein is not limited to the illustrated embodiments. The disclosure includes the illustrated embodiments and variations thereof by one of ordinary skill in the art based on them. 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 may be added to the embodiments. The disclosure includes omissions of parts and/or elements of the embodiments. The disclosure encompasses replacements or combinations of parts and/or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. It is to be understood that some technical scopes disclosed are shown by the description of the claims, and further include meanings equivalent to the description of the claims and all modifications within the scope.

[0553] Although the present disclosure has been described with reference to examples, it is understood that the present disclosure is not limited to such examples and structures. The present disclosure also includes various modifications and modifications within an equivalent range. In addition, various combinations and forms, as well as other combinations and forms, including only one element, more, or less, \\0 2020/175 333 142 卩 (: 17 2020 /006903

The state is also within the scope and spirit of the present disclosure.

Claims

\¥0 2020/175333 143 卩(: 17 2020/006903 Claims

[Claim 1] The rotor (710),

A bearing (7 92) that rotatably supports the rotating shaft (7 0 1) of the rotor;

A housing (771) having a bearing holder (780) to which the bearing is fixed,

The resolver stator (820) fixed to the bearing holder, and the resolver rotor (801) fixed to a position of the rotating shaft facing the resolver stator in the radial direction, A rotary electric machine (700) including a resolver (800) that outputs a rotation angle signal of a child,

The axial end portion of the bearing holding portion is a diametrical expansion side fixing portion (783) having a hole formed in the opening of the axial end portion.

A portion of the bearing holding portion that is adjacent to the expansion-side fixing portion in the axial direction is a reduction-side fixing portion (7 82) in which a hole smaller than the hole diameter of the expansion-side fixing portion is formed. Cage,

The rotary shaft is threaded through the holes of the diameter-increasing side fixing portion and the diameter-decreasing side fixing portion, respectively.

The bearing is fixed to one of the expanding side fixing part and the reducing side fixing part,

A rotary electric machine in which the resolver stator is fixed to one of the expansion-side fixing portion and the contraction-side fixing portion where the bearing is not fixed.

[Claim 2] The bearing is a reduced diameter side bearing,

The diameter reducing side bearing is fixed to the diameter reducing side fixing portion,

The resolver stator is fixed to the expansion-side fixing portion, and a hole is formed in the bearing holding portion on the side opposite to the expansion-side fixing portion in the axial direction with the reduction-side fixing portion interposed therebetween. The base end side fixed part (7 8 1) 〇 2020/175 333 144 卩 (: 171? 2020 /006903

The rotary shaft is threaded through the respective holes of the diameter expansion side fixing portion, the diameter reduction side fixing portion and the base end side fixing portion,

A base end bearing (7 91) fixed to the base end side fixed part and rotatably supporting the rotating shaft,

The rotor is fixed to the proximal bearing side in the axial direction of the rotary shaft,

The diameter reducing side bearing and the base end side bearing are radial ball bearings having an outer ring, an inner ring, and a plurality of balls arranged between the outer ring and the inner ring,

The rotary electric machine according to claim 1, wherein an outer diameter dimension of the base end side bearing is larger than an outer diameter dimension of the contraction side bearing.

[Claim 3] The clearance dimension between the outer ring and the inner ring and the ball in the proximal bearing is larger than the clearance dimension between the outer ring and the inner ring and the ball in the reduced diameter bearing. The rotating electric machine described.

4. The ring-shaped cover member (80 3) fixed to the opening side of the resolver stator and the bearing in the axial direction of the radially expanded fixing portion. The rotating electrical machine according to any one of items.

[Claim 5] A stator (730) facing the rotor in a radial direction is provided, and the rotor is

A carrier (7 1 1) having a disk-shaped end plate portion (7 1 3) fixed to the rotation axis, and arranged coaxially with the rotation axis;

An annular magnet unit (7 1 2) arranged coaxially with the rotation axis,

The magnet unit is

A cylindrical magnet holder (7 2 1) whose one end in the axial direction is fixed to the end plate portion,

A magnet (7 2 2) fixed to the circumferential surface on the stator side in the radial direction of the magnet holder and having alternating polarities in the circumferential direction; 〇 2020/175 333 145 卩 (: 171? 2020 /006903

The magnet holder is made of a non-magnetic material,

The rotating electric machine according to any one of claims 1 to 4, wherein, in the magnet, a direction of an easy axis of magnetization is displaced from a direction parallel to the axis.

[Claim 6] In the magnet, 9 axes

A circle whose center is the intersection with the magnetic flux transfer surface (7 2 4) between the 9 axes and whose radius is the radial thickness of the magnet is the orientation circle that determines the easy axis of magnetization of the magnet. In the case of (X), the rotating electric machine according to claim 5, wherein the magnet includes a quarter circle of the orientation circle.