WO2021107026A1 - Rotary electrical machine - Google Patents

Rotary electrical machine Download PDF

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Publication number
WO2021107026A1
WO2021107026A1 PCT/JP2020/044052 JP2020044052W WO2021107026A1 WO 2021107026 A1 WO2021107026 A1 WO 2021107026A1 JP 2020044052 W JP2020044052 W JP 2020044052W WO 2021107026 A1 WO2021107026 A1 WO 2021107026A1
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WO
WIPO (PCT)
Prior art keywords
stator
magnet
slot
conductor
winding
Prior art date
Application number
PCT/JP2020/044052
Other languages
French (fr)
Japanese (ja)
Inventor
暁斗 田村
貴宏 土屋
Original Assignee
株式会社デンソー
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 株式会社デンソー filed Critical 株式会社デンソー
Priority to CN202080082250.8A priority Critical patent/CN114762220A/en
Publication of WO2021107026A1 publication Critical patent/WO2021107026A1/en

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors

Definitions

  • the disclosure in this specification relates to a rotary electric machine.
  • a rotary electric machine including a field magnet including a magnet portion having a plurality of magnetic poles having alternating polarities in the circumferential direction and an armature having a multi-phase armature winding is known.
  • a concentrated winding coil short-section concentrated winding coil
  • a configuration is disclosed in which a slot (groove) to be opened is formed and a coil is incorporated in the slot.
  • every other tooth has a rectangular cross-sectional shape and a trapezoidal cross-sectional shape, and a coil having a rectangular cross section is incorporated in a slot formed between the teeth so as not to leave a gap in the slot. It is configured to accommodate the coil.
  • the rotary electric machine described in Patent Document 1 has a configuration in which one centralized winding coil is wound around a single tooth of an armature core, and the coils do not interfere with each other in the circumferential direction. Arranged side by side.
  • a distributed winding coil for example, a centralized winding coil for all nodes
  • the coil end portions of the coils interfere with each other when the coils are assembled in the radial direction. That is, when a distributed winding coil is used, each coil is arranged so as to straddle two or more teeth, and there is a concern about mutual interference in the circumferential direction. Therefore, it is considered that there is room for technical improvement in a rotary electric machine that uses a distributed winding coil as an armature winding.
  • the present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide a rotary electric machine capable of suitably assembling an armature winding to an armature core.
  • Means 1 A field magnet having a magnet portion containing a plurality of magnetic poles having alternating polarities in the circumferential direction, An armature having a multi-phase armature winding having a phase winding composed of a plurality of partial windings per phase, and an armature core integrally provided with the armature winding. It is a rotary electric machine equipped with The armature core has a cylindrical yoke and a plurality of teeth provided at predetermined intervals in the circumferential direction on the radial inner side or the radial outer side of the yoke, and between the respective teeth in the radial direction.
  • a slot extending to is formed,
  • the partial winding has a pair of intermediate conductor portions provided at predetermined intervals in the circumferential direction, and a crossover portion provided on one end side and the other end side in the axial direction to connect the pair of intermediate conductor portions in an annular shape.
  • the intermediate conducting wire portion is housed in the slot, and is arranged so as to straddle two or more of the teeth.
  • the first slot and the second slot which are a set of two slots, are a pair of slots in which the pair of intermediate conductors are housed.
  • the inner side walls that are inside each other in the circumferential direction are parallel to each other or close to each other on the anti-yoke side, and the outer walls that are outward to each other in the circumferential direction are parallel to each other or on the anti-yoke side. It is provided so as to move away from each other, and the circumferential width of the yoke side in each of these slots is smaller than the circumferential width of the anti-yoke side.
  • the pair of intermediate conductors are housed in the first slot and the second slot in a state of being close to the inner side wall and the outer wall.
  • the crossovers are separated from each other in the axial direction or the radial direction.
  • the armature core in the armature core, a plurality of teeth are provided at predetermined intervals in the circumferential direction on the radial inner side or the radial outer side of the cylindrical yoke, and between the teeth, the radial direction is provided.
  • a slot extending to is formed.
  • the armature winding has a plurality of partial windings including a pair of intermediate conductors and a crossover for each phase, and the partial windings include two or more intermediate conductors in slots. It is arranged so as to straddle the teeth of.
  • the slot in which the pair of intermediate conductors of the partial winding is housed is a slot pair consisting of a pair of slots (first slot and second slot), and the diameter is relative to this slot pair. It is possible to assemble partial windings from the direction.
  • the first slot and the second slot are provided so that the inner side walls of each of the slots are close to each other on the parallel or anti-yoke side, and the outer walls are separated from each other on the parallel or anti-yoke side.
  • the circumferential width (W1) on the yoke side of each slot is smaller than the circumferential width (W2) on the anti-yoke side (see FIG. 107).
  • the inner side walls are provided so as to be separated from each other on the anti-yoke side
  • the outer walls are provided so as to be close to each other on the anti-yoke side
  • the circumferential width of the yoke side in each slot is opposite.
  • the pair of intermediate conductors does not interfere with the corners on the tip side of the teeth, and there is unnecessary dead in the slot.
  • a pair of intermediate lead wires can be accommodated in the first slot and the second slot of the slot pair without creating a space. That is, it is possible to accommodate a pair of intermediate conductors in each slot in a state of being close to the inner side wall and the outer wall.
  • each partial winding is arranged so as to straddle two or more teeth, and the coil end is formed in each partial winding arranged adjacent to each other in the circumferential direction and partially overlapping.
  • the first center line, the first slot, and the straight line passing through the circumferential center position in the range from the first slot to the second slot and the armature center point in the slot pair are defined as the first center line, the first slot, and the second slot.
  • the second center lines are parallel to each other in the first slot and the second slot.
  • the first slot and the second slot are provided line-symmetrically in the circumferential direction with respect to the second center line.
  • the partial winding can be suitably assembled by sliding the partial winding in parallel along the first center line.
  • the first slot and the second slot symmetrically in the circumferential direction with respect to the second center line parallel to the first center line, the sizes of the teeth arranged in the circumferential direction in the armature core are equalized. It has an advantageous configuration for the purpose of conversion.
  • the inner side wall and the outer wall are parallel to each other in each of the first slot and the second slot, and the circumferential side surfaces of the pair of intermediate conductors are parallel to each other.
  • each slot is provided as a parallel slot having a uniform width in the circumferential direction.
  • each intermediate conductor portion of the partial winding is provided as a parallel conductor having a uniform width in the circumferential direction. In this case, by making each slot a parallel slot and each intermediate conductor portion being a parallel conductor, it is possible to improve the space factor of the armature winding.
  • each slot is a parallel slot
  • the partial winding is formed by winding a plurality of square wires having a quadrangular cross section of the conductor, and crosses the conductor collecting portion which is an aggregate of the square wires.
  • the surface has a quadrangular shape.
  • the circumferential width of the base end portion on the yoke side of each of the teeth arranged in the circumferential direction in the armature core is larger than the circumferential width of the tip end portion on the anti-yoke side.
  • a first tooth having a small size and a second tooth having a circumferential width of the base end portion larger than the circumferential width of the tip end portion are included, and the circumferential width of the base end portion in the first tooth and the first tooth.
  • the width of the tip in the two teeth in the circumferential direction is the same.
  • each tooth arranged in the circumferential direction is uniform. It includes the first tooth, which is "the circumferential width of the base end ⁇ the circumferential width of the tip portion", and the second tooth, which is "the circumferential width of the base end portion> the circumferential width of the tip portion". It will be.
  • the circumferential width of the base end portion in the first teeth and the circumferential width of the tip portion in the second teeth are made the same, the minimum width in the circumferential direction of each slot can be uniformly matched. .. As a result, it is possible to suppress the occurrence of local magnetic saturation in the armature core, and it is possible to suppress the deterioration in performance due to the local magnetic saturation.
  • the back side wall on the yoke side of the slot is provided so as to be oriented along a circle concentric with the inner peripheral surface on the anti-yoke side of the armature core.
  • the radial dimension (depth dimension) of the slot can be made the same in the circumferential direction.
  • the partial winding can be suitably arranged without creating an excess space in the slot.
  • the first partial winding and the second partial winding are used as the partial windings that are arranged side by side in a state of being adjacent to each other in the circumferential direction and partially overlapping.
  • the cross section is bent radially inward or radially outward, and in the second partial winding, the cross section is axially relative to the cross section of the first partial winding. Alternatively, it is provided at a position separated in the radial direction.
  • At least the crossover of the first partial winding is bent radially inward or radially outward, and the crossover of the second partial winding is axially or radially relative to the crossover of the first partial winding. Since it is provided at a position separated in the direction, interference between the crossovers can be suitably avoided in each of these partial windings, and a configuration excellent in assembling property can be realized.
  • the tip of the tooth has a flange portion extending in the circumferential direction so as to narrow the opening of the slot, and the flange portion is plastically deformed at the tip of the tooth.
  • the portion is plastically deformed, or the flange forming member is fixed to the tip of the tooth.
  • the opening of the slot is narrowed by the flange provided at the tip of the tooth, and it is possible to prevent the partial winding from falling off.
  • the collar portion is formed in a state where the plastically deformed portion at the tip of the tooth is plastically deformed, or a state where the collar forming member is fixed to the tip of the tooth, and the partial winding is from the radial direction with respect to the armature core.
  • a desired collar structure can be provided without any hindrance to assembly.
  • the partial winding is provided one for each phase in a one-pole pair.
  • one partial winding is provided for each phase in one pole pair, and in the armature core, one slot is provided for each phase in the circumferential direction.
  • It is a single slot specification.
  • at least two types of partial windings are used, it is possible to avoid interference between the partial windings, and a configuration advantageous from the viewpoint of manufacturing is realized. be able to.
  • the field magnet has a skew structure in which the magnetic pole positions in the magnet portion are different in the circumferential direction in the axial direction.
  • Cogging torque is an issue for single-slot armatures, but the field magnet has a skew structure, which makes it possible to reduce cogging torque. As a result, it is possible to realize a rotary electric machine in which the cogging torque is suppressed while improving the space factor.
  • FIG. 1 is a vertical cross-sectional perspective view of a rotary electric machine.
  • FIG. 2 is a vertical cross-sectional view of the rotary electric machine.
  • FIG. 3 is a sectional view taken along line III-III of FIG.
  • FIG. 4 is a cross-sectional view showing a part of FIG. 3 in an enlarged manner.
  • FIG. 5 is an exploded view of the rotary electric machine.
  • FIG. 6 is an exploded view of the inverter unit.
  • FIG. 7 is a torque diagram showing the relationship between the ampere turn of the stator winding and the torque density.
  • FIG. 8 is a cross-sectional view of the rotor and the stator.
  • FIG. 9 is an enlarged view of a part of FIG.
  • FIG. 10 is a cross-sectional view of the stator.
  • FIG. 11 is a vertical cross-sectional view of the stator.
  • FIG. 12 is a perspective view of the stator winding.
  • FIG. 13 is a perspective view showing the configuration of the conducting wire.
  • FIG. 14 is a schematic view showing the configuration of the strands.
  • FIG. 15 is a diagram showing the morphology of each conducting wire in the nth layer.
  • FIG. 16 is a side view showing the conductors of the nth layer and the n + 1th layer.
  • FIG. 17 is a diagram showing the relationship between the electric angle and the magnetic flux density of the magnet of the embodiment.
  • FIG. 18 is a diagram showing the relationship between the electric angle and the magnetic flux density of the magnet of the comparative example.
  • FIG. 19 is an electric circuit diagram of the control system of the rotary electric machine.
  • FIG. 20 is a functional block diagram showing a current feedback control process by the control device.
  • FIG. 21 is a functional block diagram showing torque feedback control processing by the control device.
  • FIG. 22 is a cross-sectional view of the rotor and the stator according to the second embodiment.
  • FIG. 23 is an enlarged view of a part of FIG. 22.
  • FIG. 24 is a diagram specifically showing the flow of magnetic flux in the magnet unit.
  • FIG. 25 is a cross-sectional view of the stator in the first modification.
  • FIG. 26 is a cross-sectional view of the stator in the first modification.
  • FIG. 25 is a cross-sectional view of the stator in the first modification.
  • FIG. 27 is a cross-sectional view of the stator in the modified example 2.
  • FIG. 28 is a cross-sectional view of the stator in the modified example 3.
  • FIG. 29 is a cross-sectional view of the stator in the modified example 4.
  • FIG. 30 is a cross-sectional view of the rotor and the stator in the modified example 7.
  • FIG. 31 is a functional block diagram showing a part of the processing of the operation signal generation unit in the modified example 8.
  • FIG. 32 is a flowchart showing the procedure of the carrier frequency change process.
  • FIG. 33 is a diagram showing a connection form of each of the conductors constituting the conductor group in the modified example 9.
  • FIG. 34 is a diagram showing a configuration in which four pairs of conducting wires are stacked and arranged in the modified example 9.
  • FIG. 35 is a cross-sectional view of the inner rotor type rotor and stator in the modified example 10.
  • FIG. 36 is an enlarged view of a part of FIG. 35.
  • FIG. 37 is a vertical sectional view of an inner rotor type rotary electric machine.
  • FIG. 38 is a vertical cross-sectional view showing a schematic configuration of an inner rotor type rotary electric machine.
  • FIG. 39 is a diagram showing a configuration of a rotary electric machine having an inner rotor structure in the modified example 11.
  • FIG. 40 is a diagram showing a configuration of a rotary electric machine having an inner rotor structure in the modified example 11.
  • FIG. 41 is a diagram showing a configuration of a rotary armature type rotary electric machine in the modified example 12.
  • FIG. 42 is a cross-sectional view showing the configuration of the conducting wire in the modified example 14.
  • FIG. 43 is a diagram showing the relationship between the reluctance torque, the magnet torque, and the DM.
  • FIG. 44 is a diagram showing teeth.
  • FIG. 45 is a perspective view showing a wheel having an in-wheel motor structure and its peripheral structure.
  • FIG. 46 is a vertical cross-sectional view of the wheel and its peripheral structure.
  • FIG. 47 is an exploded perspective view of the wheel.
  • FIG. 48 is a side view of the rotary electric machine as viewed from the protruding side of the rotating shaft.
  • FIG. 49 is a cross-sectional view taken along the line 49-49 of FIG. 48.
  • FIG. 50 is a cross-sectional view taken along the line 50-50 of FIG. 49.
  • FIG. 51 is an exploded sectional view of the rotary electric machine.
  • FIG. 52 is a partial cross-sectional view of the rotor.
  • FIG. 53 is a perspective view of the stator winding and the stator core.
  • FIG. 54 is a front view showing the stator winding developed in a plane.
  • FIG. 55 is a diagram showing the skew of the conductor.
  • FIG. 56 is an exploded sectional view of the inverter unit.
  • FIG. 57 is an exploded sectional view of the inverter unit.
  • FIG. 58 is a diagram showing a state of arrangement of each electric module in the inverter housing.
  • FIG. 59 is a circuit diagram showing the electrical configuration of the power converter.
  • FIG. 60 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 60 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 61 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 62 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 63 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 64 is a diagram showing an example of a cooling structure of the switch module.
  • FIG. 65 is a diagram showing the arrangement order of each electric module with respect to the cooling water passage.
  • FIG. 66 is a cross-sectional view taken along the line 66-66 of FIG. 49.
  • FIG. 67 is a cross-sectional view taken along the line 67-67 of FIG. 49.
  • FIG. 68 is a perspective view showing the bus bar module as a single unit.
  • FIG. 69 is a diagram showing an electrical connection state between each electric module and the bus bar module.
  • FIG. 70 is a diagram showing an electrical connection state between each electric module and the bus bar module.
  • FIG. 71 is a diagram showing an electrical connection state between each electric module and the bus bar module.
  • FIG. 72 is a configuration diagram for explaining a modification 1 of the in-wheel motor.
  • FIG. 73 is a configuration diagram for explaining a modification 2 of the in-wheel motor.
  • FIG. 74 is a configuration diagram for explaining a modification 3 of the in-wheel motor.
  • FIG. 75 is a configuration diagram for explaining a modification 4 of the in-wheel motor.
  • FIG. 76 is a perspective view showing the entire rotary electric machine in the modified example 15.
  • FIG. 77 is a vertical cross-sectional view of the rotary electric machine.
  • FIG. 78 is an exploded sectional view of the rotary electric machine.
  • FIG. 79 is a cross-sectional view of the rotor.
  • FIG. 80 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit.
  • FIG. 81 is a partial cross-sectional view showing a part of the magnet unit in an enlarged manner.
  • FIG. 82 is a perspective view showing the configuration of the stator.
  • FIG. 83 is a perspective view showing the stator winding and the stator core in an exploded manner.
  • FIG. 84 is a perspective view showing only the configuration corresponding to the U-phase winding among the phase windings of each phase.
  • FIG. 85 is a vertical cross-sectional view of the stator.
  • FIG. 86 is a circuit diagram showing a connection state of partial windings in each of the three-phase windings.
  • FIG. 87 is a diagram showing the configuration of the coil module.
  • FIG. 88 is a diagram showing the configuration of the coil module.
  • FIG. 89 is a diagram showing the configuration of the coil module.
  • FIG. 90 is a diagram showing the configuration of the coil module.
  • FIG. 91 is a cross-sectional view showing a vertical cross section of the stator.
  • FIG. 92 is a cross-sectional view showing a cross section of the stator.
  • FIG. 93 is a cross-sectional view showing the stator core, the end ring, and the coil module separated from each other.
  • FIG. 91 is a cross-sectional view showing a vertical cross section of the stator.
  • FIG. 92 is a cross-sectional view showing a cross section of the stator.
  • FIG. 94 is a vertical sectional view of the inner unit.
  • FIG. 95 is a vertical sectional view of the inner unit.
  • FIG. 96 is a perspective view of the bus bar module.
  • FIG. 97 is a cross-sectional view showing a part of the vertical cross section of the bus bar module.
  • FIG. 98 is a schematic diagram showing the connection positions of the connection terminals for each bus bar.
  • FIG. 99 is a diagram showing the winding order of the conducting wires in the partial winding.
  • FIG. 100 is a diagram showing the configuration of the coil module.
  • FIG. 101 is a vertical cross-sectional view showing the configuration of the rotary electric machine in the modified example 16.
  • FIG. 102 is a cross-sectional view of the rotary electric machine.
  • FIG. 103 is an enlarged cross-sectional view showing a part of the configuration of the rotary electric machine.
  • FIG. 104 is a perspective view showing the configuration of the partial winding.
  • FIG. 105 is a side view showing the first partial winding and the second partial winding side by side in comparison.
  • FIG. 106 is a cross-sectional view taken along the line 106-106 in FIG. 104 (a).
  • FIG. 107 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core.
  • FIG. 108 is a schematic view for explaining the assembly of the partial winding with respect to the stator core.
  • FIG. 109 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core.
  • FIG. 110 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core.
  • FIG. 111 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core.
  • FIG. 112 is a schematic view for explaining the configuration of the partial winding.
  • FIG. 113 is a schematic view for explaining the skew structure of the rotor.
  • the rotary electric machine in this embodiment is used as a vehicle power source, for example.
  • the rotary electric machine can be widely used for industrial use, vehicle use, home appliance use, OA equipment use, game machine use, and the like.
  • parts that are the same or equal to each other are designated by the same reference numerals in the drawings, and the description thereof will be incorporated for the parts having the same reference numerals.
  • the rotary electric machine 10 is a synchronous multi-phase AC motor and has an outer rotor structure (abduction structure).
  • the outline of the rotary electric machine 10 is shown in FIGS. 1 to 5.
  • FIG. 1 is a vertical sectional perspective view of the rotary electric machine 10
  • FIG. 2 is a vertical sectional view of the rotary electric machine 10 in a direction along the rotation axis 11
  • FIG. 3 is a vertical sectional view in a direction orthogonal to the rotation axis 11.
  • It is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along line III-III of FIG. 2)
  • FIG. 4 is an enlarged cross-sectional view of a part of FIG. 3, and FIG. Is.
  • the hatching indicating the cut surface is omitted except for the rotating shaft 11.
  • the direction in which the rotating shaft 11 extends is the axial direction
  • the direction extending radially from the center of the rotating shaft 11 is the radial direction
  • the direction extending radially around the rotating shaft 11 is the circumferential direction.
  • the rotary electric machine 10 is roughly classified into 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 rotary electric machine 10 of the present embodiment has a configuration having a rotor 40 as a "field magnet” and a stator 50 as an "armature”, and is embodied as a rotary field type rotary electric machine. It has become a thing.
  • the bearing unit 20 has two bearings 21 and 22 arranged apart from each other in the axial direction, and a holding member 23 for holding the bearings 21 and 22.
  • the bearings 21 and 22 are, for example, radial ball bearings, each of which has an outer ring 25, an inner ring 26, and a plurality of balls 27 arranged between the outer ring 25 and the inner ring 26.
  • the holding member 23 has a cylindrical shape, and bearings 21 and 22 are assembled inside the holding member 23 in the radial direction.
  • the rotating shaft 11 and the rotor 40 are rotatably supported inside the bearings 21 and 22 in the radial direction.
  • Bearings 21 and 22 form a set of bearings that rotatably support the rotating shaft 11.
  • each bearing 21 and 22 the balls 27 are held by retainers (not shown), and the pitch between the balls is maintained in that state.
  • the bearings 21 and 22 have sealing members at the upper and lower portions in the axial direction of the retainer, and the inside thereof is filled with non-conductive grease (for example, non-conductive urea-based grease). Further, the position of the inner ring 26 is mechanically held by the spacer, and a constant pressure preload that is convex in the vertical direction from the inside is applied.
  • the housing 30 has a cylindrical peripheral wall 31.
  • the peripheral wall 31 has a first end and a second end facing each other in the axial direction thereof.
  • the peripheral wall 31 has an end face 32 at the first end and an opening 33 at the second end.
  • the opening 33 is open throughout the second end.
  • a circular hole 34 is formed in the center of the end surface 32, and the bearing unit 20 is fixed by a fixing tool such as a screw or a rivet while being inserted through the hole 34.
  • a hollow cylindrical rotor 40 and a hollow cylindrical stator 50 are housed in the housing 30, that is, in the internal space partitioned by the peripheral wall 31 and the end surface 32.
  • the rotary electric machine 10 is an outer rotor type, and a stator 50 is arranged inside the housing 30 in the radial direction of the cylindrical rotor 40.
  • the rotor 40 is cantilevered by the rotating shaft 11 on the side of the end face 32 in the axial direction.
  • the rotor 40 has a magnet holder 41 formed in a hollow tubular shape 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 has a function as a magnet holding member.
  • the magnet holder 41 has a cylindrical portion 43 having a cylindrical shape, an attachment 44 having a cylindrical shape and a diameter smaller than that of the cylindrical portion 43, and an intermediate portion serving as a portion connecting the cylindrical portion 43 and the fixed portion 44. It has 45 and.
  • a magnet unit 42 is attached to the inner peripheral surface of the cylindrical portion 43.
  • the magnet holder 41 is made of a cold-rolled steel plate (SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
  • SPCC cold-rolled steel plate
  • CFRP carbon fiber reinforced plastic
  • the rotating shaft 11 is inserted through the through hole 44a of the fixing portion 44.
  • the fixing portion 44 is fixed to the rotating shaft 11 arranged in the through hole 44a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing portion 44.
  • the fixing portion 44 may be fixed to the rotating shaft 11 by spline coupling, key coupling, welding, caulking, or the like using unevenness. As a result, the rotor 40 rotates integrally with the rotating shaft 11.
  • bearings 21 and 22 of the bearing unit 20 are assembled on the radial outer side of the fixing portion 44.
  • the bearing unit 20 is fixed to the end surface 32 of the housing 30, the rotating shaft 11 and the rotor 40 are rotatably supported by the housing 30.
  • the rotor 40 is rotatable in the housing 30.
  • the rotor 40 is provided with a fixing portion 44 only on one of its two end portions facing in the axial direction, whereby the rotor 40 is cantilevered and supported by the rotating shaft 11.
  • the fixing portion 44 of the rotor 40 is rotatably supported by bearings 21 and 22 of the bearing unit 20 at two positions different in the axial direction. That is, the rotor 40 is rotatably supported by two bearings 21 and 22 which are separated from each other in the axial direction at one of the two end portions of the magnet holder 41 which face each other in the axial direction. Therefore, even if the rotor 40 is cantilevered and supported by the rotating shaft 11, stable rotation of the rotor 40 can be realized. In this case, the rotor 40 is supported by the bearings 21 and 22 at a position shifted to one side with respect to the axial center position of the rotor 40.
  • the bearing 22 near the center of the rotor 40 (lower side in the figure) and the bearing 21 on the opposite side (upper side in the figure) are the gaps between the outer ring 25 and the inner ring 26 and the ball 27.
  • the dimensions are different.
  • the bearing 22 near the center of the rotor 40 has a larger clearance dimension than the bearing 21 on the opposite side. In this case, even if vibration of the rotor 40 or vibration due to imbalance caused by component tolerance acts on the bearing unit 20 on the side closer to the center of the rotor 40, the influence of the vibration or vibration is well absorbed. Tolerant.
  • the vibration generated in the cantilever structure is absorbed by the play portion.
  • the preload may be either a fixed position preload or a constant pressure preload.
  • 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.
  • 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 preload can be generated by arranging the outer ring 25 of the bearing 21 at different positions in the axial direction with respect to the inner ring 26 of the bearing 21.
  • Preload can also be generated by arranging the outer ring 25 of the bearing 22 at different positions in the axial direction with respect to the inner ring 26 of the bearing 22.
  • a preload spring for example, a wave washer 24 or the like is bearing so that a preload is generated from the region sandwiched between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22 in the axial direction. It is arranged in the same region sandwiched between the 22 and the bearing 21. 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 bonding. The bearing 21 or the outer ring 25 of the bearing 22 is arranged with respect to the holding member 23 via a predetermined clearance. With such a configuration, the spring force of the preload spring acts on the outer ring 25 of the bearing 22 in the direction away from the bearing 21.
  • a preload spring for example, a wave washer 24 or the like is bearing so that a preload is generated from the region sandwiched between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22 in the axial direction. It is arranged in the same region sandwiched between the 22 and the bearing 21.
  • a spring force may be applied to the outer ring 25 of the bearing 21.
  • the inner ring 26 of any of the bearings 21 and 22 is arranged with respect to the rotating shaft 11 through a predetermined clearance, and the outer ring 25 of the bearings 21 and 22 is press-fitted or bonded to the holding member 23. Preload may be applied to the two bearings by joining them together.
  • the intermediate portion 45 has an annular inner shoulder portion 49a and an annular outer shoulder portion 49b.
  • the outer shoulder portion 49b is located outside the inner shoulder portion 49a in the radial direction of the intermediate portion 45.
  • the inner shoulder portion 49a and the outer shoulder portion 49b are separated from each other in the axial direction of the intermediate portion 45.
  • the cylindrical portion 43 and the fixed portion 44 partially overlap in the radial direction of the intermediate portion 45. That is, the cylindrical portion 43 protrudes outward in the axial direction from the base end portion (lower end portion on the lower side of the figure) of the fixed portion 44.
  • the rotor 40 can be supported with respect to the rotating shaft 11 at a position near the center of gravity of the rotor 40, as compared with the case where the intermediate portion 45 is provided in a flat plate shape without a step.
  • the stable operation of 40 can be realized.
  • the rotor 40 has a bearing accommodating recess 46 that accommodates a part of the bearing unit 20 at a position that surrounds the fixing portion 44 in the radial direction and is inward of the intermediate portion 45.
  • the accommodating recesses 46 and 47 are arranged so as to be adjacent to each other inside and outside in the radial direction. That is, a part of the bearing unit 20 and the coil end 54 of the stator winding 51 are arranged so as to overlap in and out in the radial direction. This makes it possible to shorten the axial length dimension in the rotary electric machine 10.
  • the intermediate portion 45 is provided so as to project radially outward from the rotation shaft 11 side.
  • the intermediate portion 45 is provided with a contact avoiding portion that extends in the axial direction and avoids contact of the stator winding 51 of the stator 50 with respect to the coil end 54.
  • the intermediate portion 45 corresponds to the overhanging portion.
  • the axial dimension of the coil end 54 can be reduced, and the axial length of the stator 50 can be shortened.
  • the bending direction of the coil end 54 may be in consideration of assembly with the rotor 40. Assuming that the stator 50 is assembled inside the rotor 40 in the radial direction, the coil end 54 may be bent inward in the radial direction on the insertion tip side with respect to the rotor 40.
  • the bending direction of the coil end on the opposite side of the coil end 54 may be arbitrary, but a shape in which the coil end is bent outward with a sufficient space is preferable in manufacturing.
  • the magnet unit 42 as the magnet portion is composed of a plurality of permanent magnets arranged so as to alternately change the polarities along the circumferential direction inside the cylindrical portion 43 in the radial direction.
  • the magnet unit 42 has a plurality of magnetic poles in the circumferential direction.
  • the details of the magnet unit 42 will be described later.
  • the stator 50 is provided inside the rotor 40 in the radial direction.
  • the stator 50 has a stator winding 51 formed by winding in a substantially tubular shape (annular shape) and a stator core 52 as a base member arranged radially inside the stator winding.
  • the wire 51 is arranged so as to face the annular magnet unit 42 with a predetermined air gap in between.
  • the stator winding 51 is composed of a plurality of phase windings. Each of these phase windings is configured by connecting a plurality of conductors arranged in the circumferential direction to each other at a predetermined pitch.
  • a U-phase, V-phase, and W-phase three-phase winding and an X-phase, Y-phase, and Z-phase three-phase winding are used, and two of these three-phase windings are used.
  • the stator winding 51 is configured as a 6-phase phase winding.
  • the stator core 52 is formed in an annular shape by laminated steel plates on which electromagnetic steel plates which are soft magnetic materials are laminated, and is assembled inside the stator winding 51 in the radial direction.
  • the electromagnetic steel sheet is, for example, a silicon steel sheet in which about several% (for example, 3%) of silicon is added to iron.
  • the stator winding 51 corresponds to the armature winding
  • the stator core 52 corresponds to the armature core.
  • the stator winding 51 is a portion that overlaps the stator core 52 in the radial direction, and is a coil side portion 53 that is radially outside the stator core 52, and one end side of the stator core 52 and others in the axial direction. It has coil ends 54 and 55 overhanging on the end side, respectively.
  • the coil side portion 53 faces the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction, respectively.
  • the inverter unit 60 has a unit base 61 fixed to the housing 30 by fasteners such as bolts, and a plurality of electrical components 62 assembled to the unit base 61.
  • the unit base 61 is made of, for example, carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the unit base 61 has an end plate 63 fixed to the edge of the opening 33 of the housing 30, and a casing 64 integrally provided with the end plate 63 and extending in the axial direction.
  • the end plate 63 has a circular opening 65 at the center thereof, and the casing 64 is formed so as to stand up from the peripheral edge of the opening 65.
  • a stator 50 is assembled on the outer peripheral surface of the casing 64. That is, the outer diameter of the casing 64 is the same as the inner diameter of the stator core 52, or slightly smaller than the inner diameter of the stator core 52.
  • the stator core 52 By assembling the stator core 52 to the outside of the casing 64, the stator 50 and the unit base 61 are integrated. Further, since the unit base 61 is fixed to the housing 30, the stator 50 is integrated with the housing 30 when the stator core 52 is assembled to the casing 64.
  • the stator core 52 may be assembled to the unit base 61 by adhesion, shrink fitting, press fitting, or the like. As a result, the displacement of the stator core 52 in the circumferential direction or the axial direction with respect to the unit base 61 side is suppressed.
  • the radial inside of the casing 64 is a storage space for accommodating the electric component 62, and the electric component 62 is arranged so as to surround the rotating shaft 11 in the accommodation space.
  • the casing 64 has a role as a storage space forming portion.
  • the electric component 62 includes a semiconductor module 66 constituting an inverter circuit, a control board 67, and a capacitor module 68.
  • the unit base 61 is provided 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 the motor housing of the rotary electric machine 10.
  • the holding member 23 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 are coupled to each other on the other side.
  • the rotary electric machine 10 is attached to the vehicle or the like by attaching a motor housing to the side of the vehicle or the like.
  • FIG. 6 is an exploded view of the inverter unit 60.
  • the casing 64 has a tubular portion 71 and end faces 72 provided on one of both ends (ends on the bearing unit 20 side) facing each other in the axial direction thereof. Of both ends of the tubular portion 71 in the axial direction, the opposite side of the end surface 72 is completely opened through the opening 65 of the end plate 63.
  • a circular hole 73 is formed in the center of the end surface 72, and the rotating shaft 11 can be inserted into the hole 73.
  • the hole 73 is provided with a sealing material 171 that seals a gap between the rotating shaft 11 and the outer peripheral surface.
  • the sealing material 171 may be, for example, a sliding seal made of a resin material.
  • the tubular portion 71 of the casing 64 is a partition portion that partitions the rotor 40 and the stator 50 arranged on the outer side in the radial direction and the electric component 62 arranged on the inner side in the radial direction.
  • the rotor 40, the stator 50, and the electrical component 62 are arranged side by side in and out of the radial direction with the shape portion 71 in between.
  • the electric component 62 is an electric component constituting an inverter circuit, and has a power running function of passing a current through each phase winding of the stator winding 51 in a predetermined order to rotate the rotor 40, and a rotating shaft 11. It has a power generation function of inputting a three-phase AC current flowing through the stator winding 51 with the rotation of the stator winding 51 and outputting it to the outside as generated power.
  • the electric component 62 may have only one of the power running function and the power generation function.
  • the power generation function is, for example, a regenerative function that outputs regenerative power to the outside when the rotary electric machine 10 is used as a power source for a vehicle.
  • a hollow cylindrical capacitor module 68 is provided around the rotating shaft 11, and a plurality of capacitor modules 68 are provided on the outer peripheral surface of the capacitor module 68.
  • the semiconductor modules 66 of the above are arranged side by side in the circumferential direction.
  • the capacitor module 68 includes a plurality of smoothing capacitors 68a connected in parallel to each other.
  • the capacitor 68a is a laminated film capacitor in which a plurality of film capacitors are laminated, and has a trapezoidal cross section.
  • the capacitor module 68 is configured by arranging twelve capacitors 68a side by side in an annular shape.
  • the capacitor 68a for example, a long film having a predetermined width in which a plurality of films are laminated is used, the film width direction is the trapezoidal height direction, and the upper bottom and the lower bottom of the trapezoid are alternately alternated.
  • a capacitor element is made by cutting a long film into an isosceles trapezoidal shape so as to be. Then, a capacitor 68a is manufactured by attaching an electrode or the like to the capacitor element.
  • the semiconductor module 66 has a semiconductor switching element such as a MOSFET or an IGBT, and is formed in a substantially plate shape.
  • a semiconductor switching element such as a MOSFET or an IGBT
  • an inverter circuit is provided for each of the three-phase windings
  • a total of 12 semiconductor modules 66 are formed by arranging them in an annular shape.
  • the semiconductor module group 66A is provided in the electric component 62.
  • the semiconductor module 66 is arranged so as to be sandwiched between the tubular portion 71 of the casing 64 and the capacitor module 68.
  • the outer peripheral surface of the semiconductor module group 66A is in contact with the inner peripheral surface of the tubular portion 71, and the inner peripheral surface of the semiconductor module group 66A is in contact with the outer peripheral surface of the capacitor module 68.
  • the heat generated in the semiconductor module 66 is transferred to the end plate 63 via the casing 64 and released from the end plate 63.
  • the semiconductor module group 66A may have a spacer 69 on the outer peripheral surface side, that is, in the radial direction between the semiconductor module 66 and the tubular portion 71.
  • the cross-sectional shape of the cross section orthogonal to the axial direction is a regular dodecagon
  • the cross-sectional shape of the inner peripheral surface of the tubular portion 71 is circular, so that the spacer 69 is an inner peripheral surface. Is a flat surface and the outer peripheral surface is a curved surface.
  • the spacer 69 may be integrally provided so as to be connected in an annular shape on the radial outer side of the semiconductor module group 66A.
  • the spacer 69 is a good thermal conductor, and may be, for example, a metal such as aluminum, a heat radiating gel sheet, or the like. It is also possible to make the cross-sectional shape of the inner peripheral surface of the tubular portion 71 into a dodecagonal shape, which is the same as that of the capacitor module 68. In this case, it is preferable that both the inner peripheral surface and the outer peripheral surface of the spacer 69 are flat surfaces.
  • a cooling water passage 74 for flowing cooling water is formed in the tubular portion 71 of the casing 64, and the heat generated in the semiconductor module 66 is directed to the cooling water flowing through the cooling water passage 74. Even released. That is, the casing 64 is provided with a water cooling mechanism. As shown in FIGS. 3 and 4, the cooling water passage 74 is formed in an annular shape so as to surround the electrical component 62 (semiconductor module 66 and condenser module 68). The semiconductor module 66 is arranged along the inner peripheral surface of the tubular portion 71, and a cooling water passage 74 is provided at a position where the semiconductor module 66 overlaps the semiconductor module 66 in the radial direction inside and outside.
  • stator 50 Since the stator 50 is arranged on the outside of the tubular portion 71 and the electrical component 62 is arranged on the inside, the heat of the stator 50 is transferred to the tubular portion 71 from the outside, and the heat of the stator 50 is transferred to the tubular portion 71.
  • the heat of the electric component 62 (for example, the heat of the semiconductor module 66) 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.
  • the semiconductor module 66 constituting a part or the whole of the inverter circuit for operating the rotary electric machine by energizing the stator winding 51 is radially outside the tubular portion 71 of the casing 64. It is arranged in the area surrounded by the stator core 52 arranged in. Desirably, the entire semiconductor module 66 is arranged in the region surrounded by the stator core 52. Further, preferably, the entire semiconductor module 66 is arranged in the region surrounded by the stator core 52.
  • the semiconductor module 66 is arranged in the area surrounded by the cooling water passage 74. Desirably, the entire semiconductor module 66 is located in the region surrounded by the yoke 141.
  • 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.
  • the capacitor module 68 has two end faces facing each other in the axial direction, that is, a first end face and a second end face.
  • the first end surface of the capacitor module 68 near the bearing unit 20 faces the end surface 72 of the casing 64, and is superposed on the end surface 72 with the insulating sheet 75 sandwiched between them.
  • a wiring module 76 is assembled on the second end surface of the capacitor module 68 near the opening 65.
  • the wiring module 76 has a main body portion 76a made of a synthetic resin material and having a circular plate shape, and a plurality of bus bars 76b and 76c embedded therein.
  • the bus bars 76b and 76c are used to form a semiconductor module 66 and a capacitor. It has an electrical connection with module 68.
  • the semiconductor module 66 has a connecting pin 66a extending from its axial end face, and the connecting pin 66a is connected to the bus bar 76b on the radial outer side of the main body portion 76a.
  • the bus bar 76c extends to the side opposite to the capacitor module 68 on the radial outer side of the main body portion 76a, and is connected to the wiring member 79 at the tip end portion thereof (see FIG. 2).
  • the heat dissipation path of the capacitor module 68 is provided.
  • a path is formed from the first end face and the second end face of the capacitor module 68 to the end face 72 and the tubular portion 71. That is, a path from the first end face to the end face 72 and a path from the second end face to the tubular portion 71 are formed.
  • heat can be dissipated from the end surface portion other than the outer peripheral surface on which the semiconductor module 66 is provided. That is, not only heat dissipation in the radial direction but also heat dissipation in the axial direction is possible.
  • the capacitor module 68 has a hollow cylindrical shape and the rotating shaft 11 is arranged on the inner peripheral portion thereof with a predetermined gap interposed therebetween, the heat of the capacitor module 68 can be released from the hollow portion as well. ing. In this case, the rotation of the rotating shaft 11 causes an air flow to enhance the cooling effect.
  • a disk-shaped control board 67 is attached to the wiring module 76.
  • the control board 67 has a printed circuit board (PCB) on which a predetermined wiring pattern is formed, and a control device 77 corresponding to a control unit including various ICs and a microcomputer is mounted on the board. There is.
  • the control board 67 is fixed to the wiring module 76 by a fixture such as a screw.
  • the control board 67 has an insertion hole 67a in which the rotation shaft 11 is inserted in the central portion thereof.
  • 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 thereof.
  • the first surface faces the capacitor module 68.
  • the wiring module 76 is provided with a control board 67 on the second surface thereof.
  • the bus bar 76c of the wiring module 76 extends from one side of both sides of the control board 67 to the other side.
  • the control board 67 may be provided with a notch for avoiding interference with the bus bar 76c.
  • the electric component 62 is generated in the inverter circuit.
  • Electromagnetic noise is suitably shielded. That is, in the inverter circuit, switching control is performed in each semiconductor module 66 by utilizing PWM control by a predetermined carrier frequency, and it is conceivable that electromagnetic noise is generated by the switching control. It can be suitably shielded by the housing 30, the rotor 40, the stator 50, etc. on the radial outer side of the 62.
  • the semiconductor module 66 is arranged in the region surrounded by the stator core 52 arranged radially outside the tubular portion 71 of the casing 64, whereby the semiconductor module 66 and the stator winding are arranged.
  • the semiconductor module 66 even if magnetic flux is generated from the semiconductor module 66, it is less likely to affect the stator winding 51. Further, even if the magnetic flux is generated from the stator winding 51, it is unlikely to affect the semiconductor module 66. It is more effective if the entire semiconductor module 66 is arranged in a region surrounded by the stator core 52 arranged on the radial outer side of the tubular portion 71 of the casing 64. Further, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, it is possible to obtain the effect that the heat generated from the stator winding 51 and the magnet unit 42 is difficult to reach the semiconductor module 66.
  • a through hole 78 is formed in the vicinity of the end plate 63 through which a wiring member 79 (see FIG. 2) for electrically connecting the outer stator 50 and the inner electrical component 62 is inserted.
  • the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 76c of the wiring module 76 by crimping, welding, or the like.
  • the wiring member 79 is, for example, a bus bar, and it is desirable that the joint surface thereof be flattened.
  • the through holes 78 are preferably provided at one place or a plurality of places, and in the present embodiment, the through holes 78 are provided at two places. In a configuration in which through holes 78 are provided at two locations, winding terminals extending from two sets of three-phase windings can be easily connected by wiring members 79, which is suitable for multi-phase connection. It has become.
  • a rotor 40 and a stator 50 are provided in the housing 30 in this order from the outside in the radial direction, and an inverter unit 60 is provided inside the stator 50 in the radial direction.
  • the rotor 40 and the stator 50 are arranged radially outside the distance of d ⁇ 0.705 from the center of rotation of the rotor 40. There is.
  • the region of the rotor 40 and the stator 50 that is radially inward from the inner peripheral surface of the stator 50 that is radially inner is the first region X1 in the radial direction.
  • the cross-sectional area of the first region X1 is larger than the cross-sectional area of the second region X2.
  • the volume of the first region X1 is larger than the volume of the second region X2 when viewed in the range where the magnet unit 42 of the rotor 40 and the stator winding 51 overlap in the radial direction.
  • the first region X1 radially inside from the inner peripheral surface of the magnetic circuit component assembly in the housing 30 is the magnetic circuit component assembly in the radial direction.
  • the volume is larger than that of the second region X2 between the inner peripheral surface of the above and the housing 30.
  • a stator core made of a laminated steel plate and forming an annular shape is provided with a plurality of slots in the circumferential direction, and a stator winding is wound in the slots.
  • the stator core has a plurality of teeth extending in the radial direction from the yoke at predetermined intervals, and slots are formed between the teeth adjacent to each other in the circumferential direction. Then, for example, a plurality of layers of conductors are accommodated in the slot in the radial direction, and the stator winding is formed by the conductors.
  • stator winding when the stator winding is energized, magnetic saturation occurs in the teeth portion of the stator core as the magnetomotive force of the stator winding increases, which causes magnetic saturation in the rotating electric machine. It is possible that the torque density is limited. That is, in the stator core, it is considered that magnetic saturation occurs when the rotational magnetic flux generated by the energization of the stator winding is concentrated on the teeth.
  • a permanent magnet is arranged on the d-axis in the dq coordinate system, and a rotor core is arranged on the q-axis.
  • the stator winding near the d-axis is excited, so that 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 portion of the rotor.
  • FIG. 7 is a torque diagram showing the relationship between the ampere turn [AT] showing the magnetomotive force of the stator winding and the torque density [Nm / L].
  • the broken line shows the characteristics of a general IPM rotor type rotary electric machine.
  • FIG. 7 in a general rotary electric machine, by increasing the magnetomotive force in the stator, magnetic saturation occurs in two places, the tooth portion between the slots and the q-axis core portion, which causes magnetic saturation. The increase in torque is limited.
  • the ampere turn design value is limited by A1.
  • the rotary electric machine 10 in order to eliminate the limitation caused by magnetic saturation, is provided with the following configuration. That is, as a first device, in order to eliminate the magnetic saturation that occurs in the teeth of the stator core in the stator, a slotless structure is adopted in the stator 50, and in order to eliminate the magnetic saturation that occurs in the q-axis core portion of the IPM rotor. , SPM (Surface Permanent Magnet) rotor is used. According to the first device, it is possible to eliminate the above-mentioned two parts where magnetic saturation occurs, but it is conceivable that the torque in the low current region is reduced (see the alternate long and short dash line in FIG. 7).
  • SPM Surface Permanent Magnet
  • the magnet unit 42 of the rotor 40 adopts a polar anisotropic structure in which the magnetic path is lengthened to increase the magnetic force. ing.
  • the coil side portion 53 of the stator winding 51 adopts a flat conductor structure in which the radial thickness of the stator 50 of the conductor is reduced to recover the torque reduction.
  • a larger eddy current is generated in the stator winding 51 facing the magnet unit 42 due to the above-mentioned polar anisotropic structure in which the magnetic force is increased.
  • the flat conductor structure is thin in the radial direction, it is possible to suppress the generation of eddy current in the radial direction in the stator winding 51.
  • a magnet having a high magnetic force is adopted to expect a significant improvement in torque characteristics, but the magnet has a high magnetic force. Concerns about the generation of large eddy currents that can occur can also be improved.
  • a magnet unit that uses a polar anisotropic structure and has a magnetic flux density distribution close to a sine wave is adopted.
  • the sine wave matching rate can be increased by pulse control or the like described later to increase the torque, and eddy current loss (copper loss due to eddy current: eddy current loss) due to a gentler magnetic flux change than that of a radial magnet. ) Can also be further suppressed.
  • the sine wave matching factor will be described below.
  • the sine wave matching factor can be obtained by comparing the measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe and the sine wave having the same period and peak value.
  • the ratio of the amplitude of the primary waveform, which is the fundamental wave of the rotating electric machine, to the amplitude of the actually measured waveform, that is, the amplitude obtained by adding other harmonic components to the fundamental wave corresponds to the sine wave matching factor.
  • the sinusoidal matching factor increases, the waveform of the surface magnetic flux density distribution approaches the sinusoidal shape.
  • the surface magnetic flux density distribution may be estimated by a method other than actual measurement, for example, electromagnetic field analysis using Maxwell's equations.
  • the stator winding 51 has a wire conductor structure in which a plurality of wire wires are gathered and bundled. According to this, since the strands are connected in parallel, a large current can flow, and the eddy current generated by the conductors that spread in the circumferential direction of the stator 50 in the flat conductor structure is generated by the cross-sectional area of each strand. Is smaller, so it can be suppressed more effectively than thinning in the radial direction by the third device.
  • the torque can be increased while using the magnet with a high magnetic force, which is the second device, while suppressing the eddy current loss caused by the high magnetic force. Can be planned.
  • FIG. 8 is a cross-sectional view of the rotor 40 and the stator 50
  • FIG. 11 is a cross-sectional view showing a vertical cross section of the stator 50.
  • FIG. 12 is a perspective view of the stator winding 51.
  • the magnetization direction of the magnet in the magnet unit 42 is indicated by an arrow.
  • the stator core 52 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction, and is on the rotor 40 side.
  • the stator winding 51 is assembled on the outer side in the radial direction.
  • the outer peripheral surface on the rotor 40 side serves as a conductor area.
  • the outer peripheral surface of the stator core 52 has a curved surface without unevenness, and a plurality of conductor groups 81 are arranged at predetermined intervals in the circumferential direction on the outer peripheral surface thereof.
  • the stator core 52 functions as a back yoke that is a part of a magnetic circuit for rotating the rotor 40.
  • a tooth that is, an iron core
  • a soft magnetic material is not provided between each of the two conductor groups 81 adjacent to each other in the circumferential direction (that is, a slotless structure).
  • the resin material of the sealing member 57 is inserted into the gap 56 of each of the conductor groups 81. That is, in the stator 50, the interconductor member provided between each conductor group 81 in the circumferential direction is configured as a sealing member 57 which is a non-magnetic material.
  • each conductor group 81 is composed of two conductors 82 as described later, and only the non-magnetic material occupies between the two conductor groups 81 adjacent to each other in the circumferential direction of the stator 50.
  • the non-magnetic material includes a non-magnetic gas such as air, a non-magnetic liquid, and the like in addition to the sealing member 57.
  • the sealing member 57 is also referred to as a conductor-to-conductor member.
  • the configuration in which the teeth are provided between the conductor groups 81 arranged in the circumferential direction means that the teeth have a predetermined thickness in the radial direction and a predetermined width in the circumferential direction, so that each conductor group has a predetermined width. It can be said that a part of the magnetic circuit, that is, a magnetic magnetic path is formed between 81. In this respect, it can be said that the configuration in which the teeth are not provided between the conducting wire groups 81 is the configuration in which the above-mentioned magnetic circuit is not formed.
  • the stator winding (that is, armature winding) 51 has a predetermined thickness T2 (hereinafter, also referred to as a first dimension) and a width W2 (hereinafter, also referred to as a second dimension). It is formed.
  • the thickness T2 is the shortest distance between the outer surface and the inner surface facing each other in the radial direction of the stator winding 51.
  • the width W2 is a fixation that functions as one of the polyphases of the stator winding 51 (three phases in the embodiment: three phases of U phase, V phase and W phase, or three phases of X phase, Y phase and Z phase). It is the length in the circumferential direction of the stator winding 51 which is a part of the child winding 51.
  • the thickness T2 is preferably smaller than the total width dimension of the two conductor groups 81 existing in the width W2. If the cross-sectional shape of the stator winding 51 (more specifically, the wire 82) is a perfect circle, an ellipse, or a polygon, the cross section of the stator 82 along the radial direction of the stator 50. In the cross section, the maximum length of the stator 50 in the radial direction may be W12, and the maximum length of the stator 50 in the circumferential direction may be W11.
  • the stator winding 51 is sealed by a sealing member 57 made of a synthetic resin material as a sealing material (molding material). That is, the stator winding 51 is molded by the molding material together with the stator core 52.
  • the sealing member 57 is provided between the conductor groups 81, that is, the gap 56 is filled with the synthetic resin material, and the sealing member 57 between the conductor groups 81. Insulation member is interposed in the structure. That is, the sealing member 57 functions as an insulating member in the gap 56.
  • the sealing member 57 is provided on the radial outer side of the stator core 52 in a range including all of the lead wire groups 81, that is, in a range in which the radial thickness dimension is larger than the radial thickness dimension of each lead wire group 81. It is provided.
  • the sealing member 57 is provided in a range including the turn portion 84 of the stator winding 51. Inside the stator winding 51 in the radial direction, a sealing member 57 is provided within a range including at least a part of the end faces of the stator core 52 facing in the axial direction. In this case, the stator winding 51 is resin-sealed almost entirely except for the ends of the phase windings of each phase, that is, the connection terminals with the inverter circuit.
  • the laminated steel plate of the stator core 52 can be pressed inward in the axial direction by the sealing member 57. Thereby, the laminated state of each steel plate can be maintained by using the sealing member 57.
  • the inner peripheral surface of the stator core 52 is not resin-sealed, but instead, the entire stator core 52 including the inner peripheral surface of the stator core 52 is resin-sealed. It may be a configuration.
  • the sealing member 57 is made of a highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, or the like. It is preferably configured. Further, considering the coefficient of linear expansion from the viewpoint of suppressing cracks due to the difference in expansion, it is desirable that the material is the same as the outer coating of the conductor of the stator winding 51. That is, a silicon resin having a coefficient of linear expansion that is generally more than double that of other resins is preferably excluded. For electric products that do not have an engine that utilizes combustion, such as electric vehicles, PPO resin, phenol resin, and FRP resin that have heat resistance of about 180 ° C. are also candidates. This does not apply in the field where the ambient temperature of the rotary electric machine can be regarded as less than 100 ° C.
  • the torque of the rotary electric machine 10 is proportional to the magnitude of the magnetic flux.
  • the maximum amount of magnetic flux in the stator is limited depending on the saturation magnetic flux density in the teeth, but the stator core does not have teeth. In this case, the maximum amount of magnetic flux in the stator is not limited. Therefore, the configuration is advantageous in increasing the energizing current for the stator winding 51 to increase the torque of the rotary electric machine 10.
  • the inductance of the stator 50 is reduced by using a structure (slotless structure) in which the stator 50 has no teeth.
  • the inductance is, for example, around 1 mH, whereas in the stator 50 of the present embodiment, the inductance is high. It is reduced to about 5 to 60 ⁇ H.
  • it is possible to reduce the mechanical time constant Tm by reducing the inductance of the stator 50 while using the rotary electric machine 10 having an outer rotor structure. That is, it is possible to reduce the mechanical time constant Tm while increasing the torque.
  • the mechanical time constant Tm (J ⁇ L) / (Kt ⁇ Ke) In this case, it can be confirmed that the mechanical time constant Tm is reduced by reducing the inductance L.
  • Each conductor group 81 on the radial outer side of the stator core 52 is configured by arranging a plurality of conductors 82 having a flat rectangular cross section side by side in the radial direction of the stator core 52.
  • Each of the conductors 82 is arranged in a direction such that "diameter dimension ⁇ circumferential dimension" in the cross section.
  • the thickness of each conductor group 81 is reduced in the radial direction.
  • the thickness in the radial direction is reduced, and the conductor region extends flat to the region where the teeth have been conventionally, forming a flat conductor region structure.
  • each of the conductor group 81 and each of the conductor 82 will also be referred to as a conductive member.
  • the conductor region occupied by the stator winding 51 in one circumference in the circumferential direction is designed to be larger than the conductor non-occupied region in which the stator winding 51 does not exist. be able to.
  • the conductor region / conductor non-occupied region in one circumference of the stator winding in the circumferential direction is 1 or less.
  • each conductor group 81 is provided so that the conductor region is equal to the conductor non-occupied region or the conductor region is larger than the conductor non-occupied region.
  • the conductor region in which the conductor 82 (that is, the straight line portion 83 described later) is arranged in the circumferential direction is WA and the region between the conductors 82 between the adjacent conductors 82 is WB, the conductor The region WA is larger in the circumferential direction than the interconductor region WB.
  • the thickness dimension of the conductor group 81 in the radial direction is smaller than the width dimension of one phase in one magnetic pole in the circumferential direction. That is, in a configuration in which the conductor group 81 is composed of two layers of conductors 82 in the radial direction and two conductor groups 81 are provided in the circumferential direction for each phase in one magnetic pole, the thickness dimension of each conductor 82 in the radial direction is set.
  • Tc and the width dimension of each conducting wire 82 in the circumferential direction are Wc, it is configured to be "Tc ⁇ 2 ⁇ Wc ⁇ 2".
  • the conductor group 81 is composed of two layers of conductors 82 and one conductor group 81 is provided in one magnetic pole in the circumferential direction for each phase. It is preferable that it is configured so as to be.
  • the conductor portions (conductor group 81) arranged at predetermined intervals in the circumferential direction in the stator winding 51 have a thickness dimension in the radial direction that is larger than the width dimension in the circumferential direction for one phase in one magnetic pole. It is small.
  • the thickness dimension Tc in the radial direction of each conductor 82 is smaller than the width dimension Wc in the circumferential direction. Furthermore, the radial thickness dimension (2Tc) of the conductor group 81 composed of two layers of conductors 82 in the radial direction, that is, the radial thickness dimension (2Tc) of the conductor group 81 is larger than the circumferential width dimension Wc. It should be small.
  • the torque of the rotary electric machine 10 is substantially inversely proportional to the radial thickness of the stator core 52 of the conductor group 81.
  • the thickness of the conductor group 81 is reduced on the radial outer side of the stator core 52, which is advantageous in increasing the torque of the rotary electric 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 iron-free portion). 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.
  • the thickness of the conductor group 81 even if the magnetic flux leaks from the conductor group 81, it is easily collected by the stator core 52, and the magnetic flux is not effectively used for improving torque and leaks to the outside. Can be suppressed. That is, it is possible to suppress a decrease in magnetic force due to magnetic flux leakage, and it is possible to increase the interlinkage magnetic flux of the stator core 52 by the permanent magnet to increase the torque.
  • the conductor 82 is composed of a coated conductor whose surface is coated with an insulating coating 82b, and is between the conductors 82 that overlap each other in the radial direction and between the conductor 82 and the stator core 52. Insulation is ensured in each.
  • the insulating coating 82b is composed of a coating thereof if the strand 86 described later is a self-bonding coated wire, or an insulating member laminated separately from the coating of the strand 86.
  • Each phase winding composed of the conducting wire 82 retains the insulating property by the insulating coating 82b except for the exposed portion for connection.
  • the exposed portion is, for example, an input / output terminal portion or a neutral point portion in the case of a star-shaped connection.
  • the conductors 82 adjacent to each other in the radial direction are fixed to each other by using resin fixing or self-bonding coated wire. As a result, dielectric breakdown, vibration, and sound due to the rubbing of the conducting wires 82 against each other are suppressed.
  • the conductor 82a is configured as an aggregate of a plurality of wires 86. Specifically, as shown in FIG. 13, the conductor 82a is formed in a twisted state by twisting a plurality of strands 86. Further, as shown in FIG. 14, the wire 86 is configured as a composite in which thin fibrous conductive materials 87 are bundled.
  • the wire 86 is a composite of CNT (carbon nanotube) fibers, and as the CNT fiber, a fiber containing boron-containing fine fibers in which at least a part of carbon is replaced with boron is used.
  • a vapor phase growth method carbon fiber (VGCF) or the like can be used in addition to the CNT fiber, but it is preferable to use the CNT fiber.
  • the surface of the wire 86 is covered with a polymer insulating layer such as enamel. Further, it is preferable that the surface of the wire 86 is covered with a so-called enamel film made of a polyimide film or an amidimide film.
  • the conductor 82 constitutes an n-phase winding in the stator winding 51. Then, the respective strands 86 of the conductor 82 (that is, the conductor 82a) are adjacent to each other in contact with each other.
  • the winding conductor has a portion formed by twisting a plurality of strands 86 at one or more places in the phase, and the resistance value between the twisted strands 86 is the strand 86 itself. It is a wire aggregate larger than the resistance value of.
  • the conducting wire 82 may be formed of a plurality of strands 86, and may be an aggregate of strands covering the plurality of strands 86 by an insulating member having an extremely high first electrical resistivity. Further, the conductor 82a of the conductor 82 is composed of a plurality of twisted strands 86.
  • the conductor 82a is configured by twisting a plurality of strands 86, the generation of eddy currents in each strands 86 can be suppressed, and the eddy currents in the conductor 82a can be reduced. Further, since each wire 86 is twisted, a portion where the magnetic field application directions are opposite to each other is generated in one wire 86, and the counter electromotive voltage is canceled out. Therefore, the eddy current can also be reduced. In particular, by forming the wire 86 with the fibrous conductive material 87, it is possible to make the wire thinner and to significantly increase the number of twists, and it is possible to more preferably reduce the eddy current.
  • the method of insulating the wires 86 from each other here is not limited to the above-mentioned polymer insulating film, and may be a method of making it difficult for current to flow between the twisted wires 86 by using contact resistance. That is, if the resistance value between the twisted strands 86 is larger than the resistance value of the strands 86 itself, the above effect can be obtained by the potential difference generated due to the difference in the resistance values. ..
  • the wire is used based on the movement time, work interval, and the like. 86 is suitable because it can be oxidized and the contact resistance can be increased.
  • the conductor 82 has a flat rectangular cross section and is arranged side by side in the radial direction.
  • a plurality of conductors 82 covered with a self-bonding coated wire having a fusion layer and an insulating layer.
  • the wire 86 is assembled in a twisted state, and the fused layers are fused to maintain the shape.
  • the strands having no fusion layer or the strands of the self-bonding coated wire may be twisted and solidified into a desired shape with a synthetic resin or the like for molding.
  • the thickness of the insulating coating 82b in the conductor 82 is set to, for example, 80 ⁇ m to 100 ⁇ m and is thicker than the film thickness (5 to 40 ⁇ m) of the commonly used conductor, insulation is provided between the conductor 82 and the stator core 52. Insulation between the two can be ensured without the intervention of paper or the like.
  • the insulating coating 82b has higher insulating performance than the insulating layer of the wire 86 and is configured to be able to insulate between the phases.
  • the thickness of the polymer insulating layer of the wire 86 is set to, for example, about 5 ⁇ m
  • the thickness of the insulating coating 82b of the conducting wire 82 is set to about 80 ⁇ m to 100 ⁇ m so that insulation between the phases can be preferably performed. Is desirable.
  • the conductor 82 may have a configuration in which a plurality of strands 86 are bundled without being twisted. That is, the conductor 82 has a configuration in which a plurality of strands 86 are twisted in the total length, a configuration in which a plurality of strands 86 are twisted in a part of the total length, and a plurality of strands 86 are twisted in the total length. It may be any of the configurations that are bundled together.
  • each conductor 82 constituting the conductor portion is a wire aggregate in which a plurality of conductors 86 are bundled and the resistance value between the bundled wires is larger than the resistance value of the wire 86 itself. It has become.
  • Each conductor 82 is bent and formed so as to be arranged in a predetermined arrangement pattern in the circumferential direction of the stator winding 51, whereby a phase winding for each phase is formed as the stator winding 51. ..
  • the coil side portion 53 is formed by the straight portion 83 of each conducting wire 82 extending linearly in the axial direction, and the coil side portion 53 is formed on both outer sides of the coil side portion 53 in the axial direction.
  • the coil ends 54 and 55 are formed by the protruding turn portions 84.
  • Each conducting wire 82 is configured as a series of wave-shaped conducting wires by alternately repeating a straight line portion 83 and a turn portion 84.
  • the straight line portions 83 are arranged at positions facing the magnet unit 42 in the radial direction, and in-phase straight line portions 83 arranged at positions on the outer side in the axial direction of the magnet unit 42 at predetermined intervals are arranged. They are connected to each other by a turn portion 84.
  • the straight line portion 83 corresponds to the “magnet facing portion”.
  • the stator winding 51 is wound in an annular shape by distributed winding.
  • linear portions 83 are arranged in the circumferential direction at intervals corresponding to one pole pair of the magnet unit 42 for each phase, and in the coil ends 54 and 55, each linear portion 83 for each phase is arranged. , They are connected to each other by a turn portion 84 formed in a substantially V shape.
  • the directions of the currents of the linear portions 83 that are paired corresponding to the one-pole pair are opposite to each other.
  • the combination of the pair of linear portions 83 connected by the turn portion 84 is different between the one coil end 54 and the other coil end 55, and the connections at the coil ends 54 and 55 are in the circumferential direction.
  • the stator winding 51 is formed in a substantially cylindrical shape.
  • the stator winding 51 constitutes a winding for each phase by using two pairs of conductors 82 for each phase, and one of the stator windings 51 is a three-phase winding (U).
  • X phase, Y phase, Z phase the other three-phase winding
  • S the number of phases of the stator winding 51
  • m the number of conductors 82 per phase
  • the straight portions 83 are arranged so as to overlap in two layers adjacent in the radial direction, and in the coil ends 54 and 55, the linear portions overlapping in the radial direction are respectively arranged.
  • the turn portion 84 extends in the circumferential direction in directions opposite to each other in the circumferential direction. That is, in each of the conducting 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.
  • FIG. 15 (a) and 15 (b) are views showing the form of each conductor 82 in the nth layer, and FIG. 15 (a) shows the conductor 82 seen from the side of the stator winding 51. The shape is shown, and FIG. 15B shows the shape of the conducting wire 82 seen from one side in the axial direction of the stator winding 51.
  • FIG. 15A and FIG. 15B show the shape of the conducting wire 82 seen from one side in the axial direction of the stator winding 51.
  • the positions where the conductor group 81 is arranged are shown as D1, D2, D3, ..., Respectively. Further, for convenience of explanation, only three conductors 82 are shown, which are referred to as the first conductor 82_A, the second conductor 82_B, and the third conductor 82_C.
  • the straight line portions 83 are all arranged at the nth layer position, that is, at the same position in the radial direction, and the straight line portions 83 separated by 6 positions (3 ⁇ m pairs) in the circumferential direction are separated from each other. They are connected to each other by a turn portion 84.
  • a pair of straight lines 83 are arranged at D1 and D7, respectively, and the pair of straight lines 83 are connected to each other by an inverted V-shaped turn portion 84.
  • the other conductors 82_B and 82_C are arranged in the same nth layer with their circumferential positions shifted by one.
  • the turn portions 84 interfere with each other. Therefore, in the present embodiment, an interference avoidance portion is formed in the turn portion 84 of each of the conducting wires 82_A to 82_C by offsetting a part thereof in the radial direction.
  • the turn portion 84 of each of the conducting wires 82_A to 82_C is from one inclined portion 84a which is a portion extending in the circumferential direction on the same circle (first circle) and the same circle from the inclined portion 84a.
  • the inclined portion 84c extending in the circumferential direction on the second circle, and the first circle. It has a return portion 84d that returns to the second circle.
  • the top portion 84b, the inclined portion 84c, and the return portion 84d correspond to the interference avoidance portion.
  • the inclined portion 84c may be configured to shift outward in the radial direction with respect to the inclined portion 84a.
  • the turn portions 84 of the conducting wires 82_A to 82_C have an inclined portion 84a on one side and an inclined portion 84c on the other side on both sides of the top portion 84b which is a central position in the circumferential direction.
  • the radial positions of the inclined portions 84a and 84c are different from each other.
  • the turn portion 84 of the first lead wire 82_A extends along the circumferential direction starting from the D1 position of the n layer, bends in the radial direction (for example, inward in the radial direction) at the top portion 84b which is the central position in the circumferential direction, and then. By bending again in the circumferential direction, it extends along the circumferential direction again, and further bends in the radial direction (for example, outside in the radial direction) again at the return portion 84d to reach the D7 position of the n layer, which is the end point position. There is.
  • one of the inclined portions 84a is arranged vertically in the order of the first conductor 82_A ⁇ the second conductor 82_B ⁇ the third conductor 82_C from the top, and each conductor 82_A to the top 84b.
  • the top and bottom of 82_C are interchanged, and the other inclined portions 84c are arranged vertically in the order of the third conductor 82_C ⁇ the second conductor 82_B ⁇ the first conductor 82_A from the top. Therefore, the conductors 82_A to 82_C can be arranged in the circumferential direction without interfering with each other.
  • the turn portion 84 connected to the linear portion 83 on the inner side in the radial direction and the outer side in the radial direction among the straight line portions 83 of the plurality of layers is arranged so as to be radially separated from each of the straight portions 83.
  • the conductors 82 of a plurality of layers are bent to the same side in the radial direction near the end of the turn portion 84, that is, the boundary portion with the straight portion 83, the conductors 82 of the adjacent layers have an insulating property due to interference between the conductors 82. It is good to prevent the damage from being damaged.
  • the conducting wires 82 overlapping in the radial direction are bent in the radial direction at the return portion 84d of the turn portion 84, respectively.
  • the radius of curvature of the bent portion is different between the conductor 82 of the nth layer and the conductor 82 of the n + 1 layer.
  • the radius of curvature R1 of the conductive wire 82 on the inner side in the radial direction (nth layer) is made smaller than the radius of curvature R2 of the lead wire 82 on the outer side in the radial direction (n + 1th layer).
  • the shift amount in the radial direction is made larger than the shift amount S2 of the conductor 82 on the outer side (n + 1 layer) in the radial direction.
  • the permanent magnet used in this embodiment is a sintered magnet obtained by sintering and solidifying a granular magnetic material, and the intrinsic coercive force Hcj on the JH curve is 400 [kA / m] or more.
  • the residual magnetic flux density Br is 1.0 [T] or more.
  • the magnet unit 42 has a saturation magnetic flux density Js of 1.2 [T] or more, a crystal particle size of 10 [ ⁇ m] or less, and Js ⁇ ⁇ of 1 when the orientation ratio is ⁇ . It is 0.0 [T] or higher.
  • the magnet unit 42 is supplemented below.
  • the magnet unit 42 (magnet) is characterized in that 2.15 [T] ⁇ Js ⁇ 1.2 [T].
  • examples of the magnet used in the magnet unit 42 include NdFe11TiN, Nd2Fe14B, Sm2Fe17N3, and FeNi magnets having L10 type crystals.
  • the magnet unit 42 is characterized in that the size of the particle size in the fine powder state before orientation is 10 ⁇ m or less and the particle size in the single magnetic domain or more by using the magnet combination.
  • the coercive force is increased by refining the powder particles to the order of several hundred nm. Therefore, in recent years, powders as fine as possible have been used. However, if it is made too fine, the BH product of the magnet will drop due to oxidation or the like, so a single magnetic domain particle size or larger is preferable. It is known that the coercive force increases due to miniaturization when the particle size is up to the single magnetic domain particle size.
  • the size of the particle size described here is the size of the particle size in the fine powder state at the time of the alignment step in the magnet manufacturing process.
  • each of the first magnet 91 and the second magnet 92 of the magnet unit 42 is a sintered magnet formed by so-called sintering, in which magnetic powder is baked and hardened at a high temperature.
  • sintering when the saturation magnetization Js of the magnet unit 42 is 1.2 T or more, the crystal grain size of the first magnet 91 and the second magnet 92 is 10 ⁇ m or less, and the orientation ratio is ⁇ , Js ⁇ ⁇ is It is performed so as to satisfy the condition of 1.0 T (tesla) or more. Further, each of the first magnet 91 and the second magnet 92 is sintered so as to satisfy the following conditions.
  • the orientation ratio (orientation ratio) is different from the definition of the magnetic force direction by the magnetizing step of the isotropic magnet.
  • the saturation magnetization Js of the magnet unit 42 of the present embodiment is 1.2 T or more, and the orientation ratio ⁇ of the first magnet 91 and the second magnet 92 is high so that Jr ⁇ Js ⁇ ⁇ ⁇ 1.0 [T].
  • the orientation rate is set.
  • the orientation rate ⁇ referred to here means, for example, six easy-to-magnetize axes in each of the first magnet 91 and the second magnet 92, five of which face the direction A10 in the same direction, and the remaining one.
  • the first magnet 91 and the second magnet 92 are formed by sintering, but if the above conditions are satisfied, the first magnet 91 and the second magnet 92 may be molded by another method. .. For example, a method of forming an MQ3 magnet or the like can be adopted.
  • the magnetic circuit length inside the magnet is set to the magnetic circuit length of a linearly oriented magnet that conventionally produces 1.0 [T] or more. Compared, it can be made longer. That is, the magnetic circuit length per pole pair can be achieved with a small amount of magnets, and the reversible demagnetization range is maintained even when exposed to harsh high thermal conditions as compared with the conventional design using linearly oriented magnets. Can be done. Further, the discloser of the present application has found a configuration in which characteristics similar to those of a polar anisotropic magnet can be obtained even by using a magnet of the prior art.
  • the easy-to-magnetize axis refers to the crystal orientation that is easily magnetized in a magnet.
  • the orientation of the easy-to-magnetize axis in the magnet is a direction in which the orientation ratio indicating the degree to which the directions of the easy-magnetization axes are aligned is 50% or more, or a direction in which the orientation of the magnet is average.
  • the magnet unit 42 has an annular shape and is provided inside the magnet holder 41 (specifically, inside the cylindrical portion 43 in the radial direction).
  • the magnet unit 42 has a first magnet 91 and a second magnet 92, which are polar anisotropic magnets and have different polarities 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 an N pole in a portion close to the stator winding 51
  • the second magnet 92 is a magnet that forms an S pole in a portion close to the stator winding 51.
  • the first magnet 91 and the second magnet 92 are permanent magnets made of rare earth magnets such as neodymium magnets.
  • the magnetization direction extends in an arc shape with the q axis (quadrature-axis).
  • the magnetization direction is the radial direction of the annular magnet unit 42 on the d-axis side, and the magnetization direction of the annular magnet unit 42 is the circumferential direction on the q-axis side.
  • Each of the magnets 91 and 92 has a first portion 250 and two second portions 260 located on both sides of the first portion 250 in the circumferential direction of the magnet unit 42, as shown in FIG.
  • the first portion 250 is closer to the d-axis than the second portion 260
  • the second portion 260 is closer to the q-axis than the first portion 250.
  • the magnet unit 42 is configured so that the direction of the easy-to-magnetize axis 300 of the first portion 250 is more parallel to the d-axis than the direction of the easy-to-magnetize axis 310 of the second portion 260.
  • the magnet unit 42 is configured so that the angle ⁇ 11 formed by the easily magnetized axis 300 of the first portion 250 with the d-axis is smaller than the angle ⁇ 12 formed by the easily magnetized axis 310 of the second portion 260 with the q-axis.
  • the angle ⁇ 11 is the angle formed by the d-axis and the easily magnetized axis 300 when the direction from the stator 50 (armature) to the magnet unit 42 is positive on the d-axis.
  • the angle ⁇ 12 is an angle formed by the q-axis and the easily magnetized axis 310 when the direction from the stator 50 (armature) to the magnet unit 42 is positive on the q-axis. Both the angle ⁇ 11 and the angle ⁇ 12 are 90 ° or less in this embodiment.
  • Each of the easily magnetized axes 300 and 310 referred to here is defined by the following.
  • ) is set to the easy magnetization axis 300 or the easy magnetization axis 310.
  • the directions of the easy-to-magnetize axes of the magnets 91 and 92 are different between the d-axis side (the portion closer to the d-axis) and the q-axis side (the portion closer to the q-axis), and magnetization is performed on the d-axis side.
  • the direction of the easy axis is close to the direction parallel to the d-axis, and the direction of the easy magnetization axis is close to the direction orthogonal to the q-axis on the q-axis side.
  • an arcuate magnet magnetic path is formed according to the direction of the easily magnetized axis.
  • the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side, and the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side.
  • the outer surface on the stator side on the stator 50 side (lower side in FIG. 9) and the end surface on the q-axis side in the circumferential direction are magnetic flux. It is a magnetic flux acting surface that is an inflow and outflow surface, and a magnetic magnetic path is formed so as to connect these magnetic flux acting surfaces (the outer surface on the stator side and the end surface on the q-axis side).
  • the magnet unit 42 magnetic flux flows in an arc shape between adjacent N and S poles due to the magnets 91 and 92, so that the magnet path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 17, the magnetic flux density distribution is close to that of a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in FIG. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotary 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.
  • the horizontal axis represents the electric angle and the vertical axis represents the magnetic flux density. Further, in FIGS. 17 and 18, 90 ° on the horizontal axis indicates the d-axis (that is, the center of the magnetic pole), and 0 ° and 180 ° on the horizontal axis indicate the q-axis.
  • the magnet magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed.
  • magnets 91 and 92 in which the change in surface magnetic flux from the q-axis to the d-axis at each magnetic pole is gentle can be preferably realized.
  • the sine wave matching factor of the magnetic flux density distribution may be, for example, a value of 40% or more. By doing so, it is possible to surely improve the amount of magnetic flux in the central portion of the waveform as compared with the case of using a radial alignment magnet or a parallel alignment magnet having a sinusoidal matching factor of about 30%. Further, if the sine wave matching factor is 60% or more, the amount of magnetic flux in the central portion of the waveform can be surely improved as compared with the magnetic flux concentrated arrangement such as the Halbach array.
  • the magnetic flux density changes sharply near the q-axis.
  • the steeper the change in magnetic flux density the greater the eddy current generated in the stator winding 51.
  • the change in magnetic flux on the stator winding 51 side is also steep.
  • the magnetic flux density distribution is a magnetic flux waveform close to a sine wave. Therefore, the change in the magnetic flux density near the q-axis is smaller than the change in the magnetic flux density of the radial anisotropic magnet. As a result, the generation of eddy current can be suppressed.
  • a magnetic flux is generated in the vicinity of the d-axis (that is, the center of the magnetic pole) of each of the magnets 91 and 92 in a direction orthogonal to the magnetic flux action surface 280 on the stator 50 side, and the magnetic flux acts on the magnetic flux action on the stator 50 side.
  • the stator 50 can receive a strong magnetic flux from the rotor 40.
  • stator 50 is provided with a cylindrical stator core 52 on the radial inside of the stator winding 51, that is, on the opposite side of the rotor 40 with the stator winding 51 interposed therebetween. Therefore, the magnetic flux extending from the magnetic flux acting surface of each of the magnets 91 and 92 is attracted to the stator core 52 and orbits 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.
  • the inverter unit 60 has a unit base 61 and an electric component 62, and each work process including an assembling process of the unit base 61 and the electric component 62 will be described.
  • the assembly including the stator 50 and the inverter unit 60 is referred to as the first unit
  • the assembly including the bearing unit 20, the housing 30 and the rotor 40 is referred to as the second unit.
  • This manufacturing process is -The first step of mounting the electrical component 62 inside the unit base 61 in the radial direction, and -The second step of mounting the unit base 61 inside the stator 50 in the radial direction to manufacture the first unit, and A third step of inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled to the housing 30 to manufacture the second unit, and ⁇ The fourth step of mounting the first unit inside the second unit in the radial direction, and Fifth step of fastening and fixing the housing 30 and the unit base 61, have.
  • the execution order of each of these steps is as follows: 1st step ⁇ 2nd step ⁇ 3rd step ⁇ 4th step ⁇ 5th step.
  • the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 are assembled as a plurality of assemblies (subassemblies), and then the assemblies are assembled to each other. Ease of handling and completion of inspection for each unit can be realized, and a rational assembly line can be constructed. Therefore, it is possible to easily cope with high-mix production.
  • a good thermal conductor having good thermal conductivity is attached to at least one of the radial inside of the unit base 61 and the radial outside of the electric component 62 by coating, adhesion, etc., and in that state,
  • the electrical component 62 may be attached to the unit base 61. This makes it possible to effectively transmit the heat generated by the semiconductor module 66 to the unit base 61.
  • the third step it is advisable to insert the rotor 40 while maintaining the coaxiality between the housing 30 and the rotor 40.
  • the position of 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) is determined with reference to the inner peripheral surface of the housing 30.
  • the housing 30 and the rotor 40 are assembled while sliding either the housing 30 or the rotor 40 along the magnet.
  • heavy parts can be assembled without applying an eccentric load to the bearing unit 20, and the reliability of the bearing unit 20 is improved.
  • the fourth step it is advisable to assemble both units while maintaining the coaxiality between the first unit and the second unit.
  • a jig for determining 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 unit and the second unit are formed along the jig. Assemble each of these units while sliding one of them.
  • each of the above steps is as follows: 2nd step ⁇ 3rd step ⁇ 4th step ⁇ 5th step ⁇ 1st step.
  • the delicate electric component 62 is assembled last, and the stress on the electric component 62 in the assembling process can be minimized.
  • FIG. 19 is an electric circuit diagram of the control system of the rotary electric machine 10
  • FIG. 20 is a functional block diagram showing a control process by the control device 110.
  • FIG. 19 two sets of three-phase windings 51a and 51b are shown as the stator windings 51, and the three-phase winding 51a is composed of a U-phase winding, a V-phase winding, and a W-phase winding.
  • the phase winding 51b includes an X-phase winding, a Y-phase winding, and a Z-phase winding.
  • a first inverter 101 and a second inverter 102 corresponding to a power converter are provided for each of the three-phase windings 51a and 51b, respectively.
  • the inverters 101 and 102 are composed of a full bridge circuit having the same number of upper and lower arms as the number of phases of the phase windings, and the stator windings 51 can be turned on and off by turning on / off a switch (semiconductor switching element) provided on each arm. The energizing current is adjusted in each phase winding.
  • a DC power supply 103 and a smoothing capacitor 104 are connected in parallel to each of the inverters 101 and 102.
  • the DC power supply 103 is composed of, for example, an assembled battery in which a plurality of single batteries are connected in series.
  • the switches of the inverters 101 and 102 correspond to the semiconductor module 66 shown in FIG. 1 and the like, and the capacitor 104 corresponds to the capacitor module 68 shown in FIG. 1 and the like.
  • the control device 110 includes a microcomputer composed of a CPU and various memories, and performs energization control by turning on / off each switch in the inverters 101 and 102 based on various detection information in the rotary electric machine 10 and requests for power running and power generation. carry out.
  • the control device 110 corresponds to the control device 77 shown in FIG.
  • the detection information of the rotary electric machine 10 includes, for example, the rotation angle (electric angle information) of the rotor 40 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by the voltage sensor, and the current sensor. Includes the energizing current of each phase detected by.
  • the control device 110 generates and outputs an operation signal for operating each of the switches of the inverters 101 and 102.
  • the power generation requirement is, for example, a regenerative drive requirement when the rotary electric machine 10 is used as a power source for a vehicle.
  • the first inverter 101 includes a series connection body of the upper arm switch Sp and the lower arm switch Sn in three phases including the U phase, the V phase, and the W phase.
  • the high potential side terminal of the upper arm switch Sp of each phase is connected to the positive electrode terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative electrode terminal (ground) of the DC power supply 103. ..
  • One ends of the U-phase winding, the V-phase winding, and the W-phase winding are connected to the intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase, respectively.
  • Each of these phase windings is star-shaped (Y-connected), and the other end of each phase winding is connected to each other at a neutral point.
  • the second inverter 102 has the same configuration as the first inverter 101, and includes a series connection body of the upper arm switch Sp and the lower arm switch Sn in three phases including the X phase, the Y phase, and the Z phase, respectively. ing.
  • the high potential side terminal of the upper arm switch Sp of each phase is connected to the positive electrode terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative electrode terminal (ground) of the DC power supply 103. ..
  • One ends of the X-phase winding, the Y-phase winding, and the Z-phase winding are connected to the intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase, respectively.
  • Each of these phase windings is star-shaped (Y-connected), and the other end of each phase winding is connected to each other at a neutral point.
  • FIG. 20 shows a current feedback control process that controls each phase current of the U, V, and W phases, and a current feedback control process that controls each phase current of the X, Y, and Z phases.
  • the control processing on the U, V, and W phases will be described.
  • the current command value setting unit 111 uses a torque ⁇ dq map and is based on a power running torque command value or a power generation torque command value for the rotary electric machine 10 and an electric angular velocity ⁇ obtained by time-differentiating the electric angle ⁇ . ,
  • the d-axis current command value and the q-axis current command value are set.
  • the current command value setting unit 111 is commonly provided on the U, V, W phase side and the X, Y, Z phase side.
  • the power generation torque command value is, for example, a regenerative torque command value when the rotary electric machine 10 is used as a power source for a vehicle.
  • the dq conversion unit 112 sets the current detection values (three phase currents) by the current sensors provided for each phase to the orthogonal 2 with the field direction (direction of an axis of a magnetic field, or field direction) as the d-axis. It is converted into a d-axis current and a q-axis current, which are components of the dimensional rotation coordinate system.
  • the d-axis current feedback control unit 113 calculates the d-axis command voltage as an operation amount for feedback-controlling the d-axis current to the d-axis current command value. Further, the q-axis current feedback control unit 114 calculates 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 and 114, the command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current with respect to the current command value.
  • the three-phase conversion unit 115 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages.
  • Each of the above units 111 to 115 is a feedback control unit that performs feedback control of the fundamental wave current according to the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are feedback control values.
  • the operation signal generation unit 116 uses a well-known triangular wave carrier comparison method to generate an operation signal of the first inverter 101 based on the three-phase command voltage. Specifically, the operation signal generation unit 116 switches the upper and lower arms in each phase by PWM control based on the magnitude comparison between the signal obtained by standardizing the command voltage of the three phases with the power supply voltage and the carrier signal such as the triangular wave signal. Generates an operation signal (duty signal).
  • the X, Y, and Z phases also have the same configuration, and the dq conversion unit 122 sets the current detection value (three phase currents) by the current sensor provided for each phase in the field direction. It is converted into a d-axis current and a q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system having the d-axis.
  • the d-axis current feedback control unit 123 calculates the d-axis command voltage
  • the q-axis current feedback control unit 124 calculates the q-axis command voltage.
  • the three-phase conversion unit 125 converts the d-axis and q-axis command voltages into X-phase, Y-phase, and Z-phase command voltages.
  • the operation signal generation unit 126 generates an operation signal of the second inverter 102 based on the three-phase command voltage. Specifically, the operation signal generation unit 126 switches the upper and lower arms in each phase by PWM control based on the magnitude comparison between the signal obtained by standardizing the command voltage of the three phases with the power supply voltage and the carrier signal such as the triangular wave signal. Generates an operation signal (duty signal).
  • the driver 117 turns on / off the switches Sp and Sn of each of the three phases in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 116 and 126.
  • This process is mainly used for the purpose of increasing the output of the rotary electric machine 10 and reducing the loss under operating conditions in which the output voltage of each of the inverters 101 and 102 becomes large, such as in a high rotation region and a high output region.
  • the control device 110 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotary electric machine 10.
  • FIG. 21 shows a torque feedback control process corresponding to the U, V, and W phases and a torque feedback control process corresponding to the X, Y, and Z phases.
  • the same configuration as that in FIG. 20 is designated by the same reference numerals and the description thereof will be omitted.
  • the control processing on the U, V, and W phases will be described.
  • the voltage amplitude calculation unit 127 is a command value of the magnitude of the voltage vector based on the power running torque command value or the power generation torque command value for the rotary electric machine 10 and the electric angular velocity ⁇ obtained by time-differentiating the electric angle ⁇ . Calculate the voltage amplitude command.
  • the torque estimation unit 128a calculates the torque estimation value corresponding to the U, V, and W phases based on the d-axis current and the q-axis current converted by the dq conversion unit 112.
  • the torque estimation unit 128a may calculate the voltage amplitude command based on the map information associated with the d-axis current, the q-axis current, and the voltage amplitude command.
  • the torque feedback control unit 129a calculates a voltage phase command, which is a command value of the phase of the voltage vector, as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the generated torque command value.
  • the torque feedback control unit 129a calculates the voltage phase command using the PI feedback method based on the deviation of the torque estimated value with respect to the power running torque command value or the generated torque command value.
  • the operation signal generation unit 130a generates an operation signal of the first inverter 101 based on the voltage amplitude command, the voltage phase command, and the electric angle ⁇ . Specifically, the operation signal generation unit 130a calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electric angle ⁇ , and the calculated three-phase command voltage is standardized by the power supply voltage. And, by PWM control based on the magnitude comparison with the carrier signal such as the triangular wave signal, the switch operation signal of the upper and lower arms in each phase is generated.
  • the operation signal generation unit 130a is based on the pulse pattern information, the voltage amplitude command, the voltage phase command, and the electric angle ⁇ , which are map information related to the voltage amplitude command, the voltage phase command, the electric angle ⁇ , and the switch operation signal.
  • the switch operation signal may be generated.
  • the X, Y, Z phase side also has the same configuration, and the torque estimation unit 128b has the X, Y, X, Y, based on the d-axis current and the q-axis current converted by the dq conversion unit 122. The torque estimate corresponding to the Z phase is calculated.
  • the torque feedback control unit 129b calculates a voltage phase command as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the power generation torque command value.
  • the torque feedback control unit 129b calculates the voltage phase command using the PI feedback method based on the deviation of the torque estimated value with respect to the power running torque command value or the generated torque command value.
  • the operation signal generation unit 130b generates an operation signal of the second inverter 102 based on the voltage amplitude command, the voltage phase command, and the electric angle ⁇ . Specifically, the operation signal generation unit 130b calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electric angle ⁇ , and the calculated three-phase command voltage is standardized by the power supply voltage. And, by PWM control based on the magnitude comparison with the carrier signal such as the triangular wave signal, the switch operation signal of the upper and lower arms in each phase is generated. The driver 117 turns on / off the switches Sp and Sn of each of the three phases in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 130a and 130b.
  • the operation signal generation unit 130b is based on the pulse pattern information, the voltage amplitude command, the voltage phase command, and the electric angle ⁇ , which are map information related to the voltage amplitude command, the voltage phase command, the electric angle ⁇ , and the switch operation signal.
  • the switch operation signal may be generated.
  • the first electrolytic corrosion countermeasure is an electrolytic corrosion suppression countermeasure by reducing the inductance due to the coreless stator 50 and by smoothing the magnetic flux of the magnet of the magnet unit 42.
  • the second electrolytic corrosion countermeasure is an electrolytic corrosion suppression measure by adopting a cantilever structure with bearings 21 and 22 for the rotating shaft.
  • the third electrolytic corrosion countermeasure is an electrolytic corrosion suppression countermeasure by molding the annular stator winding 51 together with the stator core 52 with a molding material. The details of each of these measures will be described below individually.
  • the spaces between the conductor groups 81 in the circumferential direction are made toothless, and the seals between the conductor groups 81 are made of a non-magnetic material instead of the teeth (iron core).
  • the member 57 is provided (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 the switching timing shift occurs when the stator winding 51 is energized, the occurrence of magnetic flux distortion due to the shift timing shift can be suppressed, and eventually the bearings 21 and 22. It is possible to suppress the electrolytic corrosion of. It is preferable that the inductance of the d-axis is equal to or less than the inductance of the q-axis.
  • the magnets 91 and 92 are oriented so that the direction of the easy-magnetizing axis is parallel to the d-axis on the d-axis side as compared with the q-axis side (see FIG. 9).
  • the magnetic flux of the magnet on the d-axis is strengthened, and the change in surface magnetic flux (increase / decrease in magnetic flux) from the q-axis to the d-axis at each magnetic pole becomes gentle. Therefore, the sudden voltage change caused by the switching imbalance is suppressed, and the configuration is such that it can contribute to the suppression of electrolytic corrosion.
  • the bearings 21 and 22 are arranged unevenly on either side in the axial direction with respect to the center in the axial direction of the rotor 40 (see FIG. 2).
  • the influence of electrolytic corrosion can be reduced as compared with a configuration in which a plurality of bearings are provided on both sides of the rotor in the axial direction. That is, in a configuration in which the rotor is supported by a plurality of bearings, a closed circuit that passes through the rotor, the stator, and each bearing (that is, each bearing on both sides in the axial direction with the rotor in between) is generated as a high frequency magnetic flux is generated.
  • the rotary electric machine 10 has the following configurations in connection with the configuration for arranging the bearings 21 and 22 on one side.
  • a contact avoiding portion that extends in the axial direction and avoids contact with the stator 50 is provided at an intermediate portion 45 that projects in the radial direction of the rotor 40 (see FIG. 2).
  • the closed circuit length can be lengthened to increase the circuit resistance. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be suppressed.
  • the holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 (stator holder) are coupled to each other on the other side. (See FIG. 2).
  • the unit base 61 since the unit base 61 is connected to the rotating shaft 11 via the housing 30, the unit base 61 can be arranged at a position electrically separated from the rotating shaft 11. If an insulating member such as resin is interposed between the unit base 61 and the housing 30, the unit base 61 and the rotating shaft 11 are electrically separated from each other. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be appropriately suppressed.
  • the shaft voltage acting on the bearings 21 and 22 is reduced by arranging the bearings 21 and 22 on one side and the like. Further, the potential difference between the rotor 40 and the stator 50 is reduced. Therefore, it is possible to reduce the potential difference acting on the bearings 21 and 22 without using conductive grease in the bearings 21 and 22. Since the conductive grease generally contains fine particles such as carbon, it is considered that noise is generated. In this respect, in the present embodiment, the bearings 21 and 22 are configured to use non-conductive grease. Therefore, it is possible to suppress the inconvenience of noise in the bearings 21 and 22. For example, when it is applied to an electric vehicle such as an electric vehicle, it is considered that a countermeasure against the noise of the rotary electric machine 10 is required, and it is possible to preferably implement the countermeasure against the noise.
  • the stator winding 51 is molded together with the stator core 52 with a molding material to suppress the displacement of the stator winding 51 in the stator 50 (see FIG. 11). ).
  • the rotary electric machine 10 of the present embodiment does not have a wire-to-lead member (teeth) between the wire groups 81 in the circumferential direction of the stator winding 51, there is a concern that the stator winding 51 may be displaced.
  • the stator winding 51 by molding the stator winding 51 together with the stator core 52, deviation of the lead wire position of the stator winding 51 is suppressed. Therefore, it is possible to suppress the distortion of the magnetic flux due to the misalignment of the stator winding 51 and the occurrence of electrolytic corrosion of the bearings 21 and 22 due to the distortion.
  • the unit base 61 as a housing member for fixing the stator core 52 is made of carbon fiber reinforced plastic (CFRP), the discharge to the unit base 61 is suppressed as compared with the case where it is made of, for example, aluminum. As a result, suitable measures against electrolytic corrosion are possible.
  • CFRP carbon fiber reinforced plastic
  • the magnet unit 42 is configured by using a magnet array called a Halbach array. That is, the magnet unit 42 has a first magnet 131 whose radial direction is the magnetization direction (direction of the magnetization vector) and a second magnet 132 whose circumferential direction is the magnetization direction (direction of the magnetization vector).
  • the first magnet 131 is arranged at predetermined intervals in the circumferential direction
  • the second magnet 132 is arranged at a position between the adjacent first magnet 131 in the circumferential direction.
  • the first magnet 131 and the second magnet 132 are permanent magnets made of rare earth magnets such as neodymium magnets.
  • the first magnet 131 is arranged so as to be spaced apart from each other in the circumferential direction so that the poles on the side facing the stator 50 (inside in the radial direction) are alternately N poles and S poles. Further, the second magnet 132 is arranged next to each first magnet 131 so that the polarities alternate in the circumferential direction.
  • the cylindrical portion 43 provided so as to surround each of the magnets 131 and 132 is preferably a soft magnetic core made of a soft magnetic material, and functions as a back core.
  • the magnet unit 42 of the second embodiment also has the same relationship between the d-axis and the easy-magnetization axis with respect to the q-axis in the dq coordinate system as in the first embodiment.
  • a magnetic material 133 made of a soft magnetic material is arranged on the radial side of the first magnet 131, that is, on the side of the cylindrical portion 43 of the magnet holder 41.
  • the magnetic material 133 may be made of an electromagnetic steel plate, soft iron, or a dust core material.
  • the circumferential length of the magnetic body 133 is the same as the circumferential length of the first magnet 131 (particularly, the circumferential length of the outer peripheral portion of the first magnet 131).
  • the radial thickness of the integrated object in the state where the first magnet 131 and the magnetic body 133 are integrated is the same as the radial thickness of the second magnet 132.
  • the thickness of the first magnet 131 in the radial direction is thinner than that of the second magnet 132 by the amount of the magnetic body 133.
  • the magnets 131 and 132 and the magnetic material 133 are fixed to each other by, for example, an adhesive.
  • the radial outside of the first magnet 131 is on the opposite side of the stator 50, and the magnetic body 133 is on the opposite side of the stator 50 from both sides of the first magnet 131 in the radial direction (opposite). It is provided on the stator side).
  • a key 134 is formed on the outer peripheral portion of the magnetic body 133 as a convex portion protruding outward in the radial direction, that is, toward the cylindrical portion 43 of the magnet holder 41. Further, a key groove 135 is formed on the inner peripheral surface of the cylindrical portion 43 as a recess for accommodating the key 134 of the magnetic body 133.
  • the protruding shape of the key 134 and the groove shape of the key groove 135 are the same, and the same number of key grooves 135 as the key 134 are formed corresponding to the key 134 formed on each magnetic material 133.
  • the key 134 and the key groove 135 are provided in the cylindrical portion 43 or the magnetic body 133 of the magnet holder 41, and contrary to the above, on the outer peripheral portion of the magnetic body 133.
  • the key 134 and the key groove 135 are provided in the cylindrical portion 43 or the magnetic body 133 of the magnet holder 41, and contrary to the above, on the outer peripheral portion of the magnetic body 133.
  • the magnetic flux density in the first magnet 131 can be increased by alternately arranging the first magnet 131 and the second magnet 132. 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.
  • the magnet unit 42 of the present embodiment has, so to speak, a configuration in which a portion of the first magnet 131 in which demagnetization is likely to occur is replaced with a magnetic body 133.
  • FIGS. 24 (a) and 24 (b) are views specifically showing the flow of magnetic flux in the magnet unit 42, and FIG. 24 (a) shows a conventional configuration in which the magnet unit 42 does not have a magnetic body 133.
  • 24 (b) shows the case where the configuration of the present embodiment having the magnetic material 133 in the magnet unit 42 is used.
  • the cylindrical portion 43 of the magnet holder 41 and the magnet unit 42 are shown in a straight line, with the lower side of the drawing being the stator side and the upper side being the anti-stator side. It is on the side.
  • the magnetic flux acting surface of the first magnet 131 and the side surface of the second magnet 132 are in contact with the inner peripheral surface of the cylindrical portion 43, respectively. Further, the magnetic flux acting surface of the second magnet 132 is in contact with the side surface of the first magnet 131.
  • the cylindrical portion 43 receives a magnetic flux F1 that enters the contact surface with the first magnet 131 through the outer path of the second magnet 132 and a magnetic flux F2 that is substantially parallel to the cylindrical portion 43 and enters the contact surface of the second magnet 132.
  • a combined magnetic flux with the attractive magnetic flux is generated. Therefore, there is a concern that magnetic saturation may partially occur in the vicinity of the contact surface between the first magnet 131 and the second magnet 132 in the cylindrical portion 43.
  • the magnetic material 133 is formed between the magnetic flux acting surface of the first magnet 131 and the inner peripheral surface of the cylindrical portion 43 on the side opposite to the stator 50 of the first magnet 131. Since it is provided, the magnetic body 133 allows the passage of magnetic flux. Therefore, magnetic saturation in the cylindrical portion 43 can be suppressed, and the proof stress against demagnetization is improved.
  • FIG. 24 (b) unlike FIG. 24 (a), F2 that promotes magnetic saturation can be erased. As a result, the permeance of the entire magnetic circuit can be effectively improved. With such a configuration, the magnetic circuit characteristics can be maintained even under severe high heat conditions.
  • the magnetic path through the inside of the magnet is longer than that of the radial magnet in the conventional SPM rotor. Therefore, the magnet permeance can be increased, the magnetic force can be increased, and the torque can be increased. Further, the magnetic flux is concentrated in the center of the d-axis, so that the sine wave matching rate can be increased. In particular, if the current waveform is made into a sine wave or a trapezoidal wave by PWM control, or if a switching IC energized at 120 degrees is used, the torque can be increased more effectively.
  • the radial thickness of the stator core 52 is preferably half or more than 1/2 of the radial thickness of the magnet unit 42.
  • the radial thickness of the stator core 52 is preferably 1 ⁇ 2 or more of the radial thickness of the first magnet 131 provided at the center of the magnetic pole in the magnet unit 42.
  • the radial thickness of the stator core 52 is preferably smaller than the radial thickness of the magnet unit 42.
  • the magnetic flux of the magnet is about 1 [T]
  • the saturation magnetic flux density of the stator core 52 is 2 [T]. Therefore, the radial thickness of the stator core 52 is the radial thickness of the magnet unit 42.
  • the magnetic path has a pseudo-arc shape, so the magnetic flux can be increased in proportion to the thickness of the magnet that handles the magnetic flux in the circumferential direction.
  • the magnetic flux flowing through the stator core 52 does not exceed the magnetic flux in the circumferential direction. That is, when an iron-based metal having a saturation magnetic flux density of 2 [T] is used with respect to the magnetic flux of the magnet 1 [T], if the thickness of the stator core 52 is set to half or more of the magnet thickness, magnetic saturation is not preferably performed. It is possible to provide a small and lightweight rotary electric machine.
  • the demagnetic field from the stator 50 acts on the magnet magnetic flux, the magnet magnetic flux is generally 0.9 [T] or less. Therefore, if the stator core has half the thickness of the magnet, its magnetic permeability can be kept suitably high.
  • the outer peripheral surface of the stator core 52 has a curved surface without unevenness, and a plurality of conductor groups 81 are arranged side by side at predetermined intervals on the outer peripheral surface, but this may be changed.
  • the stator core 52 includes an annular yoke 141 provided on both sides of the stator winding 51 in the radial direction opposite to the rotor 40 (lower side in the drawing). It has a protrusion 142 extending from the yoke 141 so as to project between the straight portions 83 adjacent to each other in the circumferential direction.
  • the protrusions 142 are provided at predetermined intervals on the radial outer side of the yoke 141, that is, on the rotor 40 side.
  • Each conductor group 81 of the stator winding 51 is engaged with the protrusion 142 in the circumferential direction, and is arranged side by side in the circumferential direction while using the protrusion 142 as a positioning portion of the conductor group 81.
  • the protrusion 142 corresponds to the "member between conductors".
  • the protrusion 142 has a thickness dimension in the radial direction from the yoke 141, in other words, as shown in FIG. 25, from the inner side surface 320 adjacent to the yoke 141 of the straight portion 83 in the radial direction of the yoke 141 to the protrusion 142.
  • the distance W to the apex is smaller than 1/2 (H1 in the figure) of the radial thickness dimension of the linear portion 83 radially adjacent to the yoke 141 among the linear portions 83 of the plurality of layers inside and outside the radial direction. It is composed.
  • the dimensions (thickness) of the conductor group 81 (conducting member) in the radial direction of the stator winding 51 (stator core 52) T1 (twice the thickness of the conductor 82, in other words, the stator core of the conductor group 81).
  • the non-magnetic member (sealing member 57) may occupy a range of three-quarters of the range (the shortest distance between the surface 320 in contact with the 52 and the surface 330 facing the rotor 40 of the conductor group 81).
  • the protrusion 142 does not function as a tooth between the conductor groups 81 (that is, the straight portion 83) adjacent to each other in the circumferential direction, and the magnetic path is not formed by the tooth. ..
  • the protrusions 142 may not be all provided between the conductor groups 81 arranged in the circumferential direction, but may be provided between at least one set of conductor groups 81 adjacent to each other in the circumferential direction.
  • the protrusions 142 may be provided at equal intervals in a predetermined number between the conductor groups 81 in the circumferential direction.
  • the shape of the protrusion 142 may be any shape such as a rectangular shape or an arc shape.
  • the straight portion 83 may be provided as a single layer on the outer peripheral surface of the stator core 52. Therefore, in a broad sense, the radial thickness dimension of the protrusion 142 from the yoke 141 may be smaller than 1/2 of the radial thickness dimension of the straight portion 83.
  • the protrusion 142 is within the range of the virtual circle. It is preferable that the shape protrudes from the yoke 141, in other words, the shape does not protrude outward in the radial direction (that is, the rotor 40 side) from the virtual circle.
  • the protrusion 142 has a limited thickness dimension in the radial direction and does not function as a teeth between the straight portions 83 adjacent to each other in the circumferential direction. Therefore, the teeth are formed between the straight portions 83. It is possible to bring the adjacent straight portions 83 closer to each other as compared with the case where is provided. As a result, the cross-sectional area of the conductor 82a can be increased, and the heat generated by the energization of the stator winding 51 can be reduced. In such a configuration, the absence of teeth makes it possible to eliminate magnetic saturation and increase the energizing current to the stator winding 51.
  • the thickness dimension of the protrusion 142 in the radial direction is shown in FIG. 25. It is not tied to H1. Specifically, if the yoke 141 and the magnet unit 42 are separated by 2 mm or more, the radial thickness dimension of the protrusion 142 may be H1 or more in FIG. 25.
  • the straight portion 83 when the radial thickness dimension of the straight portion 83 exceeds 2 mm and the conductor group 81 is composed of two layers of conductors 82 inside and outside the radial direction, the straight portion 83 not adjacent to the yoke 141, That is, the protrusion 142 may be provided in the range from the yoke 141 to the half position of the second layer conductor 82. In this case, if the radial thickness dimension of the protrusion 142 is up to "H1 x 3/2", the effect can be obtained not a little by increasing the cross-sectional area of the conductor in the conductor group 81.
  • stator core 52 may have the configuration shown in FIG. 26.
  • the sealing member 57 is omitted in FIG. 26, the sealing member 57 may be provided.
  • the magnet unit 42 and the stator core 52 are shown in a linearly developed manner.
  • the stator 50 has a protrusion 142 as a member between the conductors between the conductors 82 (that is, the straight line portion 83) adjacent to each other in the circumferential direction.
  • the stator winding 51 When the stator winding 51 is energized, the stator 50 magnetically functions together with one of the magnetic poles (N pole or S pole) of the magnet unit 42, and a part 350 extending in the circumferential direction of the stator 50 is formed.
  • the circumferential length of the stator 50 of this portion 350 is Wn
  • the total width of the protrusions 142 existing in this length range Wn that is, the total dimension of the stator 50 in the circumferential direction
  • the saturation magnetic flux density of the protrusion 142 is Bs
  • the width dimension of one pole of the magnet unit 42 in the circumferential direction is Wm
  • the residual magnetic flux density of the magnet unit 42 is Br
  • the protrusion 142 is Wt ⁇ Bs ⁇ Wm ⁇ Br... (1) It is composed of a magnetic material that serves as.
  • the range Wn is set to include a plurality of conductor groups 81 adjacent to each other in the circumferential direction and include a plurality of conductor groups 81 having overlapping excitation timings. At that time, it is preferable to set the center of the gap 56 of the conductor group 81 as a reference (boundary) when setting the range Wn.
  • the fourth conductor group 81 corresponds to the plurality of conductor groups 81 in order from the one having the shortest distance from the magnetic pole center of the N pole in the circumferential direction.
  • the range Wn is set so as to include the four conductor groups 81. At that time, the ends (starting point and ending point) of the range Wn are set as the center of the gap 56.
  • the three-phase winding of the stator winding 51 is a distributed winding, and in the stator winding 51, the number of protrusions 142 with respect to one pole of the magnet unit 42, that is, each The number of gaps 56 between the conductor groups 81 is "number of phases x Q".
  • Q is the number of the one-phase conducting wires 82 that are in contact with the stator core 52.
  • the protrusion 142 is configured as a magnetic material satisfying the relationship (1) above.
  • the total width dimension Wt is also the circumferential dimension of the portion where the relative magnetic permeability can be larger than 1 in one pole.
  • the total width dimension Wt may be set as the width dimension in the circumferential direction of the protrusion 142 at one magnetic pole.
  • the width dimension (total width dimension Wt) of the protrusions 142 in one magnetic pole in the circumferential direction is set to ".
  • the distributed winding referred to here is a one-pole pair period (N-pole and S-pole) of the magnetic poles, and has a one-pole pair of the stator winding 51.
  • the one-pole pair of the stator winding 51 referred to 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. If the above conditions are met, even if it is a short Pitch Winding, it is regarded as an equivalent of the distribution volume of the Full Pitch Winding.
  • the centralized winding here means that the width of the one-pole pair of magnetic poles and the width of the one-pole pair of the stator winding 51 are different.
  • concentrated winding there are three conductor groups 81 for one magnetic pole pair, three conductor groups 81 for two magnetic pole pairs, nine conductor groups 81 for four magnetic pole pairs, and five. Examples thereof include a case in which the conductor group 81 has a relationship of nine with respect to one magnetic pole pair.
  • the stator winding 51 is a centralized winding
  • the stator windings 51 for two phases are excited.
  • the protrusions 142 for the two phases are excited. Therefore, the width dimension Wt in the circumferential direction of the protrusion 142 excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is “A ⁇ 2”. Then, after the width dimension Wt is defined in this way, the protrusion 142 is configured as a magnetic material satisfying the relationship (1) above.
  • the total width of the protrusions 142 in the circumferential direction of the stator 50 in the region surrounded by the conductors 81 of the same phase is defined as A.
  • Wm in the concentrated winding corresponds to "the entire circumference of the surface of the magnet unit 42 facing the air gap" x "the number of phases” ⁇ "the number of dispersions of the conductor group 81".
  • the protrusion 142 may be a magnetic material satisfying the relationship of Wt ⁇ 1/2 ⁇ Wm.
  • the conductor 82 when the conductor 82 includes the outer layer coating 182 as described later, the conductor 82 may be arranged in the circumferential direction of the stator core 52 so that the outer layer coatings 182 of the conductors 82 come into contact with each other.
  • Wt can be regarded as 0 or the thickness of the outer layer coating 182 of both conducting wires 82 in contact with each other.
  • the configurations shown in FIGS. 25 and 26 have a conductor-to-conductor member (projection 142) that is disproportionately small with respect to the magnetic flux of the magnet on the rotor 40 side.
  • the rotor 40 is a surface magnet type rotor having a low inductance and a flat surface, and has no reluctance in terms of magnetic resistance. In 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 the electrolytic corrosion of the bearings 21 and 22 is suppressed. ..
  • a tooth-shaped portion 143 is provided as a member between conductors on the outer peripheral surface side (upper surface side in the drawing) of the stator core 52.
  • the dentate portions 143 are provided at predetermined intervals in the circumferential direction so as to protrude from the yoke 141, and have the same thickness dimension as the conductor group 81 in the radial direction.
  • the side surface of the dentate portion 143 is in contact with each of the conductors 82 of the conductor group 81. However, there may be a gap between the tooth-shaped portion 143 and each of the conducting wires 82.
  • the dentate portion 143 is provided with a limitation on the width dimension in the circumferential direction, and is provided with polar teeth (statoth teeth) that are disproportionately thin with respect to the amount of magnets. With such a configuration, the dentate portion 143 is surely saturated by the magnetic flux of the magnet at 1.8 T or more, and the inductance can be lowered by lowering the permeance.
  • the magnetic flux on the magnet unit side is, for example, "Sm x Br".
  • the surface area on the rotor side of each dentate portion 143 is St
  • the number per phase of the conducting wire 82 is m
  • the dentate portion 143 for two phases is excited in one pole by energization of the stator winding 51.
  • the magnetic flux on the stator side is, for example, "St ⁇ m ⁇ 2 ⁇ Bs”. in this case, St ⁇ m ⁇ 2 ⁇ Bs ⁇ Sm ⁇ Br...
  • the inductance is reduced by making the width dimension Wst of the tooth-shaped portion 143 smaller than 1/8 of the width dimension Wm of one pole of the magnet unit 42. If the number m is 1, the width dimension Wst of the tooth-shaped portion 143 may be smaller than 1/4 of the width dimension Wm of one pole of the magnet unit 42.
  • the interconductor member (dental portion 143) which is disproportionately small with respect to the magnetic flux of the magnet on the rotor 40 side is provided.
  • 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 the electrolytic corrosion of the bearings 21 and 22 is suppressed. ..
  • the sealing member 57 covering the stator winding 51 is provided in a range including all the conductor groups 81 on the radial outside of the stator core 52, that is, the thickness dimension in the radial direction is the diameter of each conductor group 81.
  • the configuration is provided in a range larger than the thickness dimension in the direction, but this may be changed.
  • the sealing member 57 is provided so that a part of the conducting wire 82 protrudes. More specifically, the sealing member 57 is provided in a state where a part of the conductor 82 which is the outermost in the radial direction in the conductor group 81 is exposed on the radial outer side, that is, on the stator 50 side.
  • the radial thickness dimension of the sealing member 57 may be the same as or smaller than the radial thickness dimension of each conductor group 81.
  • each conductor group 81 may not be sealed by the sealing member 57. That is, the structure does not use the sealing member 57 that covers the stator winding 51. In this case, no interconductor member is provided between the conductor groups 81 arranged in the circumferential direction, and a gap is formed. In short, the conductors are not provided between the conductor groups 81 arranged in the circumferential direction.
  • the stator 50 may be configured not to include the stator core 52.
  • the stator 50 is composed of the stator winding 51 shown in FIG.
  • the stator winding 51 may be sealed with a sealing material.
  • the stator 50 may be configured to 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.
  • a plurality of magnets 91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40, but this is changed and the magnet unit 42 is an annular permanent magnet.
  • a magnet may be used.
  • 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 having alternating polarities in the circumferential direction, and the magnet is integrally formed on both the d-axis and the q-axis.
  • the annular magnet 95 is formed with an arcuate magnet magnetic path such that the direction of orientation is the radial direction on the d-axis of each magnetic pole and the direction of orientation is the circumferential direction on the q-axis between the magnetic poles.
  • the easy-magnetizing axis is parallel to the d-axis or close to parallel to the d-axis in the portion near the d-axis, and the easy-magnetizing axis is orthogonal to the q-axis or is in the q-axis in the portion near the q-axis. It suffices if the orientation is made so that an arcuate magnet magnetic path having a direction close to orthogonal is formed.
  • Modification 8 In this modification, a part of the control method of the control device 110 is changed. In this modification, the difference from the configuration described in the first embodiment will be mainly described.
  • the operation signal generation unit 116 includes a carrier generation unit 116a and U, V, W phase comparators 116bU, 116bV, 116bW.
  • the carrier generation unit 116a generates and outputs a triangular wave signal as the carrier signal SigmaC.
  • the carrier signal Sigma generated by the carrier generation unit 116a and the U, V, W phase command voltage calculated by the three-phase conversion unit 115 are input to the U, V, W phase comparators 116bU, 116bV, 116bW.
  • the U, V, and W phase command voltages are, for example, sinusoidal waveforms, and the phases are shifted by 120 ° depending on the electric angle.
  • the U, V, W phase comparators 116bU, 116bV, 116bW are U in the first inverter 101 by PWM (pulse width modulation) control based on the magnitude comparison between the U, V, W phase command voltage and the carrier signal Sigma.
  • V, W phase upper arm and lower arm switches Sp, Sn operation signals are generated.
  • the operation signal generation unit 116 performs each of the U, V, and W phases by PWM control based on the magnitude comparison between the signal obtained by normalizing the U, V, W phase command voltage with the power supply voltage and the carrier signal.
  • the driver 117 turns on / off the U, V, and W phase switches Sp and Sn in the first inverter 101 based on the operation signal generated by the operation signal generation unit 116.
  • the control device 110 performs a process of changing the carrier frequency fc of the carrier signal SignC, that is, the switching frequency of each of the switches Sp and Sn.
  • the carrier frequency fc is set high in the low torque region or high rotation region of the rotary electric machine 10 and low in the high torque region of the rotary electric machine 10. This setting is made in order to suppress a decrease in controllability of the current flowing through each phase winding.
  • the inductance of the stator 50 can be reduced.
  • the inductance becomes low, the electrical time constant of the rotary electric machine 10 becomes small.
  • the ripple of the current flowing through each phase winding increases, the controllability of the current flowing through the winding decreases, and there is a concern that the current control diverges.
  • the effect of this decrease in controllability can be more pronounced when the current flowing through the winding (for example, the effective value of the current) is included in the low current region than in the high current region.
  • the control device 110 changes the carrier frequency fc.
  • the process of changing the carrier frequency fc will be described with reference to FIG. 32. This process is repeatedly executed by the control device 110, for example, at a predetermined control cycle as the process of the operation signal generation unit 116.
  • step S10 it is determined whether or not the current flowing through the winding 51a of each phase is included in the low current region.
  • This process is a process for determining that the current torque of the rotary electric machine 10 is in the low torque region. Examples of the method for determining whether or not the product is included in the low current region include the following first and second methods.
  • the torque estimation value of the rotary electric machine 10 is calculated based on the d-axis current and the q-axis current converted by the dq conversion unit 112.
  • the torque threshold value may be set to, for example, 1/2 of the starting torque (also referred to as restraint torque) of the rotary electric machine 10.
  • the speed threshold value may be set to, for example, the rotation speed when the maximum torque of the rotary electric machine 10 becomes the torque threshold value.
  • step S10 If a negative determination is made in step S10, it is determined that the current region is high, and the process proceeds to step S11.
  • step S11 the carrier frequency fc is set to the first frequency fL.
  • step S10 If an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to the second frequency fH, which is higher than the first frequency fL.
  • the carrier frequency fc is set higher when the current flowing through each phase winding is included in the low current region than when it is included in the high current region. Therefore, in the low current region, the switching frequencies of the switches Sp and Sn can be increased, and the increase in current ripple can be suppressed. As a result, it is possible to suppress a decrease in current controllability.
  • the carrier frequency fc when the current flowing through each phase winding is included in the high current region, the carrier frequency fc is set lower than when it is included in the low current region.
  • the amplitude of the current flowing through the winding is larger than in the low current region, so that the increase in current ripple due to the low inductance has a small effect on the current controllability. Therefore, in the high current region, the carrier frequency fc can be set lower than in the low current region, and the switching loss of the inverters 101 and 102 can be reduced.
  • the carrier frequency fc is set to the first frequency fL and a positive determination is made in step S10 of FIG. 32, the carrier frequency fc is gradually changed from the first frequency fL to the second frequency fH. May be good.
  • the carrier frequency fc when the carrier frequency fc is set to the second frequency fH and a negative determination is made in step S10, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL. ..
  • a switch operation signal may be generated by space vector modulation (SVM) control. Even in this case, the above-mentioned change in switching frequency can be applied.
  • SVM space vector modulation
  • FIG. 33A is a diagram showing the electrical connection of the first and second conductors 88a and 88b, which are two pairs of conductors.
  • the first and second conductors 88a and 88b may be connected in series.
  • FIG. 34 shows a configuration in which the first to fourth conductors 88a to 88d, which are four pairs of conductors, are laminated and arranged.
  • the first to fourth conductors 88a to 88d are arranged in the radial direction in the order of the first, second, third, and fourth conductors 88a, 88b, 88c, 88d from the side closer to the stator core 52. ..
  • the third and fourth conductors 88c and 88d are connected in parallel, the first conductor 88a is connected to one end of the parallel connection body, and the second conductor is connected to the other end. 88b may be connected.
  • the current density of the conductors connected in parallel can be reduced, and heat generation during energization can be suppressed. Therefore, in the configuration in which the tubular stator winding is assembled to the housing (unit base 61) in which the cooling water passage 74 is formed, the first and second conductors 88a and 88b that are not connected in parallel come into contact with the unit base 61.
  • the configuration is such that the third and fourth conductors 88c and 88d arranged in parallel on the stator core 52 side are arranged on the anti-stator core side. Thereby, the cooling performance of each of the conductors 88a to 88d in the multilayer conductor structure can be equalized.
  • the thickness dimension of the conductor group 81 composed of the first to fourth conductors 88a to 88d in the radial direction may be smaller than the width dimension of one phase in one magnetic pole in the circumferential direction.
  • the rotary electric machine 10 may have an inner rotor structure (additional structure).
  • 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.
  • the inverter unit 60 is provided on one side or both sides of both ends of the stator 50 and the rotor 40 in the axial direction.
  • FIG. 35 is a cross-sectional view of the rotor 40 and the stator 50
  • FIG. 36 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG. 35.
  • FIGS. 35 and 36 which are premised on the inner rotor structure, have the rotor 40 and the stator 50 reversed in the radial direction with respect to the configurations of FIGS. 8 and 9 which are premised on the outer rotor structure. Except for, it has the same configuration.
  • the stator 50 has a stator winding 51 having a flat conductor structure and a stator core 52 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.
  • a conductor-to-conductor member is provided between each conductor portion in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member at one magnetic pole in the circumferential direction is Wt, and the conductor-to-conductor member is saturated.
  • the magnetic flux density is Bs
  • the width dimension of the magnet unit at one magnetic pole in the circumferential direction is Wm
  • the residual magnetic flux density of the magnet unit is Br
  • a magnetic material having a relationship of Wt ⁇ Bs ⁇ Wm ⁇ Br is used.
  • stator 50 In the stator 50, a conductor-to-conductor member is provided between the conductors in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
  • the stator 50 has a configuration in which no interconductor member is provided between the conductors in the circumferential direction.
  • the magnet unit 42 is oriented so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary. Is configured using. Details such as the magnetization directions of the magnets 91 and 92 are as described above. It is also possible to use an annular magnet 95 (see FIG. 30) in the magnet unit 42.
  • FIG. 37 is a vertical cross-sectional view of the rotary electric machine 10 in the case of an inner rotor type, which is a drawing corresponding to FIG. 2 described above. Differences from the configuration of FIG. 2 will be briefly described.
  • an annular stator 50 is fixed to the inside of the housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap interposed therebetween.
  • 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, whereby the rotor 40 is cantilevered and supported.
  • an inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.
  • FIG. 38 shows another configuration of the rotary electric machine 10 having an inner rotor structure.
  • the rotating shaft 11 is rotatably supported by bearings 21 and 22 in the housing 30, and the rotor 40 is fixed to the rotating shaft 11.
  • the bearings 21 and 22 are arranged so as to be biased to either one side in the axial direction with respect to the center in the axial direction of the rotor 40.
  • the rotor 40 has a magnet holder 41 and a magnet unit 42.
  • the rotary electric machine 10 of FIG. 38 is different from the rotary electric machine 10 of FIG. 37 in that the inverter unit 60 is not provided inside the rotor 40 in the radial direction.
  • the magnet holder 41 is connected to the rotating shaft 11 at a position inside the magnet unit 42 in the radial direction.
  • the stator 50 has a stator winding 51 and a stator core 52, and is attached to the housing 30.
  • FIG. 39 is an exploded perspective view of the rotary electric machine 200
  • FIG. 40 is a side sectional view of the rotary electric machine 200.
  • the vertical direction is shown with reference to the states of FIGS. 39 and 40.
  • the rotary electric machine 200 is rotatably arranged inside the stator core 201 and the stator 203 having an annular stator core 201 and a multi-phase stator winding 202. It is equipped with a rotor 204.
  • the stator 203 corresponds to the armature and the rotor 204 corresponds to the field magnet.
  • the stator core 201 is formed by laminating a large number of silicon steel plates, and a stator winding 202 is attached to the stator core 201.
  • the rotor 204 has a rotor core and a plurality of permanent magnets as magnet units.
  • the rotor core is provided with a plurality of magnet insertion holes at equal intervals in the circumferential direction.
  • Each of the magnet insertion holes is equipped with a permanent magnet magnetized so that the magnetization direction changes alternately for each adjacent magnetic pole.
  • the permanent magnet of the magnet unit may have a Halbach array or a similar configuration as described with reference to FIG. 23.
  • the permanent magnet of the magnet unit has a pole in which the orientation direction (magnetization direction) extends in an arc shape between the d-axis, which is the center of the magnetic pole, and the q-axis, which is the boundary between the magnetic poles, as described with reference to FIGS. 9 and 30. It is preferable that the magnet has anisotropy characteristics.
  • the stator 203 may have any of the following configurations.
  • a conductor-to-conductor member is provided between each conductor portion in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member at one magnetic pole in the circumferential direction is Wt, and the conductor-to-conductor member is saturated.
  • the magnetic flux density is Bs
  • the width dimension of the magnet unit at one magnetic pole in the circumferential direction is Wm
  • the residual magnetic flux density of the magnet unit is Br
  • a magnetic material having a relationship of Wt ⁇ Bs ⁇ Wm ⁇ Br is used.
  • stator 203 In the stator 203, a conductor-to-conductor member is provided between the conductors in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
  • the stator 203 has a configuration in which no interconductor member is provided between the conductors in the circumferential direction.
  • the magnet unit is oriented on the d-axis side, which is the center of the magnetic pole, so that the direction of the easy-magnetizing axis is parallel to the d-axis as compared with the side of the q-axis, which is the magnetic pole boundary. It is configured using a plurality of magnets.
  • An annular inverter case 211 is provided on one end side of the rotary electric machine 200 in the axial direction.
  • the inverter case 211 is arranged so that the lower surface of the case is in contact with the upper surface of the stator core 201.
  • a plurality of power modules 212 constituting the inverter circuit, a smoothing capacitor 213 that suppresses voltage / current pulsation (ripple) generated by the switching operation of the semiconductor switching element, and a control board 214 having a control unit are provided inside the inverter case 211.
  • a current sensor 215 that detects the phase current and a resolver stator 216 that is a rotation speed sensor of the rotor 204 are provided.
  • the power module 212 has an IGBT and a diode which are semiconductor switching elements.
  • the inverter case 211 On the periphery of the inverter case 211, there is a power connector 217 connected to the DC circuit of the battery mounted on the vehicle, and a signal connector 218 used for passing various signals between the rotary electric machine 200 side and the vehicle side control device. Is provided.
  • the inverter case 211 is covered with a top cover 219.
  • the DC power from the in-vehicle battery is input via the power connector 217, converted into AC by switching of the power module 212, and sent to the stator winding 202 of each phase.
  • the bearing unit 221 On both sides of the stator core 201 in the axial direction, on the opposite side of the inverter case 211, there are a bearing unit 221 that rotatably holds the rotating shaft of the rotor 204 and an annular rear case 222 that houses the bearing unit 221. It is provided.
  • the bearing unit 221 has, for example, a set of two bearings, and is arranged so as to be biased to either one side in the axial direction with respect to the center in the axial direction of the rotor 204.
  • a plurality of bearings in the bearing unit 221 may be provided so as to be dispersed on both sides in the axial direction of the stator core 201, and the rotating shaft may be supported by both bearings.
  • the rotary electric machine 200 can be mounted on the vehicle side by bolting and fixing the rear case 222 to a mounting portion such as a gear case or a transmission of the vehicle.
  • a cooling flow path 211a for flowing a refrigerant is formed in the inverter case 211.
  • the cooling flow path 211a is formed by closing a space recessed in an annular shape from the lower surface of the inverter case 211 with the upper surface of the stator core 201.
  • the cooling flow path 211a is formed so as to surround the coil end of the stator winding 202.
  • the module case 212a of the power module 212 is inserted in the cooling flow path 211a.
  • the rear case 222 is also formed with a cooling flow path 222a so as to surround the coil end of the stator winding 202.
  • the cooling flow path 222a is formed by closing a space recessed in an annular shape from the upper surface of the rear case 222 with the lower surface of the stator core 201.
  • FIG. 41 shows the configuration of the rotary armature type rotary electric machine 230.
  • bearings 232 are fixed to the housings 231a and 231b, respectively, and the rotary shaft 233 is rotatably supported by the bearings 232.
  • the bearing 232 is, for example, an oil-impregnated bearing made by impregnating a porous metal with oil.
  • a rotor 234 as an armature is fixed to the rotating shaft 233.
  • the rotor 234 has a rotor core 235 and a polyphase rotor winding 236 fixed to the outer peripheral portion thereof.
  • the rotor core 235 has a slotless structure
  • the rotor winding 236 has a flat conductor structure. That is, the rotor winding 236 has a flat structure in which the region for each phase is longer in the circumferential direction than in the radial direction.
  • a stator 237 as a field magnet is provided on the radial outer side of the rotor 234.
  • the stator 237 has a stator core 238 fixed to the housing 231a and a magnet unit 239 fixed to the inner peripheral side of the stator core 238.
  • the magnet unit 239 has a configuration including a plurality of magnetic poles having alternating polarities in the circumferential direction, and is a magnetic pole boundary on the d-axis side, which is the center of the magnetic poles, like the magnet unit 42 described above. It is configured so that the direction of the easy-to-magnetize axis is parallel to the d-axis as compared with the side of the axis.
  • the magnet unit 239 has an oriented sintered neodymium magnet, the intrinsic coercive force thereof is 400 [kA / m] or more, and the residual magnetic flux density is 1.0 [T] or more.
  • the rotary electric machine 230 of this example is a 2-pole 3-coil brushed coreless motor, the rotor winding 236 is divided into three, and the magnet unit 239 has two poles.
  • the number of poles and the number of coils of the brushed motor varies depending on the application, such as 2: 3, 4:10, 4:21.
  • a commutator 241 is fixed to the rotating shaft 233, and a plurality of brushes 242 are arranged on the outer side in the radial direction thereof.
  • the commutator 241 is electrically connected to the rotor winding 236 via a conductor 243 embedded in the rotating shaft 233.
  • a direct current flows in and out of the rotor winding 236 through the commutator 241, the brush 242, and the conducting wire 243.
  • the commutator 241 is appropriately divided in the circumferential direction according to the number of phases of the rotor winding 236.
  • the brush 242 may be directly connected to a DC power source such as a storage battery via electrical wiring, or may be connected to a DC power source via a terminal block or the like.
  • the rotating shaft 233 is provided with a resin washer 244 as a sealing material between the bearing 232 and the commutator 241.
  • the resin washer 244 suppresses the oil seeping out from the bearing 232, which is an oil-impregnated bearing, from flowing out to the commutator 241 side.
  • each conducting wire 82 may have a plurality of insulating coatings inside and outside.
  • the insulating coating of the wire constitutes the inner insulating coating
  • the outer layer coating constitutes the outer insulating coating.
  • the insulating capacity of the outer insulating coating among the plurality of insulating coatings on the conductor 82 is higher than the insulating capacity of the inner insulating coating.
  • the thickness of the outer insulating coating is made thicker than the thickness of the inner insulating coating.
  • the thickness of the outer insulating coating is 100 ⁇ m, and the thickness of the inner insulating coating is 40 ⁇ m.
  • a material having a lower dielectric constant than the inner insulating coating may be used as the outer insulating coating. At least one of these may be applied.
  • the strands are configured as an aggregate of a plurality of conductive materials.
  • the rotary electric machine 10 can be properly driven even in highlands where the atmospheric pressure is low.
  • the conductor 82 includes a plurality of (four in the figure) strands 181 and, for example, a resin outer layer coating 182 (outer insulating coating) surrounding the plurality of strands 181 and each of the conductors in the outer layer coating 182. It has an intermediate layer 183 (intermediate insulating film) filled around the wire 181.
  • the wire 181 has a conductive portion 181a made of a copper material and a conductor coating 181b (inner insulating coating) made of an insulating material.
  • the outer layer coating 182 insulates the phases.
  • the strand 181 is configured as an aggregate of a plurality of conductive materials.
  • the intermediate layer 183 has a higher coefficient of linear expansion than the conductor coating 181b of the wire 181 and a lower coefficient of linear expansion than the outer layer coating 182. That is, in the conductor 82, the coefficient of linear expansion is higher toward the outside.
  • the outer layer coating 182 has a higher coefficient of linear expansion than the conductor coating 181b, but by providing an intermediate layer 183 having an intermediate linear expansion coefficient between them, the intermediate layer 183 functions as a cushioning material. , Simultaneous cracking on the outer layer side and the inner layer side can be prevented.
  • the conductive portion 181a and the conductor coating 181b are adhered to each other in the wire 181 and the conductor coating 181b and the intermediate layer 183, and the intermediate layer 183 and the outer layer coating 182 are adhered to each other. Then, the adhesive strength becomes weaker toward the outside of the conductor 82. That is, the adhesive strength of the conductive portion 181a and the conductor coating 181b is weaker than the adhesive strength of the conductor coating 181b and the intermediate layer 183 and the adhesive strength of the intermediate layer 183 and the outer layer coating 182.
  • the adhesive strength of the conductor coating 181b and the intermediate layer 183 is weaker or equivalent.
  • the magnitude of the adhesive strength between the coatings can be grasped from, for example, the tensile strength required when peeling off the two layers of coatings.
  • the heat generation and temperature change of the rotary electric machine mainly occur as copper loss generated from the conductive portion 181a of the wire 181 and iron loss generated from the inside of the iron core, and these two types of losses occur in the conducting wire 82. It is transmitted from the outside of the conductive portion 181a or the conducting wire 82 of the above, and the intermediate layer 183 does not have a heat generating source. In this case, the intermediate layer 183 has an adhesive force that can serve as a cushion for both of them, so that simultaneous cracking can be prevented. Therefore, suitable use is possible even when used in fields with high withstand voltage or large temperature changes such as vehicle applications.
  • the strand 181 may be, for example, an enamel wire, and in such a case, it has a resin coating layer (conductor coating 181b) such as PA, PI, and PAI. Further, it is desirable that the outer layer coating 182 outside the wire 181 is made of the same PA, PI, PAI, etc., and has a large thickness. As a result, the destruction of the coating film due to the difference in linear expansion coefficient is suppressed.
  • the outer layer coating 182 has a dielectric constant such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP, in addition to those made by thickening the above materials such as PA, PI, and PAI.
  • PI and PAI are also desirable to use in order to increase the conductor density of the rotating machine.
  • these resins even if they are thinner than the PI and PAI coatings equivalent to the conductor coating 181b or the thickness equivalent to the conductor coating 181b, their dielectric strength can be increased, thereby occupying the conductive portion. Can be increased.
  • the resin has better insulation than the insulating coating of enamel wire in terms of dielectric constant.
  • PPS and PEEK are suitable as the outer layer coating of the second layer because their linear expansion coefficient is generally larger than that of the enamel coating but smaller than that of other resins.
  • the adhesive strength between the two types of coatings (intermediate insulating coating and outer insulating coating) on the outside of the strand 181 and the enamel coating on the strand 181 is the adhesive strength between the copper wire and the enamel coating on the strand 181. It is desirable to be weaker than that. As a result, the phenomenon that the enamel coating and the two types of coatings are destroyed at once is suppressed.
  • thermal stress or impact stress is basically applied to the outer layer coating 182 first.
  • the thermal stress and impact stress can be reduced by providing a portion where the coatings are not adhered. That is, the insulating structure is formed by providing a wire (enamel wire) and a gap and arranging fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP.
  • Formability of epoxy, PPS, PEEK, LCP, etc. is used as the outermost layer fixing, which is generally the final step around the stator winding, which is responsible for mechanical strength, fixing, etc. to the lead wire 82 having the above configuration. It is preferable to use a resin having properties such as dielectric constant and coefficient of linear expansion similar to those of an enamel film.
  • the distance DM between the surface of the magnet unit 42 on the armature side in the radial direction and the axial center of the rotor in the radial direction may be 50 mm or more.
  • the distance DM may be 50 mm or more.
  • the mainstream rotary electric machines in recent years are roughly classified into the following four types. These rotary electric machines are a brushed motor, a basket type induction motor, a permanent magnet type synchronous motor, and a reluctance motor.
  • the reluctance motor is a motor that utilizes the reluctance change of the iron core, and it is not desirable to eliminate the iron core in principle.
  • IPM that is, embedded magnet type rotor
  • IPM has the characteristic of having both magnet torque and reluctance torque, and is operated while the ratio of those torques is adjusted in a timely manner by inverter control. Therefore, the IPM is a small motor with excellent controllability.
  • the torque on the surface of the rotor that generates the magnet torque and the relaxation torque is determined by the distance DM in the radial direction between the surface of the magnet unit on the armature side in the radial direction and the axial center of the rotor, that is, The radius of the stator core of a general inner rotor is drawn with the horizontal axis as shown in FIG. 43.
  • the potential of the magnet torque is determined by the magnetic field strength generated by the permanent magnet as shown in the following equation (eq1), whereas the reluctance torque is determined by the inductance, especially q, as shown in the following equation (eq2).
  • the magnitude of the shaft inductance determines its potential.
  • Magnet torque k ⁇ ⁇ ⁇ Iq ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ (eq1)
  • Reluctance torque k ⁇ (Lq-Ld) ⁇ Iq ⁇ Id ⁇ ⁇ ⁇ ⁇ ⁇ (eq2)
  • the magnetic field strength generated by the permanent magnet that is, the amount of magnetic flux ⁇
  • the magnetic field strength generated by the permanent magnet is proportional to the total area of the permanent magnet on the surface facing the stator. If it is a cylindrical rotor, it will be the surface area of the cylinder. Strictly speaking, since there are N pole and S pole, 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.
  • the inductance Lq of the winding depends on the shape of the iron core, but its sensitivity is low, and rather it is proportional to the square of the number of turns of the stator winding, so the dependence on the number of turns is high.
  • ⁇ is the magnetic permeability of the magnetic circuit
  • N is the number of turns
  • S is the cross-sectional area of the magnetic circuit
  • ⁇ is the effective length of the magnetic circuit
  • the inductance L ⁇ ⁇ N ⁇ 2 ⁇ S / ⁇ . Since the number of 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, since the slot shape is substantially quadrangular, the slot area is proportional to the product a ⁇ b of the circumferential length dimension a and the radial length dimension b.
  • the length dimension in the circumferential direction of the slot increases as the diameter of the cylinder increases, so it is proportional to the diameter of the cylinder.
  • the radial length dimension of the slot is exactly proportional to the diameter of the cylinder. That is, the slot area is proportional to the square of the diameter of the cylinder.
  • the reluctance torque is proportional to the square of the stator current, so the performance of the rotating electric machine is determined by how large the current can flow, and that performance depends on the slot area of the stator. Dependent. From the above, if the length of the cylinder is constant, the reluctance torque is proportional to the square of the diameter of the cylinder. Based on this, FIG. 43 is a diagram plotting the relationship between the magnet torque and the reluctance torque and DM.
  • the magnet torque increases linearly with respect to DM, and the reluctance torque increases quadratically with respect to DM. It can be seen that the magnet torque is dominant when the DM is relatively small, and the reluctance torque is dominant as the stator core radius increases.
  • the magnetic flux is shared by three to six teeth per magnetic pole, but the magnetic flux tends to concentrate on the teeth in the circumferential direction.
  • the magnetic flux does not flow evenly over the three to six teeth.
  • the teeth that are magnetically saturated with the rotation of the rotor also move in the circumferential direction. This also causes slot ripple.
  • the rotary electric machine having an outer rotor structure has a distance DM of 50 mm or more in the radial direction between the surface of the magnet unit on the armature side and the axial center of the rotor. You may be.
  • the straight portion 83 of the conducting wire 82 may be provided in a single layer in the radial direction. Further, when the linear portion 83 is arranged in a plurality of layers inside and outside the radial direction, the number of layers may be arbitrary, and may be provided in three layers, four layers, five layers, six layers and the like.
  • the rotating shaft 11 is provided so as to project to both one end side and the other end side of the rotary electric machine 10 in the axial direction. May be good.
  • the rotating shaft 11 may be provided so as to extend outward in the axial direction, with a portion that is cantilevered by the bearing unit 20 as an end portion.
  • the internal space of the inverter unit 60 specifically the internal space of the tubular portion 71, can be used more widely.
  • the bearings 21 and 22 are configured to use non-conductive grease, but this may be changed to a configuration in which the bearings 21 and 22 use conductive grease.
  • a conductive grease containing metal particles, carbon particles, or the like is used.
  • bearings may be provided at two locations, one end side and the other end side in the axial direction of the rotor 40. In this case, in the configuration of FIG. 1, it is preferable that bearings are provided at two locations on one end side and the other end side of the inverter unit 60.
  • the intermediate portion 45 of the magnet holder 41 has an inner shoulder portion 49a and an emotional outer shoulder portion 49b.
  • these shoulder portions 49a and 49b are eliminated and the rotor portion is flat. It may be configured to have various surfaces.
  • the conductor 82a is configured as an aggregate of a plurality of strands 86 in the conductor 82 of the stator winding 51, but this is changed and a square conductor having a rectangular cross section is used as the conductor 82. It may be configured. Further, as the conducting wire 82, a round conducting wire having a circular cross section or an elliptical cross section may be used.
  • the inverter unit 60 is provided inside the stator 50 in the radial direction, but instead of this, the inverter unit 60 may not be provided inside the stator 50 in the radial direction. .. In this case, it is possible to set an internal region inside the stator 50 in the radial direction as a space. Further, it is possible to arrange parts different from the inverter unit 60 in the internal region.
  • the rotary electric machine 10 having the above configuration may not include the housing 30.
  • the rotor 40, the stator 50, and the like may be held in a part of the wheel or other vehicle parts.
  • FIG. 45 is a perspective view showing the wheel 400 having an in-wheel motor structure and its peripheral structure
  • FIG. 46 is a vertical sectional view of the wheel 400 and its peripheral structure
  • FIG. 47 is an exploded perspective view of the wheel 400. is there.
  • Each of these figures is a perspective view of the wheel 400 as viewed from the inside of the vehicle.
  • the in-wheel motor structure of the present embodiment can be applied in various forms. For example, in a vehicle having two wheels in front of and behind the vehicle, two wheels on the front side of the vehicle and two wheels on the rear side of the vehicle.
  • the in-wheel motor structure of the present embodiment can be applied to two wheels or four wheels in front of and behind the vehicle. However, it can also be applied to a vehicle in which at least one of the front and rear of the vehicle is one wheel.
  • the in-wheel motor is an application example as a vehicle drive unit.
  • the wheel 400 is fixed to, for example, the tire 401, which is a well-known pneumatic tire, the wheel 402 fixed to the inner peripheral side of the tire 401, and the inner peripheral side of the wheel 402. It is equipped with a rotary electric machine 500.
  • the rotary electric machine 500 has a fixed portion which is a portion including a stator (stator) and a rotating portion which is a portion including a rotor (rotor), and the fixed portion is fixed to the vehicle body side and the rotating portion is formed. It is fixed to the wheel 402, and the tire 401 and the wheel 402 rotate due to the rotation of the rotating portion.
  • the detailed configuration of the rotary electric machine 500 including the fixed portion and the rotating portion will be described later.
  • peripheral devices a suspension device for holding the wheels 400 with respect to a vehicle body (not shown), a steering device for changing the direction of the wheels 400, and a braking device for braking the wheels 400 are attached to the wheels 400. Has been done.
  • the suspension device is an independent suspension type suspension, and any type such as trailing arm type, strut type, wishbone type, and multi-link type can be applied.
  • the lower arm 411 is provided so as to extend toward the center of the vehicle body, and the suspension arm 412 and the spring 413 are provided so as to extend in the vertical direction.
  • the suspension arm 412 may be configured as, for example, a shock absorber. However, the detailed illustration is omitted.
  • the lower arm 411 and the suspension arm 412 are each connected to the vehicle body side and to a disk-shaped base plate 405 fixed to a fixed portion of the rotary electric machine 500. As shown in FIG. 46, the lower arm 411 and the suspension arm 412 are supported on the rotary electric machine 500 side (base plate 405 side) by the support shafts 414 and 415 in a coaxial state with each other.
  • a rack device 421 and a tie rod 422 are provided as steering devices, and the rack device 421 is connected to the base plate 405 on the rotary electric machine 500 side via the tie rod 422.
  • the tie rod 422 moves in the left-right direction of the vehicle.
  • the wheel 400 rotates around the support shafts 414 and 415 of the lower arm 411 and the suspension arm 412, and the wheel direction is changed.
  • a disc brake or a drum brake As a braking device, it is preferable to apply a disc brake or a drum brake.
  • a disc rotor 431 fixed to the rotary shaft 501 of the rotary electric machine 500 and a brake caliper 432 fixed to the base plate 405 on the rotary electric machine 500 side are provided.
  • the brake pads are operated by flood control or the like, and when the brake pads are pressed against the disc rotor 431, a braking force due to friction is generated and the rotation of the wheels 400 is stopped.
  • the wheel 400 is attached with an accommodation duct 440 that accommodates the electric wiring H1 extending from the rotary electric machine 500 and the cooling pipe H2.
  • the accommodating duct 440 extends from the end of the rotary electric machine 500 on the fixed portion side along the end surface of the rotary electric machine 500 and is provided so as to avoid the suspension arm 412, and is fixed to the suspension arm 412 in that state.
  • the connection portion of the accommodation duct 440 in the suspension arm 412 has a fixed positional relationship with the base plate 405. Therefore, it is possible to suppress the stress caused by the vibration of the vehicle in the electric wiring H1 and the cooling pipe H2.
  • the electrical wiring H1 is connected to an in-vehicle power supply unit and an in-vehicle ECU (not shown), and the cooling pipe H2 is connected to a radiator (not shown).
  • the rotary electric machine 500 has excellent operating efficiency and output as compared with the motor of a vehicle drive unit having a speed reducer as in the prior art. That is, if the rotary electric machine 500 is adopted in an application in which a practical price can be realized by reducing the cost as compared with the conventional technology, it may be used as a motor for applications other than the vehicle drive unit. Even in such a case, the excellent performance is exhibited as in the case of applying it to an in-wheel motor.
  • the operating efficiency refers to an index used during a test in a driving mode that derives the fuel efficiency of the vehicle.
  • FIG. 48 is a side view of the rotary electric machine 500 as viewed from the protruding side (inside the vehicle) of the rotary shaft 501
  • FIG. 49 is a vertical sectional view of the rotary electric machine 500 (cross-sectional view taken along lines 49-49 of FIG. 48).
  • 50 is a cross-sectional view of the rotary electric machine 500 (a cross-sectional view taken along the line 50-50 of FIG. 49)
  • FIG. 51 is an exploded cross-sectional view of the components of the rotary electric machine 500.
  • the direction in which the rotating shaft 501 extends outward of the vehicle body is the axial direction
  • the direction extending radially from the rotating shaft 501 is the radial direction
  • the center of the rotating shaft 501 in other words.
  • the circumferential direction is defined as two directions extending in a circumferential shape from an arbitrary point other than the rotation center of the rotating portion on the center line drawn to form a cross section 49 passing through the rotation center of the rotating portion.
  • the circumferential direction may be either a clockwise direction starting from an arbitrary point on the cross section 49 or a counterclockwise direction.
  • the right side is the outside of the vehicle and the left side is the inside of the vehicle in FIG. 49.
  • the rotor 510 which will be described later, is arranged in the outer direction of the vehicle body with respect to the rotor cover 670.
  • the rotary electric machine 500 is an outer rotor type surface magnet type rotary electric machine.
  • the rotary electric machine 500 is roughly classified into a rotor 510, a stator 520, an inverter unit 530, a bearing 560, and a rotor cover 670.
  • Each of these members is arranged coaxially with respect to the rotating shaft 501 integrally provided on the rotor 510, and is assembled in the axial direction in a predetermined order to form the rotating electric machine 500.
  • the rotor 510 and the stator 520 each have a cylindrical shape, and are arranged so as to face each other with an air gap in between.
  • the rotor 510 rotates integrally with the rotation shaft 501, the rotor 510 rotates on the radial outer side of the stator 520.
  • the rotor 510 corresponds to the "field magnet” and the stator 520 corresponds to the "armature”.
  • the rotor 510 has a substantially cylindrical rotor carrier 511 and an annular magnet unit 512 fixed to the rotor carrier 511.
  • the rotation shaft 501 is fixed to the rotor carrier 511.
  • the rotor carrier 511 has a cylindrical portion 513.
  • a magnet unit 512 is fixed to the inner peripheral surface of the cylindrical portion 513. That is, the magnet unit 512 is provided in a state of being surrounded by the cylindrical portion 513 of the rotor carrier 511 from the outside in the radial direction.
  • the cylindrical portion 513 has a first end and a second end facing each other in the axial direction thereof. The first end is located in the direction outside the vehicle body, and the second end is located in the direction in which the base plate 405 is present.
  • an end plate 514 is continuously provided at the first end of the cylindrical portion 513. That is, the cylindrical portion 513 and the end plate 514 have an integral structure.
  • the second end of the cylindrical portion 513 is open.
  • the rotor carrier 511 is formed of, for example, a cold-rolled steel plate having sufficient mechanical strength (SPCC or SPHC thicker than SPCC), forging steel, carbon fiber reinforced plastic (CFRP), or the like.
  • the axial length of the rotating shaft 501 is longer than the axial dimension of the rotor carrier 511.
  • the rotating shaft 501 projects toward the open end side (inward direction of the vehicle) of the rotor carrier 511, and the above-mentioned brake device or the like is attached to the protruding end side.
  • a through hole 514a is formed in the central portion of the end plate 514 of the rotor carrier 511.
  • the rotary shaft 501 is fixed to the rotor carrier 511 in a state of being inserted into the through hole 514a of the end plate 514.
  • the rotating shaft 501 has a flange 502 extending in a direction intersecting (orthogonal) in the axial direction at a portion where the rotor carrier 511 is fixed, and the flange and the outer surface of the end plate 514 are surface-joined.
  • the rotation shaft 501 is fixed to the rotor carrier 511.
  • the wheel 402 is fixed by using a fastener such as a bolt erected from the flange 502 of the rotating shaft 501 toward the outside of the vehicle.
  • the magnet unit 512 is composed of a plurality of permanent magnets arranged so that the polarities alternate along the circumferential direction of the rotor 510. As a result, the magnet unit 512 has a plurality of magnetic poles in the circumferential direction.
  • the permanent magnet is fixed to the rotor carrier 511 by, for example, adhesion.
  • the magnet unit 512 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, and as a permanent magnet, has an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux. It is constructed by using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
  • the magnet unit 512 has a first magnet 91 and a second magnet 92, which are polar anisotropic magnets and have different polarities. As described with reference to FIGS. 8 and 9, the directions of the easy magnetization axes of the magnets 91 and 92 differ between the d-axis side (the portion closer to the d-axis) and the q-axis side (the portion closer to the q-axis), respectively.
  • the direction of the easy-magnetization axis is close to the direction parallel to the d-axis
  • the direction of the easy-magnetization axis is close to the direction orthogonal to the q-axis.
  • an arcuate magnet magnetic path is formed by the orientation according to the direction of the easily magnetized axis.
  • the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side
  • the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side.
  • the magnet unit 512 is configured so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary. ..
  • the magnets 91 and 92 According to the magnets 91 and 92, the magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed. As a result, magnets 91 and 92 in which the change in surface magnetic flux from the q-axis to the d-axis at each magnetic pole is gentle can be preferably realized.
  • the magnet unit 512 the configuration of the magnet unit 42 shown in FIGS. 22 and 23 and the configuration of the magnet unit 42 shown in FIG. 30 can also be used.
  • the magnet unit 512 has a rotor core (back yoke) formed by laminating a plurality of electromagnetic steel sheets in the axial direction on the side of the cylindrical portion 513 of the rotor carrier 511, that is, on the outer peripheral surface side. May be good. That is, it is also possible to provide the rotor core on the radial inside of the cylindrical portion 513 of the rotor carrier 511 and to provide the permanent magnets (magnets 91, 92) on the radial inside of the rotor core.
  • a rotor core back yoke
  • the cylindrical portion 513 of the rotor carrier 511 is formed with recesses 513a in a direction extending in the axial direction at predetermined intervals in the circumferential direction.
  • the concave portion 513a is formed by, for example, press working, and as shown in FIG. 52, a convex portion 513b is formed on the inner peripheral surface side of the cylindrical portion 513 at a position on the back side of the concave portion 513a.
  • a concave portion 512a is formed in accordance with the convex portion 513b of the cylindrical portion 513, and the convex portion 513b of the cylindrical portion 513 enters the concave portion 512a, whereby the magnet unit 512 The displacement in the circumferential direction of the magnet is suppressed. That is, the convex portion 513b on the rotor carrier 511 side functions as a detent portion of the magnet unit 512.
  • the method of forming the convex portion 513b may be any method other than press working.
  • the direction of the magnetic path of the magnet in the magnet unit 512 is indicated by an arrow.
  • the magnet magnetic path extends in an arc shape so as to straddle the q-axis which is the magnetic pole boundary, and the d-axis which is the center of the magnetic pole is in a direction parallel to or close to parallel to the d-axis.
  • the magnet unit 512 is formed with recesses 512b at positions corresponding to the q-axis on the inner peripheral surface side thereof.
  • the length of the magnet magnetic path differs between the side closer to the stator 520 (lower side in the figure) and the side farther from the stator 520 (upper side in the figure), and the side closer to the stator 520 is magnetized.
  • the path length is shortened, and the recess 512b is formed at a position where the magnetic path length is the shortest. That is, in consideration of the fact that it is difficult for the magnet unit 512 to generate a sufficient magnet magnetic flux in a place where the magnet magnetic path length is short, the magnet is deleted in a place where the magnet magnetic flux is weak.
  • the effective magnetic flux density Bd of the magnet increases as the length of the magnetic circuit passing through the inside of the magnet becomes longer.
  • the permeance coefficient Pc and the effective magnetic flux density Bd of the magnet are in a relationship that the higher one is, the higher the other is.
  • the amount of magnets can be reduced while suppressing a decrease in the permeance coefficient Pc, which is an index of the height of the effective magnetic flux density Bd of the magnet.
  • the intersection of the permeance straight line and the demagnetization curve according to the shape of the magnet is the operating point, and the magnetic flux density at the operating point is the effective magnetic flux density Bd of the magnet.
  • the rotary electric machine 500 of the present embodiment has a configuration in which the amount of iron in the stator 520 is reduced, and in such a configuration, a method of setting a magnetic circuit straddling the q-axis is extremely effective.
  • the recess 512b of the magnet unit 512 can be used as an air passage extending in the axial direction. Therefore, it is possible to improve the air cooling performance.
  • the stator 520 has a stator winding 521 and a stator core 522.
  • FIG. 53 is a perspective view showing the stator winding 521 and the stator core 522 in an exploded manner.
  • the stator winding 521 is composed of a plurality of phase windings formed by winding in a substantially tubular shape (annular shape), and a stator core 522 as a base member is assembled inside the stator winding 521 in the radial direction.
  • the stator winding 521 is configured as a three-phase phase winding by using U-phase, V-phase, and W-phase phase windings.
  • Each phase winding is composed of two inner and outer layers of conducting wires 523 in the radial direction.
  • the stator 520 is characterized by having a slotless structure and a flat conductor structure of the stator winding 521, similarly to the stator 50 described above, with the stator 50 shown in FIGS. 8 to 16. It has a similar or similar configuration.
  • the stator core 522 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction.
  • the stator winding 521 is assembled on the outer side in the radial direction on the rotor 510 side.
  • the outer peripheral surface of the stator core 522 has a curved shape without unevenness, and when the stator winding 521 is assembled, the conductor 523 constituting the stator winding 521 is attached to the outer peripheral surface of the stator core 522. They are arranged side by side in the circumferential direction.
  • the stator core 522 functions as a back core.
  • the stator 520 may use any of the following (A) to (C).
  • the magnetic flux density is Bs
  • the width dimension of the magnet unit 512 at one magnetic pole in the circumferential direction is Wm
  • the residual magnetic flux density of the magnet unit 512 is Br
  • a magnetic material having a relationship of Wt ⁇ Bs ⁇ Wm ⁇ Br is used. There is.
  • stator 520 In the stator 520, a conductor-to-conductor member is provided between each conductor 523 in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
  • the stator 520 has a configuration in which no interconductor member is provided between the conductors 523 in the circumferential direction.
  • the inductance is higher than that of a rotating electric machine having a general teeth structure in which a tooth (iron core) for establishing a magnetic path is provided between each conducting portion as a stator winding. It will be reduced. Specifically, the inductance can be reduced to 1/10 or less. In this case, since the impedance decreases as the inductance decreases, the output power with respect to the input power of the rotary electric machine 500 can be increased, which in turn can contribute to the increase in torque. In addition, it is possible to provide a rotary electric machine with a higher output than a rotary electric machine using an embedded magnet type rotor that outputs torque using the voltage of the impedance component (in other words, uses reluctance torque). ing.
  • the stator winding 521 is integrally molded together with the stator core 522 by a molding material (insulating member) made of resin or the like, and the molding material is formed between the conducting wires 523 arranged in the circumferential direction. It has an intervening configuration. Based on such a configuration, the stator 520 of the present embodiment corresponds to the configuration of (B) among the above (A) to (C). Further, the conductor wires 523 adjacent to each other in the circumferential direction are in contact with each other in the circumferential direction, or are arranged close to each other at a minute interval. May be good.
  • the stator core 522 is aligned with the direction of the conducting wire 523 in the axial direction, that is, according to the skew angle of the stator winding 521 having a skew structure, for example. It is preferable that a protrusion is provided on the outer peripheral surface.
  • FIG. 54 is a front view showing the stator winding 521 developed in a plane
  • FIG. 54 (a) shows each conducting wire 523 located in the outer layer in the radial direction
  • FIG. 54 (b) shows the diameter.
  • Each conductor 523 located in the inner layer in the direction is shown.
  • the stator winding 521 is wound in an annular shape by distributed winding.
  • the conductor material is wound around the inner and outer two layers in the radial direction, and the conductors 523 on the inner layer side and the outer layer side are skewed in different directions (FIG. 54 (a), FIG. See FIG. 54 (b)).
  • Each conductor 523 is isolated from each other.
  • the conductor 523 may be configured as an aggregate of a plurality of strands 86 (see FIG. 13). Further, for example, two conducting wires 523 having the same phase and the same energizing direction are provided side by side in the circumferential direction.
  • one conductor portion having the same phase is formed by each conductor 523 having two layers in the radial direction and two conductors in the circumferential direction (that is, a total of four conductors), and the conductor portions are one by one in one magnetic pole. It is provided.
  • the thickness dimension of the conductor portion in the radial direction be smaller than the width dimension in the circumferential direction of one phase in one magnetic pole, whereby the stator winding 521 has a flat conductor structure.
  • one conductor portion having two layers in the radial direction and four conductors 523 in the circumferential direction may form one conductor portion having the same phase.
  • the width dimension in the circumferential direction may be larger than the thickness dimension in the radial direction.
  • the stator winding 51 shown in FIG. 12 can also be used. However, in this case, it is necessary to secure a space in the rotor carrier 511 for accommodating the coil end of the stator winding.
  • the conductor wires 523 are arranged side by side in the circumferential direction at a coil side 525 that overlaps the stator core 522 in the radial direction at a predetermined angle, and are axially outside the stator core 522.
  • the coil ends 526 on both sides are inverted (folded back) inward in the axial direction to form a continuous connection.
  • FIG. 54A shows a range of the coil side 525 and a range of the coil end 526, respectively.
  • the conductor 523 on the inner layer side and the conductor 523 on the outer layer side are connected to each other at the coil end 526, so that the conductor 523 is rotated at the coil end 526 each time the conductor 523 is inverted in the axial direction (each time it is folded back).
  • the inner layer side and the outer layer side are switched alternately.
  • the stator winding 521 has a configuration 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 523 that are continuous in the circumferential direction.
  • the skew angle ⁇ s1 in the central region and the skew angle ⁇ s2 in the end region are different, and the skew angle ⁇ s1 is smaller than the skew angle ⁇ s2.
  • the end region is defined to include the coil side 525.
  • the skew angle ⁇ s1 and the skew angle ⁇ s2 are inclination angles at which each conducting wire 523 is inclined with respect to the axial direction.
  • the skew angle ⁇ s1 in the central region may be set in an angle range appropriate for reducing the harmonic component of the magnetic flux generated by the energization of the stator winding 521.
  • the coil end 526 is reduced by making the skew angle of each conductor 523 in the stator winding 521 different between the central region and the end region and making the skew angle ⁇ s1 in the central region smaller than the skew angle ⁇ s2 in the end region.
  • the winding coefficient of the stator winding 521 can be increased.
  • the length of the coil end 526 that is, the conductor length of the portion protruding in the axial direction from the stator core 522 can be shortened while ensuring a desired winding coefficient. As a result, it is possible to improve the torque while reducing the size of the rotary electric machine 500.
  • the Xth-order harmonic component is a component that constitutes a composite wave of the X-1st-order harmonic component and the X + 1st-order harmonic component, the X-1st-order harmonic component or the X + 1 It was noted that the Xth harmonic component can be reduced by reducing at least one of the following harmonic components. Based on this focus, the discloser of the present application sets the skew angle ⁇ s1 within the angle range of “360 ° / (X + 1) to 360 ° / (X-1)” in terms of the electric angle, thereby setting the X-th order harmonic component. It was found that can be reduced.
  • the magnet magnetic fluxes alternating with NS can be positively interlocked in the central region, and the winding coefficient of the stator winding 521 is increased. be able to.
  • the skew angle ⁇ s2 in the end region is larger than the skew angle ⁇ s1 in the central region described above.
  • the angle range of the skew angle ⁇ s2 is “ ⁇ s1 ⁇ s2 ⁇ 90 °”.
  • the conductor 523 on the inner layer side and the conductor 523 on the outer layer side may be connected by welding or adhesion between the ends of the conductors 523, or may be connected by bending.
  • the end of each phase winding is electrically connected to a power converter (inverter) via a bus bar or the like on one side (that is, one end side in the axial direction) of each coil end 526 on both sides in the axial direction. It is configured to be connected to. Therefore, here, the configuration in which the conductors are connected to each other at the coil end 526 will be described while distinguishing between the coil end 526 on the bus bar connection side and the coil end 526 on the opposite side.
  • the first configuration is such that each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by means other than welding at the coil end 526 on the opposite side.
  • a connection by bending a conducting wire material can be considered.
  • the bus bar is connected by welding to the end of each phase winding. Therefore, by connecting each conducting wire 523 by welding at the same coil end 526, each welded portion can be performed in a series of steps, and work efficiency can be improved.
  • the second configuration is such that each conductor 523 is connected by means other than welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by welding at the coil end 526 on the opposite side.
  • each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, the separation distance between the bus bar and the coil end 526 is sufficient to avoid contact between the welded portion and the bus bar.
  • the separation distance between the bus bar and the coil end 526 can be reduced. Thereby, the regulation regarding the length of the stator winding 521 in the axial direction or the bus bar can be relaxed.
  • the third configuration is such that each conductor 523 is connected by welding at the coil ends 526 on both sides in the axial direction.
  • all of the conductors prepared before welding may have a short wire length, and the work efficiency can be improved by reducing the bending process.
  • each conductor 523 is connected at the coil ends 526 on both sides in the axial direction by means other than welding.
  • the portion of the stator winding 521 to be welded can be reduced as much as possible, and the concern that insulation peeling may occur in the welding process can be reduced.
  • the strip-shaped windings arranged in a plane shape and then to form the strip-shaped windings in an annular shape.
  • the strip winding may be wound directly around the stator core 522.
  • the skew angles of the central region and the end region may be the same.
  • the ends of the in-phase conducting wires 523 adjacent to each other in the circumferential direction are connected by a crossover portion extending in a direction orthogonal to the axial direction. It may be.
  • the number of layers of the stator winding 521 may be 2 ⁇ n layers (n is a natural number), and the stator winding 521 can be made into 4 layers, 6 layers, or the like in addition to the 2 layers.
  • FIGS. 56 and 57 are exploded sectional views of the inverter unit 530.
  • each member shown in FIG. 56 is shown as two subassemblies.
  • the inverter unit 530 has an inverter housing 531, a plurality of electric modules 532 assembled to the inverter housing 531 and a bus bar module 533 for electrically connecting each of the electric modules 532.
  • the inverter housing 531 has a cylindrical outer wall member 541, an inner wall member 542 having an outer peripheral diameter smaller than that of the outer wall member 541 and arranged inside the outer wall member 541 in the radial direction, and a shaft of the inner wall member 542. It has a boss forming member 543 fixed to one end side in the direction.
  • Each of these members 541 to 543 is preferably made of a conductive material, for example, made of carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the inverter housing 531 is configured such that the outer wall member 541 and the inner wall member 542 are overlapped and combined in the radial direction inside and outside, and the boss forming member 543 is assembled on one end side in the axial direction of the inner wall member 542.
  • the assembled state is the state shown in FIG. 57.
  • the stator core 522 is fixed to the radial outside of the outer wall member 541 of the inverter housing 531. As a result, the stator 520 and the inverter unit 530 are integrated.
  • the outer wall member 541 is formed with a plurality of recesses 541a, 541b, 541c on the inner peripheral surface thereof
  • the inner wall member 542 is formed with a plurality of recesses 542a, 542b, 542c on the outer peripheral surface thereof. Is formed. Then, by assembling the outer wall member 541 and the inner wall member 542 to each other, three hollow portions 544a, 544b, and 544c are formed between them (see FIG. 57). Of these, the central hollow portion 544b is used as a cooling water passage 545 for circulating cooling water as a refrigerant.
  • the sealing material 546 is housed in the hollow portions 544a and 544c on both sides of the hollow portion 544b (cooling water passage 545).
  • the hollow portion 544b (cooling water passage 545) is sealed by the sealing material 546.
  • the cooling water passage 545 will be described in detail later.
  • the boss forming member 543 is provided with a disk ring-shaped end plate 547 and a boss portion 548 protruding from the end plate 547 toward the inside of the housing.
  • the boss portion 548 is provided in a hollow tubular shape.
  • the boss forming member 543 is the second end of the first end of the inner wall member 542 in the axial direction and the second end on the protruding side (that is, inside the vehicle) of the rotating shaft 501 facing the first end. It is fixed to.
  • the base plate 405 is fixed to the inverter housing 531 (more specifically, the end plate 547 of the boss forming member 543).
  • the inverter housing 531 has a configuration having a double peripheral wall in the radial direction about the axis, and the outer peripheral wall of the double peripheral wall is formed by the outer wall member 541 and the inner wall member 542, and the inner peripheral wall is formed. Is formed by the boss portion 548.
  • the outer peripheral wall formed by the outer wall member 541 and the inner wall member 542 is also referred to as “outer peripheral wall WA1”
  • the inner peripheral wall formed by the boss portion 548 is also referred to as "inner peripheral wall WA2”.
  • an annular space is formed between the outer peripheral wall WA1 and the inner peripheral wall WA2, and a plurality of electric modules 532 are arranged side by side in the circumferential direction in the annular space.
  • the electric module 532 is fixed to the inner peripheral surface of the inner wall member 542 by adhesion, screw tightening, or the like.
  • the inverter housing 531 corresponds to the "housing member” and the electric module 532 corresponds to the "electric component".
  • a bearing 560 is housed inside the inner peripheral wall WA2 (boss portion 548), and the rotating shaft 501 is rotatably supported by the bearing 560.
  • the bearing 560 is a hub bearing that rotatably supports the wheel 400 at the center of the wheel.
  • the bearing 560 is provided at a position where the rotor 510, the stator 520, and the inverter unit 530 overlap in the axial direction.
  • the magnet unit 512 can be made thinner in accordance with the orientation of the rotor 510, and the stator 520 adopts a slotless structure or a flat lead wire structure.
  • the boss portion 548 is a bearing holding portion that holds the bearing 560 inside the boss portion 548.
  • the bearing 560 is, for example, a radial ball bearing, and has a tubular inner ring 561, an outer ring 562 having a diameter larger than that of the inner ring 561 and arranged radially outside the inner ring 561, and the inner ring 561 and the outer ring. It has a plurality of balls 563 arranged between 562.
  • the bearing 560 is fixed to the inverter housing 531 by assembling the outer ring 562 to the boss forming member 543, and the inner ring 561 is fixed to the rotating shaft 501.
  • the inner ring 561, the outer ring 562, and the ball 563 are all made of a metal material such as carbon steel.
  • the inner ring 561 of the bearing 560 has a tubular portion 561a for accommodating the rotating shaft 501 and a flange 561b extending in an axially intersecting (orthogonal) direction from one end in the axial direction of the tubular portion 561a. ..
  • the flange 561b is a portion that comes into contact with the end plate 514 of the rotor carrier 511 from the inside, and is sandwiched between the flange 502 of the rotating shaft 501 and the flange 561b of the inner ring 561 when the bearing 560 is assembled to the rotating shaft 501. In this state, the rotor carrier 511 is held.
  • the flange 502 of the rotating shaft 501 and the flange 561b of the inner ring 561 have the same angle of intersection with respect to the axial direction (both are right angles in the present embodiment), and are sandwiched between the flanges 502 and 561b.
  • the rotor carrier 511 is held in this state.
  • the angle of the rotor carrier 511 with respect to the rotating shaft 501 can be maintained at an appropriate angle, and the parallelism of the magnet unit 512 with respect to the rotating shaft 501 is improved. Can be kept. As a result, resistance to vibration and the like can be increased even in a configuration in which the rotor carrier 511 is expanded in the radial direction.
  • the plurality of electric modules 532 are obtained by dividing electric components such as semiconductor switching elements and smoothing capacitors constituting a power converter into a plurality of individual modules, and the electric module 532 is a power element.
  • a switch module 532A having a semiconductor switching element and a capacitor module 532B having a smoothing capacitor are included.
  • a plurality of spacers 549 having a flat surface for attaching the electric module 532 are fixed to the inner peripheral surface of the inner wall member 542, and the electric module 532 is attached to the spacer 549.
  • the mounting surface of the electric module 532 is a flat surface, so that the spacer 549 forms a flat surface on the inner peripheral surface side of the inner wall member 542.
  • the electric module 532 is fixed to a flat surface.
  • the configuration in which the spacer 549 is interposed between the inner wall member 542 and the electric module 532 is not essential, and the inner wall is made by flattening the inner peripheral surface of the inner wall member 542 or by making the mounting surface of the electric module 532 curved. It is also possible to attach the electric module 532 directly to the member 542. It is also possible to fix the electric module 532 to the inverter housing 531 in a state of non-contact with the inner peripheral surface of the inner wall member 542. For example, the electric module 532 is fixed to the end plate 547 of the boss forming member 543. It is also possible to fix the switch module 532A to the inner peripheral surface of the inner wall member 542 in a contact state, and to fix the capacitor module 532B to the inner peripheral surface of the inner wall member 542 in a non-contact state.
  • the outer peripheral wall WA1 and the spacer 549 correspond to the "cylindrical portion".
  • the outer peripheral wall WA1 corresponds to the "cylindrical portion”.
  • the outer peripheral wall WA1 of the inverter housing 531 is formed with a cooling water passage 545 through which cooling water as a refrigerant flows, so that each electric module 532 is cooled by the cooling water flowing through the cooling water passage 545. It has become. It is also possible to use cooling oil as the refrigerant instead of the cooling water.
  • the cooling water passage 545 is provided in an annular shape along the outer peripheral wall WA1, and the cooling water flowing in the cooling water passage 545 flows from the upstream side to the downstream side via each electric module 532. In the present embodiment, the cooling water passage 545 is provided in an annular shape so as to overlap each of the electric modules 532 in the radial direction and to surround each of the electric modules 532.
  • the inner wall member 542 is provided with an inlet passage 571 for flowing cooling water into the cooling water passage 545 and an outlet passage 572 for discharging cooling water from the cooling water passage 545.
  • a plurality of electric modules 532 are fixed to the inner peripheral surface of the inner wall member 542, and in such a configuration, the distance between the electric modules adjacent to each other in the circumferential direction is expanded by only one place, and the expansion thereof.
  • a part of the inner wall member 542 is projected inward in the radial direction to form a protruding portion 573.
  • the protruding portion 573 is provided with an inlet passage 571 and an outlet passage 572 in a state of being arranged side by side along the radial direction.
  • FIG. 58 shows the arrangement state of each electric module 532 in the inverter housing 531. Note that FIG. 58 is the same vertical cross-sectional view as that of FIG. 50.
  • the electric modules 532 are arranged side by side in the circumferential direction with the distance between the electric modules in the circumferential direction as the first interval INT1 or the second interval INT2.
  • the second interval INT2 is a wider interval than the first interval INT1.
  • Each interval INT1 and INT2 is, for example, the distance between the center positions of two electric modules 532 adjacent to each other in the circumferential direction.
  • the distance between the electric modules adjacent to each other in the circumferential direction without sandwiching the protrusion 573 is the first interval INT1
  • the distance between the electric modules adjacent to each other in the circumferential direction across the protrusion 573 is the second interval INT2. ing. That is, the distance between the electric modules adjacent to each other in the circumferential direction is partially expanded, and the protruding portion 573 is provided at, for example, the central portion of the expanded distance (second interval INT2).
  • Each interval INT1 and INT2 may be the distance of an arc between the center positions of two electric modules 532 adjacent to each other in the circumferential direction on the same circle centered on the rotation axis 501.
  • the distance between the electric modules in the circumferential direction may be defined by the angular distances ⁇ i1 and ⁇ i2 centered on the rotation axis 501 ( ⁇ i1 ⁇ i2).
  • the electric modules 532 arranged at the first interval INT1 are arranged in a state of being separated from each other in the circumferential direction (non-contact state), but instead of this configuration, the electric modules are arranged.
  • the 532s may be arranged so as to be in contact with each other in the circumferential direction.
  • the end plate 547 of the boss forming member 543 is provided with a water channel port 574 in which the passage ends of the inlet passage 571 and the outlet passage 57 2 are formed.
  • a circulation path 575 for circulating cooling water is connected to the inlet passage 571 and the outlet passage 572.
  • the circulation path 575 comprises a cooling water pipe.
  • a pump 576 and a heat radiating device 575 are provided in the circulation path 575, and the cooling water circulates through the cooling water passage 545 and the circulation path 575 as the pump 576 is driven.
  • Pump 576 is an electric pump.
  • the heat radiating device 577 is, for example, a radiator that releases the heat of the cooling water to the atmosphere.
  • stator 520 is arranged on the outside of the outer peripheral wall WA1 and the electric module 532 is arranged on the inner side, the stator 520 is arranged from the outside of the outer peripheral wall WA1. As the heat is transferred, the heat of the electric module 532 is transferred from the inside. 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 parts in the rotary electric machine 500 can be efficiently released.
  • the stator winding 521 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 600 is connected to the stator winding 521.
  • 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 including an upper arm switch 601 and a lower arm switch 602 is provided for each phase.
  • Each of these switches 601, 602 is turned on and off by the drive circuit 603, and the windings of each phase are energized by the on / off.
  • Each switch 601, 602 is composed of a semiconductor switching element such as a MOSFET or an IGBT.
  • the upper and lower arms of each phase are connected in parallel with the series connection body of the switches 601, 602 to a charge supply capacitor 604 for supplying the charges required for switching to the switches 601, 602.
  • the control device 607 includes a microcomputer composed of a CPU and various memories, and performs energization control by turning on / off the switches 601 and 602 based on various detection information in the rotary electric machine 500 and requests for power running and power generation. ..
  • the control device 607 performs on / off control of each switch 601 and 602 by, for example, PWM control at a predetermined switching frequency (carrier frequency) and rectangular wave control.
  • the control device 607 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.
  • the electric time constant is small because the inductance of the stator 520 is reduced, and in a situation where the electric time constant is small, the switching frequency (carrier frequency). ) Is increased and the switching speed is increased.
  • the charge supply capacitor 604 is connected in parallel to the series connection of the switches 601, 602 of each phase, the wiring inductance becomes low, and an appropriate surge even in a configuration in which the switching speed is increased. Countermeasures are possible.
  • the high potential side terminal of the inverter 600 is connected to the positive electrode terminal of the DC power supply 605, and the low potential side terminal is connected to the negative electrode terminal (ground) of the DC power supply 605. Further, 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.
  • the switch module 532A has each switch 601, 602 (semiconductor switching element), a drive circuit 603 (specifically, an electric element constituting the drive circuit 603), and a capacitor 604 for electric charge supply as heat generating parts. Further, the capacitor module 532B has a smoothing capacitor 606 as a heat generating component. A specific configuration example of the switch module 532A is shown in FIG.
  • the switch module 532A has a module case 611 as a storage case, and one phase of switches 601, 602 housed in the module case 611, a drive circuit 603, and a charge supply. It has a capacitor 604 and.
  • the drive circuit 603 is configured as a dedicated IC or a circuit board and is provided in the switch module 532A.
  • the module case 611 is made of an insulating material such as resin, and is fixed to the outer peripheral wall WA1 with its side surface in contact with the inner peripheral surface of the inner wall member 542 of the inverter unit 530.
  • the module case 611 is filled with a molding material such as resin.
  • the switches 601, 602 and the drive circuit 603, and the switches 601, 602 and the capacitor 604 are electrically connected by wiring 612, respectively. More specifically, the switch module 532A is attached to the outer peripheral wall WA1 via the spacer 549, but the spacer 549 is not shown.
  • the order of arrangement of the drive circuit 603 and the capacitor 604 is defined. Specifically, when comparing the calorific value, the order is from the largest to the switches 601, 602, the capacitor 604, and the drive circuit 603. Therefore, the switches are switched from the side closer to the outer peripheral wall WA1 according to the order of the calorific value. These are arranged in the order of 601, 602, the capacitor 604, and the drive circuit 603.
  • the contact surface of the switch module 532A is preferably smaller than the contactable surface on the inner peripheral surface of the inner wall member 542.
  • the capacitor module 532B is configured such that the capacitor 606 is housed in a module case having the same shape and size as the switch module 532A. Similar to the switch module 532A, the capacitor module 532B is fixed to the outer peripheral wall WA1 in a state where the side surface of the module case 611 is in contact with the inner peripheral surface of the inner wall member 542 of the inverter housing 531.
  • the switch module 532A and the capacitor module 532B do not necessarily have to be arranged concentrically on the radial inside of the outer peripheral wall WA1 of the inverter housing 531.
  • the switch module 532A may be arranged radially inside the capacitor module 532B, or vice versa.
  • Each electric module 532 may have a configuration in which cooling water is drawn into the module and the cooling water is used to cool the inside of the module.
  • the water cooling structure of the switch module 532A will be described with reference to FIGS. 61 (a) and 61 (b).
  • FIG. 61 (a) is a vertical sectional view showing a cross-sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1
  • FIG. 61 (b) is a sectional view taken along line 61B-61B of FIG. 61 (a). ..
  • the switch module 532A has a module case 611, one-phase switches 601, 602, a drive circuit 603, and a capacitor 604, as in FIG. 60.
  • it has a cooling device including a pair of piping portions 621 and 622 and a cooler 623.
  • the pair of piping portions 621 and 622 are the piping portion 621 on the inflow side for flowing the cooling water from the cooling water passage 545 of the outer peripheral wall WA1 to the cooler 623, and the cooling water from the cooler 623 to the cooling water passage 545. It is composed of a piping portion 622 on the outflow side that allows the outflow.
  • the cooler 623 is provided according to the object to be cooled, and a one-stage or a plurality of stages of the cooler 623 is used in the cooling device.
  • two-stage coolers 623 are provided in a direction away from the cooling water passage 545, that is, in the radial direction of the inverter unit 530, in a state of being separated from each other, and a pair of pipes. Cooling water is supplied to each of the coolers 623 via the sections 621 and 622.
  • the cooler 623 has, for example, a hollow inside. However, an inner fin may be provided inside the cooler 623.
  • the outer peripheral wall WA1 side of the first-stage cooler 623 In the configuration including the two-stage cooler 623, (1) the outer peripheral wall WA1 side of the first-stage cooler 623, (2) between the first-stage and second-stage coolers 623, and (3) the second stage.
  • the opposite outer peripheral wall side of the cooler 623 is a place where the electric parts to be cooled are arranged, and each of these places is (2), (1), (3) in order from the one having the highest cooling performance.
  • the place sandwiched between the two coolers 623 has the highest cooling performance
  • the place adjacent to any one of the coolers 623 the place closer to the outer peripheral wall WA1 (cooling water passage 545) has higher cooling performance. ing. Taking this into consideration, in the configurations shown in FIGS.
  • the switches 601, 602 are arranged between (2) the first-stage and second-stage coolers 623, and the condenser 604 is (2).
  • the drive circuit 603 is arranged on the outer peripheral wall WA1 side of the first-stage cooler 623, and the drive circuit 603 is arranged on the anti-outer peripheral wall side of the second-stage cooler 623.
  • the drive circuit 603 and the capacitor 604 may be arranged in reverse.
  • the switches 601, 602 and the drive circuit 603, and the switches 601, 602 and the capacitor 604 are electrically connected by wiring 612, respectively. Further, since the switches 601, 602 are located between the drive circuit 603 and the capacitor 604, the wiring 612 extending from the switches 601, 602 toward the drive circuit 603 and the wiring 612 extending from the switches 601, 602 toward the capacitor 604 Is a relationship that extends in opposite directions.
  • the pair of piping portions 621 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 the piping portions on the inflow side located on the upstream side. Cooling water flows into the cooler 623 from 621, and then the cooling water flows out from the outflow side piping portion 622 located on the downstream side.
  • the cooling water is provided in the cooling water passage 545 at a position between the inflow side piping portion 621 and the outflow side piping portion 621 when viewed in the circumferential direction.
  • a regulation unit 624 is provided to regulate the flow of the water.
  • the regulating portion 624 may be a blocking portion that shuts off the cooling water passage 545 or a throttle portion that reduces the passage area of the cooling water passage 545.
  • FIG. 62 shows another cooling structure of the switch module 532A.
  • 62 (a) is a vertical sectional view showing a cross-sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1
  • FIG. 62 (b) is a sectional view taken along line 62B-62B of FIG. 62 (a). ..
  • FIGS. 62 (a) and 62 (b) differ from the configurations of FIGS. 61 (a) and 61 (b) described above in that the pair of piping portions 621 and 622 in the cooling device are arranged differently.
  • the piping portions 621 and 622 of the above are arranged side by side in the axial direction.
  • FIG. 62 (c) in the cooling water passage 545, the passage portion communicating with the inflow side piping portion 621 and the passage portion communicating with the outflow side piping portion 622 are separated in the axial direction.
  • Each of these passage portions communicates with each other through each piping portion 621, 622 and each cooler 623.
  • the following configuration can be used as the switch module 532A.
  • the cooler 623 is changed from two stages to one stage as compared with the configuration shown in FIG. 61 (a).
  • the location with the highest cooling performance in the module case 611 is different from that in FIG. 61 (a), and the location on the outer peripheral wall WA1 side of the radial sides of the cooler 623 (both sides in the left-right direction in the figure) is the highest.
  • the cooling performance is high, and then the cooling performance is lowered in the order of the place on the opposite outer peripheral wall side of the cooler 623 and the place away from the cooler 623. Taking this into consideration, in the configuration shown in FIG.
  • the switches 601, 602 are arranged on the outer peripheral wall WA1 side of the radial sides of the cooler 623 (both sides in the left-right direction in the figure), and the condenser 604 is installed.
  • the drive circuit 603 is arranged at a place on the opposite outer peripheral wall side of the cooler 623, and is arranged at a place away from the cooler 623.
  • the switch module 532A it is possible to change the configuration in which the switches 601, 602 for one phase, the drive circuit 603, and the capacitor 604 are housed in the module case 611.
  • the module case 611 may accommodate one of the switches 601, 602 for one phase, the drive circuit 603, and the capacitor 604.
  • a pair of piping portions 621 and 622 and a two-stage cooler 623 are provided in the module case 611, and switches 601, 602 are installed in the first-stage and second-stage coolers 623.
  • the capacitor 604 or the drive circuit 603 is arranged between them, and is arranged on the outer peripheral wall WA1 side of the first stage cooler 623. Further, it is also possible to integrate the switches 601, 602 and the drive circuit 603 into a semiconductor module, and to accommodate the semiconductor module and the capacitor 604 in the module case 611.
  • the condenser is arranged on the opposite side of the switches 601, 602 in at least one of the coolers 623 arranged on both sides of the switches 601, 602. It should be done. That is, there is a configuration in which the condenser 604 is arranged only on one of the outer peripheral wall WA1 side of the first-stage cooler 623 and the opposite peripheral wall side of the second-stage cooler 623, or a configuration in which the condenser 604 is arranged on both sides. It is possible.
  • the switch module 532A is configured to draw cooling water from the cooling water passage 545 into the module.
  • the configuration may be changed so that cooling water is drawn into both modules 532A and 532B from the cooling water passage 545.
  • each electric module 532 it is also possible to cool each electric module 532 by directly applying cooling water to the outer surface of each electric module 532.
  • the cooling water is applied to the outer surface of the electric module 532.
  • a part of the electric module 532 is immersed in the cooling water passage 545, or the cooling water passage 545 is expanded in the radial direction from the configuration shown in FIG. It is conceivable to immerse it in.
  • the cooling performance can be further improved by providing fins in the module case 611 (the immersed portion of the module case 611) to be immersed.
  • the electric module 532 includes a switch module 532A and a capacitor module 532B, and there is a difference in the amount of heat generated when both of them are compared. In consideration of this point, it is possible to devise the arrangement of each electric module 532 in the inverter housing 531.
  • a plurality of switch modules 532A are arranged in the circumferential direction without being dispersed, and arranged on the upstream side of the cooling water passage 545, that is, on the side close to the inlet passage 571.
  • the cooling water flowing in from the inlet passage 571 is first used for cooling the three switch modules 532A, and then used for cooling each capacitor module 532B.
  • the pair of piping portions 621 and 622 are arranged side by side in the axial direction as shown in FIGS. 62 (a) and 62 (b), but the present invention is not limited to this, and FIG. 61 (a) above is not limited to this.
  • (B) a pair of piping portions 621 and 622 may be arranged side by side in the circumferential direction.
  • FIG. 66 is a cross-sectional view taken along the line 66-66 of FIG. 49
  • FIG. 67 is a cross-sectional view taken along the line 67-67 of FIG.
  • FIG. 68 is a perspective view showing the bus bar module 533 as a single unit.
  • the configuration related to the electrical connection of each electric module 532 and the bus bar module 533 will be described with reference to each of these figures.
  • the inverter housing 531 is provided with a protruding portion 573 provided on the inner wall member 542 (that is, a protruding portion 573 provided with an inlet passage 571 and an outlet passage 57 2 leading to the cooling water passage 545) in the circumferential direction.
  • a protruding portion 573 provided on the inner wall member 542 (that is, a protruding portion 573 provided with an inlet passage 571 and an outlet passage 57 2 leading to the cooling water passage 545) in the circumferential direction.
  • Three switch modules 532A are arranged side by side in the circumferential direction at positions adjacent to the above, and six capacitor modules 532B are arranged side by side in the circumferential direction next to the three switch modules 532A.
  • the inside of the outer peripheral wall WA1 is equally divided into 10 regions (that is, the number of modules + 1) in the circumferential direction, and one electric module 532 is arranged in each of the nine regions. At the same time, a protrusion 573 is provided in the remaining one area.
  • the three switch modules 532A are a U-phase module, a V-phase module, and a W-phase module.
  • each electric module 532 (switch module 532A and capacitor module 532B) has a plurality of module terminals 615 extending from the module case 611.
  • the module terminal 615 is a module input / output terminal for performing electrical input / output in each electric module 532.
  • the module terminal 615 is provided so as to extend in the axial direction, and more specifically, the module terminal 615 is provided so as to extend from the module case 611 toward the back side (outside the vehicle) of the rotor carrier 511 (FIG. 51). reference).
  • the module terminals 615 of each electric module 532 are connected to the bus bar module 533, respectively.
  • the number of module terminals 615 differs between the switch module 532A and the capacitor module 532B.
  • the switch module 532A is provided with four module terminals 615
  • the capacitor module 532B is provided with two module terminals 615.
  • the bus bar module 533 extends from the annular portion 631 forming an annular shape and the annular portion 631 to enable connection with an external device such as a power supply device or an ECU (electronic control device). It has three external connection terminals 632 and a winding connection terminal 633 connected to the winding end of each phase in the stator winding 521.
  • the bus bar module 533 corresponds to the "terminal module”.
  • the annular portion 631 is arranged in the inverter housing 531 at a position on the inner side in the radial direction of the outer peripheral wall WA1 and on one side in the axial direction of each electric module 532.
  • the annular portion 631 has an annular main body formed of, for example, an insulating member such as a resin, and a plurality of bus bars embedded therein.
  • the plurality of bus bars are connected to the module terminal 615 of each electric module 532, each external connection terminal 632, and each phase winding of the stator winding 521. The details will be described later.
  • the external connection terminal 632 includes a high potential side power terminal 632A and a low potential side power terminal 632B connected to the power supply device, and one signal terminal 632C connected to the external ECU.
  • Each of these external connection terminals 632 (632A to 632C) is provided so as to be arranged in a line in the circumferential direction and to extend in the radial direction inside the annular portion 631 in the radial direction.
  • FIG. 51 when the bus bar module 533 is assembled to the inverter housing 531 together with each electric module 532, one end of the external connection terminal 632 is configured to protrude from the end plate 547 of the boss forming member 543. .. Specifically, as shown in FIGS.
  • the end plate 547 of the boss forming member 543 is provided with an insertion hole 547a, and a cylindrical grommet 635 is attached to the insertion hole 547a, and the grommet is attached.
  • the external connection terminal 632 is provided with the 635 inserted.
  • the grommet 635 also functions as a sealed connector.
  • the winding connection terminal 633 is a terminal connected to the winding end of each phase of the stator winding 521, and is provided so as to extend radially outward from the annular portion 631.
  • the winding connection terminal 633 is a winding connection terminal 633U connected to the end of the U-phase winding in the stator winding 521, a winding connection terminal 633V connected to the end of the V-phase winding, and a W-phase winding.
  • Each end of the wire has a winding connection terminal 633W connected to the connection. It is preferable that each of these winding connection terminals 633 and a current sensor 634 for detecting the current (U-phase current, V-phase current, W-phase current) flowing through each phase winding are provided (see FIG. 70).
  • the current sensor 634 may be arranged outside the electric module 532 and around each winding connection terminal 633, or may be arranged inside the electric module 532.
  • FIG. 69 is a diagram showing each electric module 532 developed in a plane and schematically showing an electrical connection state between each electric module 532 and a bus bar module 533.
  • FIG. 70 is a diagram schematically showing the connection between each electric module 532 and the bus bar module 533 in a state where each electric module 532 is arranged in an annular shape.
  • the path for power transmission is shown by a solid line
  • the path of the signal transmission system is shown by a chain double-dashed line.
  • FIG. 70 shows only the path for power transmission.
  • the bus bar module 533 has a first bus bar 641, a second bus bar 642, and a third bus bar 643 as bus bars for power transmission.
  • the first bus bar 641 is connected to the power terminal 632A on the high potential side
  • the second bus bar 642 is connected to the power terminal 632B on the low potential side.
  • three third bus bars 643 are connected to the U-phase winding connection terminal 633U, the V-phase winding connection terminal 633V, and the W-phase winding connection terminal 633W, respectively.
  • winding connection terminal 633 and the third bus bar 643 are parts that easily generate heat due to the operation of the rotary electric machine 10. Therefore, a terminal block (not shown) may be interposed between the winding connection terminal 633 and the third bus bar 643, and the terminal block may be brought into contact with the inverter housing 531 having the cooling water passage 545. Alternatively, the winding connection terminal 633 or the third bus bar 643 may be bent into a crank shape to bring the winding connection terminal 633 or the third bus bar 643 into contact with the inverter housing 531 having the cooling water passage 545.
  • the heat generated at the winding connection terminal 633 and the third bus bar 643 can be dissipated to the cooling water in the cooling water passage 545.
  • the first bus bar 641 and the second bus bar 642 are shown as bus bars having a ring shape, but each of these bus bars 641 and 642 does not necessarily have to be connected in a ring shape and is one in the circumferential direction. It may have a substantially C-shape with a broken portion. Further, since each winding connection terminal 633U, 633V, 633W may be individually connected to the switch module 532A corresponding to each phase, each switch module 532A (actually, actually) does not go through the bus bar module 533. It may be configured to be connected to the module terminal 615).
  • each switch module 532A has four module terminals 615 including a positive electrode side terminal, a negative electrode side terminal, a winding terminal, and a signal terminal.
  • the positive electrode side terminal is connected to the first bus bar 641
  • the negative electrode side terminal is connected to the second bus bar 642
  • the winding terminal is connected to the third bus bar 643.
  • bus bar module 533 has a fourth bus bar 644 as a bus bar of the signal transmission system.
  • the signal terminal of each switch module 532A is connected to the fourth bus bar 644, and the fourth bus bar 644 is connected to the signal terminal 632C.
  • each switch module 532A is input from the external ECU via the signal terminal 632C. That is, each of the switches 601, 602 in each switch module 532A is turned on and off by a control signal input via the signal terminal 632C. Therefore, each switch module 532A is connected to the signal terminal 632C without going through a control device built in the rotary electric machine on the way.
  • it is also possible to change this configuration so that the rotary electric machine has a built-in control device and the control signal from the control device is input to each switch module 532A. Such a configuration is shown in FIG.
  • control board 651 on which the control device 652 is mounted is provided, and the control device 652 is connected to each switch module 532A. Further, a signal terminal 632C is connected to the control device 652.
  • the control device 652 inputs a command signal related to power running or power generation from, for example, an external ECU which is a higher-level control device, and appropriately turns on / off the switches 601, 602 of each switch module 532A based on the command signal.
  • control board 651 is arranged on the outside of the vehicle (inside the rotor carrier 511) of the bus bar module 533.
  • control board 651 may be arranged between each electric module 532 and the end plate 547 of the boss forming member 543.
  • the control board 651 may be arranged so that at least a part thereof overlaps with each electric module 532 in the axial direction.
  • each capacitor module 532B has two module terminals 615 composed of a positive electrode side terminal and a negative electrode side terminal, the positive electrode side terminal is connected to the first bus bar 641, and the negative electrode side terminal is connected to the second bus bar 642. Has been done.
  • a projecting portion 573 having an inlet passage 571 and an outlet passage 572 for cooling water is provided in the inverter housing 531 at a position aligned with each electric module 532 in the circumferential direction.
  • the external connection terminal 632 is provided so as to be adjacent to the protruding portion 573 in the radial direction.
  • the protrusion 573 and the external connection terminal 632 are provided at the same angular position in the circumferential direction.
  • the external connection terminal 632 is provided at a position inside the protruding portion 573 in the radial direction.
  • the end plate 547 of the boss forming member 543 is provided with the water channel port 574 and the external connection terminal 632 arranged in the radial direction (see FIG. 48).
  • the inverter unit 530 can be downsized, and the rotary electric machine 500 can be downsized.
  • the cooling pipe H2 is connected to the water channel port 574, and the electric wiring H1 is connected to the external connection terminal 632.
  • the pipe H2 is housed in the storage duct 440.
  • the three switch modules 532A are arranged side by side in the circumferential direction next to the external connection terminal 632 in the inverter housing 531, and the six capacitor modules 532B are arranged side by side in the circumferential direction next to the three switch modules 532A.
  • the three switch modules 532A may be arranged side by side at a position farthest from the external connection terminal 632, that is, a position opposite to the rotation shaft 501. It is also possible to disperse each switch module 532A so that the capacitor modules 532B are arranged on both sides of each switch module 532A.
  • each switch module 532A is arranged at the position farthest from the external connection terminal 632, that is, on the opposite side of the rotating shaft 501, the mutual inductance between the external connection terminal 632 and each switch module 532A. It is possible to suppress malfunctions caused by the above.
  • the inverter housing 531 is provided with a resolver 660 for detecting the electric angle ⁇ of the rotary electric machine 500.
  • the resolver 660 is an electromagnetic induction type sensor, and includes a resolver rotor 661 fixed to a rotating shaft 501 and a resolver stator 662 arranged so as to face each other on the radial outer side of the resolver rotor 661.
  • the resolver rotor 661 has a disk ring shape, and is provided coaxially with the rotating shaft 501 in a state where the rotating shaft 501 is inserted.
  • the resolver stator 662 includes an annular stator core 663 and a stator coil 664 wound around a plurality of teeth formed on the stator core 663.
  • the stator coil 664 includes a one-phase excitation coil and a two-phase output coil.
  • the exciting coil of the stator coil 664 is excited by a sinusoidal exciting signal, and the magnetic flux generated in the exciting coil by the exciting signal interlinks the pair of output coils.
  • the pair of output coils are interlocked.
  • the number of magnetic fluxes to be applied changes periodically.
  • the pair of output coils and the exciting coil are arranged so that the phases of the voltages generated in the pair of output coils are shifted by ⁇ / 2 from each other.
  • the output voltage of each of the pair of output coils becomes a modulated wave in which the excitation signal is modulated by the modulated waves sin ⁇ and cos ⁇ , respectively. More specifically, when the excitation signal is "sin ⁇ t", the modulated waves are "sin ⁇ ⁇ sin ⁇ t" and “cos ⁇ ⁇ sin ⁇ t”, respectively.
  • the resolver 660 has a resolver digital converter.
  • the resolver digital converter calculates the electric angle ⁇ by detecting the generated modulated wave and the excitation signal.
  • the resolver 660 is connected to the signal terminal 632C, and the calculation result of the resolver digital converter is output to an external device via the signal terminal 632C.
  • the calculation result of the resolver digital converter is input to the control device.
  • the boss portion 548 of the boss forming member 543 constituting the inverter housing 531 has a hollow tubular shape, and the inner peripheral side of the boss portion 548 is oriented orthogonal to the axial direction. A protrusion 548a extending to the surface is formed. Then, the resolver stator 662 is fixed by a screw or the like in a state of being in contact with the protruding portion 548a in the axial direction.
  • a bearing 560 is provided on one side in the axial direction with the protrusion 548a interposed therebetween, and a resolver 660 is coaxially provided on the other side.
  • a protruding portion 548a is provided on one side of the resolver 660 in the axial direction, and a disk ring-shaped housing cover 666 that closes the accommodating space of the resolver 660 is provided on the other side.
  • the housing cover 666 is made of a conductive material such as carbon fiber reinforced plastic (CFRP).
  • a hole 666a through which the rotary shaft 501 is inserted is formed in the central portion of the housing cover 666.
  • a sealing material 667 is provided inside the hole 666a to seal the gap between the rotating shaft 501 and the outer peripheral surface.
  • the resolver accommodating space is sealed by the sealing material 667.
  • the sealing material 667 may be, for example, a sliding seal made of a resin material.
  • the space in which the resolver 660 is housed is a space surrounded by an annular boss portion 548 in the boss forming member 543 and sandwiched between the bearing 560 and the housing cover 666 in the axial direction, and the circumference of the resolver 660 is conductive. Surrounded by material. This makes it possible to suppress the influence of electromagnetic noise on the resolver 660.
  • the inverter housing 531 has a double outer peripheral wall WA1 and an inner peripheral wall WA2 (see FIG. 57), and is located outside the double peripheral wall (outside the outer peripheral wall WA1).
  • the stator 520 is arranged, the electric module 532 is arranged between the double peripheral walls (between WA1 and WA2), and the resolver 660 is arranged inside the double peripheral wall (inside the inner peripheral wall WA2).
  • the inverter housing 531 is a conductive member
  • the stator 520 and the resolver 660 are arranged so as to be separated from each other by a conductive partition wall (particularly a double conductive partition wall in the present embodiment) and are fixed. The occurrence of mutual magnetic interference between the child 520 side (magnetic circuit side) and the resolver 660 can be suitably suppressed.
  • one side of the rotor carrier 511 in the axial direction is open, and a substantially disk ring-shaped rotor cover 670 is attached to the open end.
  • the rotor cover 670 may be fixed to the rotor carrier 511 by any joining method such as welding, bonding, or screwing. It is more preferable that the rotor cover 670 has a portion whose dimensions are set smaller than the inner circumference of the rotor carrier 511 so that the movement of the magnet unit 512 in the axial direction can be suppressed.
  • the outer diameter of the rotor cover 670 matches the outer diameter of the rotor carrier 511, and the inner diameter of the rotor cover 670 is slightly larger than the outer diameter of the inverter housing 531.
  • the outer diameter of the inverter housing 531 and the inner diameter of the stator 520 are the same.
  • the stator 520 is fixed on the radial outer side of the inverter housing 531.
  • the inverter housing 531 is shafted with respect to the stator 520. It protrudes in the direction.
  • a rotor cover 670 is attached so as to surround the protruding portion of the inverter housing 531.
  • a sealing material 671 for sealing the gap between the end surface of the rotor cover 670 on the inner peripheral side and the outer peripheral surface of the inverter housing 531 is provided.
  • the accommodating space of the magnet unit 512 and the stator 520 is sealed by the sealing material 671.
  • the sealing material 671 may be, for example, a sliding seal made of a resin material.
  • the outer peripheral wall WA1 of the inverter housing 531 was arranged inside the magnetic circuit portion including the magnet unit 512 and the stator winding 521 in the radial direction, and the cooling water passage 545 was formed on the outer peripheral wall WA1. Further, a plurality of electric modules 532 are arranged in the radial direction of the outer peripheral wall WA1 along the outer peripheral wall WA1 in the circumferential direction. As a result, the magnetic circuit unit, the cooling water passage 545, and the power converter can be arranged so as to be stacked in the radial direction of the rotary electric machine 500, and efficient component arrangement is possible while reducing the dimensions in the axial direction. It becomes. Further, the plurality of electric modules 532 constituting the power converter can be efficiently cooled. As a result, the rotary electric machine 500 can be realized with high efficiency and miniaturization.
  • An electric module 532 (switch module 532A, capacitor module 532B) having heat generating parts such as a semiconductor switching element and a capacitor is provided in a state of being in contact with the inner peripheral surface of the outer peripheral wall WA1. As a result, the heat in each electric module 532 is transferred to the outer peripheral wall WA1, and the electric module 532 is suitably cooled by the heat exchange in the outer peripheral wall WA1.
  • coolers 623 are arranged on both sides of the switches 601, 602, respectively, and at least one of the coolers 623 on both sides of the switches 601, 602 is on the opposite side of the switches 601,602.
  • the configuration is such that the capacitor 604 is arranged. As a result, the cooling performance of the switches 601, 602 can be improved, and the cooling performance of the capacitor 604 can also be improved.
  • coolers 623 are arranged on both sides of the switches 601, 602, respectively, and one of the coolers 623 on both sides of the switches 601, 602 is driven to the opposite side of the switches 601,602.
  • the circuit 603 is arranged, and the capacitor 604 is arranged on the opposite side of the switches 601, 602 in the other cooler 623.
  • cooling water is made to flow into the module from the cooling water passage 545, and the semiconductor switching element or the like is cooled by the cooling water.
  • the switch module 532A is cooled by heat exchange by the cooling water inside the module in addition to heat exchange by the cooling water on the outer peripheral wall WA1. Thereby, the cooling effect of the switch module 532A can be enhanced.
  • the switch module 532A is arranged on the upstream side near the inlet passage 571 of the cooling water passage 545, and the condenser module 532B is placed on the switch module 532A. It is configured to be placed on the downstream side of the. In this case, assuming that the cooling water flowing through the cooling water passage 545 is lower in temperature toward the upstream side, it is possible to realize a configuration in which the switch module 532A is preferentially cooled.
  • the distance between the electric modules adjacent to each other in the circumferential direction was partially widened, and a protruding portion 573 having an inlet passage 571 and an outlet passage 57 2 was provided in the portion where the distance was widened (second interval INT2).
  • the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 can be suitably formed in the portion on the outer peripheral wall WA1 in the radial direction. That is, in order to improve the cooling performance, it is necessary to secure the flow amount of the refrigerant, and for that purpose, it is conceivable to increase the opening areas of the inlet passage 571 and the outlet passage 572.
  • the inlet passage 571 and the outlet passage 572 having a desired size can be suitably formed.
  • the external connection terminal 632 of the bus bar module 533 is arranged at a position radially aligned with the protrusion 573 on the radial inside of the outer peripheral wall WA1. That is, the external connection terminal 632 is arranged together with the protrusion 573 in the portion where the distance between the electric modules adjacent to each other in the circumferential direction is widened (the part corresponding to the second distance INT2). As a result, the external connection terminal 632 can be preferably arranged while avoiding interference with each electric module 532.
  • the stator 520 is fixed on the radial outside of the outer peripheral wall WA1, and a plurality of electric modules 532 are arranged on the radial inside.
  • the heat of the stator 520 is transferred to the outer peripheral wall WA1 from the radial outer side, and the heat of the electric module 532 is transferred from the radial inner side.
  • 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 rotary electric machine 500 can be efficiently released.
  • the electric module 532 on the inner side in the radial direction and the stator winding 521 on the outer side in the radial direction are electrically connected by the winding connection terminal 633 of the bus bar module 533 with the outer peripheral wall WA1 interposed therebetween. Further, in this case, the winding connection terminal 633 is provided at a position axially separated from the cooling water passage 545. As a result, even if the cooling water passage 545 is formed in an annular shape on the outer peripheral wall WA1, that is, the inside and outside of the outer peripheral wall WA1 are separated by the cooling water passage 545, the electric module 532 and the stator winding 521 Can be suitably connected to.
  • the torque is limited due to the magnetic saturation generated between the conductors 523.
  • the torque drop is suppressed by making the conductor 523 flat and thin.
  • An outer peripheral wall WA1 having a water passage 545 and a plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be preferably arranged.
  • the magnetic flux on the d-axis is strengthened by collecting the magnetic flux on the d-axis side in the magnet unit 512, and the torque can be increased accordingly.
  • the thickness dimension in the radial direction can be reduced (thinned) in the magnet unit 512
  • the area inside the magnetic circuit portion in the radial direction can be expanded, and the inner area is used. Therefore, the outer peripheral wall WA1 having the cooling water passage 545 and a plurality of electric modules 532 provided on the inner side in the radial direction of the outer peripheral wall WA1 can be preferably arranged.
  • the magnetic circuit unit not only the magnetic circuit unit, the outer peripheral wall WA1, and the plurality of electric modules 532, but also the bearing 560 and the resolver 660 can be preferably arranged in the radial direction.
  • the wheel 400 using the rotary electric machine 500 as an in-wheel motor is mounted on the vehicle body via a base plate 405 fixed to the inverter housing 531 and a mounting mechanism such as a suspension device.
  • a base plate 405 fixed to the inverter housing 531 and a mounting mechanism such as a suspension device.
  • the rotary electric machine 500 since the rotary electric machine 500 has been miniaturized, it is possible to save space even if it is assumed to be assembled to the vehicle body. Therefore, it is possible to realize an advantageous configuration in expanding the installation area of the power supply device such as a battery in the vehicle and expanding the vehicle interior space.
  • the electric module 532 and the bus bar module 533 are arranged radially inside the outer peripheral wall WA1 of the inverter unit 530, and the electric module 532 and the bus bar are arranged radially inside and outside across the outer peripheral wall WA1.
  • the module 533 and the stator 520 are arranged respectively.
  • the position of the bus bar module 533 with respect to the electric module 532 can be arbitrarily set.
  • the winding connection line for example, winding connection terminal 633 used for the connection is connected.
  • the guide position can be set arbitrarily.
  • the position of the bus bar module 533 with respect to the electric module 532 is such that the ( ⁇ 1) bus bar module 533 is located outside the vehicle in the axial direction, that is, behind the rotor carrier 511 side. ( ⁇ 2) The bus bar module 533 is located inside the vehicle in the axial direction from the electric module 532, that is, on the front side of the rotor carrier 511 side. Can be considered.
  • ( ⁇ 1) A configuration in which the winding connection wire is guided in the axial direction on the outside of the vehicle, that is, on the back side of the rotor carrier 511.
  • ( ⁇ 2) A configuration in which the winding connection wire is guided inside the vehicle in the axial direction, that is, on the front side of the rotor carrier 511 side. Can be considered.
  • FIGS. 72 (a) to 72 (d) are vertical cross-sectional views showing the configuration of the rotary electric machine 500 in a simplified manner, and the same reference numerals are given to the configurations already described in the drawings.
  • the winding connection line 637 is an electric wiring that connects each phase winding of the stator winding 521 and the bus bar module 533, and for example, the winding connection terminal 633 described above corresponds to this.
  • the above ( ⁇ 1) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above ( ⁇ 1) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532, the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected on the outside of the vehicle (the back side of the rotor carrier 511). This corresponds to the configuration shown in FIG. 49.
  • the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637. Further, the winding connection line 637 that connects the stator winding 521 and the bus bar module 533 can be easily realized.
  • the above ( ⁇ 1) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above ( ⁇ 2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected on the outside of the vehicle (the back side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected on the inside of the vehicle (the front side of the rotor carrier 511). It is configured to be connected with.
  • the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637.
  • the above ( ⁇ 2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above ( ⁇ 1) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected inside the vehicle (front side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected outside the vehicle (back side of the rotor carrier 511). It is configured to be connected with.
  • the above ( ⁇ 2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above ( ⁇ 2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532, the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected inside the vehicle (on the front side of the rotor carrier 511).
  • the bus bar module 533 is arranged inside the vehicle (on the front side of the rotor carrier 511) to temporarily add an electric component such as a fan motor. In that case, it is considered that the wiring becomes easy. Further, it is possible that the bus bar module 533 can be brought closer to the resolver 660 arranged inside the vehicle than the bearing, and it is considered that the wiring to the resolver 660 becomes easier.
  • FIGS. 73 (a) to 73 (c) are block diagrams showing an example of a mounting structure of the resolver rotor 661 to the rotating body.
  • the resolver 660 is provided in a closed space surrounded by a rotor carrier 511, an inverter housing 531 and the like, and protected from external water and mud.
  • the bearing 560 in FIG. 73 (a), has the same configuration as that in FIG. 49.
  • the bearing 560 has a configuration different from that of FIG. 49, and is arranged at a position away from the end plate 514 of the rotor carrier 511.
  • the resolver stator 662 is not shown, for example, the boss portion 548 of the boss forming member 543 may be extended to the outer peripheral side of the resolver rotor 661 or its vicinity, and the resolver stator 662 may be fixed to the boss portion 548. ..
  • the resolver rotor 661 is attached to the inner ring 561 of the bearing 560. Specifically, the resolver rotor 661 is provided on the axial end face of the flange 561b of the inner ring 561, or is provided on the axial end face of the tubular portion 561a of the inner ring 561.
  • the resolver rotor 661 is attached to the rotor carrier 511. Specifically, the resolver rotor 661 is provided on the inner surface of the end plate 514 in the rotor carrier 511. Alternatively, in a configuration in which the rotor carrier 511 has a tubular portion 515 extending from the inner peripheral edge portion of the end plate 514 along the rotation shaft 501, the resolver rotor 661 is provided on the outer peripheral surface of the tubular portion 515 of the rotor carrier 511. ing. In the latter case, the resolver rotor 661 is arranged between the end plate 514 of the rotor carrier 511 and the bearing 560.
  • the resolver rotor 661 is attached to the rotating shaft 501. Specifically, the resolver rotor 661 is provided between the end plate 514 of the rotor carrier 511 and the bearing 560 on the rotating shaft 501, or is opposite to the rotor carrier 511 with the bearing 560 sandwiched on the rotating shaft 501. It is located on the side.
  • FIG. 74 (a) and 74 (b) are vertical cross-sectional views showing a simplified configuration of the rotary electric machine 500, in which the same reference numerals are given to the configurations already described.
  • the configuration shown in FIG. 74 (a) substantially corresponds to the configuration described in FIG. 49 and the like, and the configuration shown in FIG. 74 (b) is a configuration in which a part of the configuration of FIG. 74 (a) is modified. Corresponds to.
  • a rotor cover 670 fixed to the open end of the rotor carrier 511 is provided so as to surround the outer peripheral wall WA1 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the outer peripheral wall WA1, and a sealing material 671 is provided between them.
  • a housing cover 666 is attached to the hollow portion of the boss portion 548 of the inverter housing 531, and a sealing material 667 is provided between the housing cover 666 and the rotating shaft 501.
  • the external connection terminal 632 constituting the bus bar module 533 penetrates the inverter housing 531 and extends to the inside of the vehicle (lower side in the figure).
  • the inverter housing 531 is formed with an inlet passage 571 and an outlet passage 57 2 communicating with the cooling water passage 545, and a water channel port 574 including the passage ends of the inlet passage 571 and the outlet passage 572. ..
  • the inverter housing 531 (specifically, the boss forming member 543) is formed with an annular convex portion 681 extending toward the protruding side (inside the vehicle) of the rotating shaft 501.
  • the rotor cover 670 is provided so as to surround the convex portion 681 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the convex portion 681, and the sealing material 671 is provided between them.
  • the external connection terminal 632 constituting the bus bar module 533 penetrates the boss portion 548 of the inverter housing 531 and extends into the hollow region of the boss portion 548, and also penetrates the housing cover 666 and penetrates the inside of the vehicle (lower side of the figure). Extends to.
  • the inverter housing 531 is formed with an inlet passage 571 and an outlet passage 572 communicating with the cooling water passage 545, and the inlet passage 571 and the outlet passage 572 extend into the hollow region of the boss portion 548 and are a relay pipe. It extends to the inside of the vehicle (lower side of the figure) from the housing cover 666 via 682. In this configuration, the piping portion extending from the housing cover 666 to the inside of the vehicle is the water channel port 574.
  • the rotor carrier 511 and the rotor cover 670 are integrated with the rotor carrier 511 and the rotor cover 670 while maintaining the airtightness of the internal space of the rotor carrier 511 and the rotor cover 670. It can be suitably rotated with respect to the housing 531.
  • the inner diameter of the rotor cover 670 is smaller than that of the configuration of FIG. 74 (a). Therefore, the inverter housing 531 and the rotor cover 670 are provided twice in the axial direction at a position inside the vehicle from the electric module 532, and the inconvenience caused by electromagnetic noise, which is a concern in the electric module 532, is suppressed. can do. Further, by reducing the inner diameter of the rotor cover 670, the sliding diameter of the sealing material 671 can be reduced, and mechanical loss in the rotating sliding portion can be suppressed.
  • FIG. 75 shows a modified example of the stator winding 521.
  • the stator winding 521 uses a conducting wire having a rectangular cross section, and is wound by a wave winding with the long side of the conducting wire extending in the circumferential direction.
  • the lead wires 523 of each phase on the coil side of the stator winding 521 are arranged at predetermined pitch intervals for each phase and are connected to each other at the coil ends.
  • the conductive wires 523 adjacent to each other in the circumferential direction on the coil side are in contact with each other at the end faces in the circumferential direction, or are arranged close to each other at a minute interval.
  • the conducting wire material is bent in the radial direction for each phase at the coil end. More specifically, the stator winding 521 (conductor) is bent inward in the radial direction at different positions for each phase in the axial direction, whereby the U-phase, V-phase, and W-phase windings are formed. Interference with each other is avoided. In the illustrated configuration, the conductors are bent at right angles inward in the radial direction for each phase, with each phase winding being different by the thickness of the conductor. In each of the conductors 523 arranged in the circumferential direction, the length dimension between both ends in the axial direction may be the same for each of the conductors 523.
  • stator core 522 When the stator core 522 is assembled to the stator winding 521 to manufacture the stator 520, a part of the annular shape of the stator winding 521 is disconnected as a non-connection (that is, the stator winding).
  • 521 may be substantially C-shaped), and after assembling the stator core 522 on the inner peripheral side of the stator winding 521, the disconnecting portions may be connected to each other to form the stator winding 521 in an annular shape.
  • stator core 522 is divided into a plurality of parts (for example, three or more) in the circumferential direction, and the core pieces divided into a plurality of pieces are formed on the inner peripheral side of the stator winding 521 formed in an annular shape. It is also possible to assemble.
  • the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 are provided together in one place.
  • this configuration has been changed to change the configuration so that the inlet passage 571 and the outlet are provided.
  • the passages 572 may be provided at different positions in the circumferential direction.
  • the inlet passage 571 and the exit passage 57 2 may be provided at positions different from each other by 180 degrees in the circumferential direction, or at least one of the inlet passage 571 and the exit passage 572 may be provided in a plurality of positions.
  • the wheel 400 of the above embodiment has a configuration in which the rotary shaft 501 protrudes on one side in the axial direction of the rotary electric machine 500, but this may be changed to a configuration in which the rotary shaft 501 protrudes in both axial directions.
  • a suitable configuration can be realized in a vehicle in which at least one of the front and rear of the vehicle is one wheel.
  • FIG. 76 is a perspective view showing the entire rotary electric machine 700
  • FIG. 77 is a vertical sectional view of the rotary electric machine 700
  • FIG. 78 is an exploded sectional view of components of the rotary electric machine 700.
  • the rotary electric machine 700 is an outer rotor type surface magnet type rotary electric machine.
  • the rotary electric machine 700 is roughly classified into a rotary electric machine main body having a rotor 710, a stator 730, an inner unit 770 and a bus bar module 810, and a housing 831 and a cover 832 provided so as to surround the rotary electric machine main body. ..
  • Each of these members is arranged coaxially with respect to the rotating shaft 701 integrally provided on the rotor 710, and is assembled in the axial direction in a predetermined order to form the rotating electric machine 700.
  • the rotor 710 is cantilevered by a pair of bearings 791 and 792 provided inside the inner unit 770 in the radial direction, and can rotate in that state.
  • the rotating shaft 701 is integrally provided with a connecting shaft 705 fixed to the axle, wheels, or the like of the vehicle.
  • the rotor 710 and the stator 730 each have a cylindrical shape, and are arranged so as to face each other in the radial direction with an air gap in between.
  • the rotor 710 rotates integrally with the rotation shaft 701
  • the rotor 710 rotates on the radial outer side of the stator 730.
  • the rotor 710 corresponds to the "field magnet” and the stator 730 corresponds to the "armature”.
  • the rotor 710 has a substantially cylindrical rotor carrier 711 and an annular magnet unit 712 fixed to the rotor carrier 711.
  • the rotor carrier 711 has an end plate portion 713 and a tubular portion 714 extending in the axial direction from the outer peripheral portion of the end plate portion 713.
  • a through hole 713a is formed in the end plate portion 713, and the rotating shaft 701 is fixed to the end plate portion 713 by a fastener 715 such as a bolt in a state of being inserted into the through hole 713a.
  • the rotating shaft 701 has a flange 702 extending in a direction intersecting (orthogonal) in the axial direction at a portion where the rotor carrier 711 is fixed, and the flange 702 and the end plate portion 713 are surface-joined. In this state, the rotor carrier 711 is fixed to the rotating shaft 701.
  • the magnet unit 712 includes a cylindrical magnet holder 721, a magnet 722 fixed to the inner peripheral surface of the magnet holder 721, and an end plate fixed on both sides of the magnet 722 in the axial direction opposite to the rotor carrier 711. It has 723 and.
  • the magnet holder 721 has the same length dimension as the magnet 722 in the axial direction.
  • the magnet 722 is provided in the magnet holder 721 in a state of being surrounded from the outside in the radial direction. Further, the magnet holder 721 and the magnet 722 are fixed in a state where one end side of both ends in the axial direction is in contact with the rotor carrier 711, and the other end side is fixed in a state of being in contact with the end plate 723.
  • the rotor carrier 711, the magnet holder 721, and the end plate 723 are all made of non-magnetic aluminum or non-magnetic stainless steel (for example, SUS304).
  • Each of these members is preferably made of a light metal such as aluminum, but can be made of a synthetic resin instead.
  • Each of these members may be joined by adhesion or welding.
  • FIG. 80 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 712.
  • the easy magnetization axis of the magnet 722 is indicated by an arrow.
  • the magnets 722 are arranged side by side so that the polarities alternate along the circumferential direction of the rotor 710. As a result, the magnet 722 has a plurality of magnetic poles in the circumferential direction.
  • the magnet 722 is a polar anisotropy permanent magnet, and uses a sintered neodymium magnet having an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more. It is configured.
  • the magnet 722 is provided as one magnet between the d-axis, which is the center of each magnetic pole, in two magnetic poles adjacent to each other in the circumferential direction. That is, the magnet 722 has one magnetic pole as one magnet, and the center in the circumferential direction thereof is the q-axis.
  • the peripheral surface on the inner side of the magnet 722 in the radial direction is the magnetic flux transfer surface 724 on which magnetic flux is transferred.
  • the direction of the easy magnetization axis is different between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis), and the direction of the easy magnetization axis is the d-axis on the d-axis side.
  • the direction of the easy magnetization axis is orthogonal to the q-axis.
  • an arcuate magnet magnetic path is formed along the direction of the easy magnetization axis.
  • the magnet 722 is oriented so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary.
  • each magnet 722 arranged in the circumferential direction the magnet magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed.
  • the magnet 722 may have a configuration in which the center in the circumferential direction is the d-axis instead of the configuration in which the center in the circumferential direction is the q-axis.
  • the magnet 722 may be configured to use magnets connected in an annular shape instead of using the same number of magnets as the number of magnetic poles.
  • the magnet 722 has the following configuration.
  • the arc length of the magnetic flux transfer surface 724 between the dq axes is longer than the radial thickness of the magnet 722.
  • a circle whose center point CP is the intersection of the q-axis and the magnetic flux transfer surface 724 and whose radius is the radial thickness dimension of the magnet 722 is the easily magnetized axis of the magnet 722.
  • the magnet 722 is configured to include a quarter circle of the orientation circle X when the orientation circle X is used.
  • the magnet 722 is provided with an arc-shaped easy-to-magnetize axis that crosses the q-axis, and among the easy-to-magnetize axes, the peripheral surface on the side opposite to the magnetic flux transfer surface 724 in the radial direction and the q-axis.
  • the strongest magnet magnetic flux is generated by the easily magnetized axis passing through the intersection, that is, the easily magnetized axis passing through the alignment circle X.
  • the magnet 722 since the magnet 722 includes the quarter circle of the orientation circle X, the length of the magnet magnetic path passing through the d-axis is secured as the length defined by the orientation circle X, and then the magnet magnetic flux. It is possible to generate.
  • the magnet 722 is radially outside, that is, toward the anti-stator side. There is a concern about magnetic flux leakage. However, in the configuration of this example, since the magnet holder 721 is made of a non-magnetic material, the influence of magnetic flux leakage can be reduced.
  • the magnet 722 is formed with a recess 725 in a predetermined range including the d-axis on the outer peripheral surface in the radial direction, and a recess 726 is formed in a predetermined range including the q-axis on the inner peripheral surface in the radial direction. It is formed.
  • the magnetic path is shortened near the d-axis on the outer peripheral surface of the magnet 722, and the magnetic path is shortened near the q-axis on the inner peripheral surface of the magnet 722. .. Therefore, in consideration of the fact that it becomes difficult to generate a sufficient magnet magnetic flux in the place where the magnet magnetic path length is short in the magnet 722, the magnet is deleted in the place where the magnet magnetic flux is weak.
  • the magnet holder 721 is provided on the outer side in the radial direction of each magnet 722 arranged in the circumferential direction. Further, the magnet holder 721 may be provided in a range including between each magnet 722 in the circumferential direction and the inside in the radial direction of each magnet 722. That is, the magnet holder 721 may be provided so as to surround the magnet 722. When the magnet holder 721 has a radial outer portion and a radial inner portion of each magnet 722, it is preferable that the radial outer portion has a higher strength than the radial inner portion.
  • the magnet holder 721 has a convex portion 727 that penetrates into the concave portion 725 of the magnet 722. In this case, the displacement of the magnet 722 in the circumferential direction is suppressed by the engagement between the concave portion 725 of the magnet 722 and the convex portion 727 of the magnet holder 721. That is, the convex portion 727 of the magnet holder 721 functions as a detent portion of the magnet 722. Further, when the magnet holder 721 has a portion that is radially inside (the stator 730 side) of the magnet 722, the portion is provided with a convex portion that enters the recess 726 of the magnet 722. You may.
  • the stator 730 has a stator winding 731 and a stator core 732.
  • FIG. 82 is a perspective view showing the configuration of the stator 730
  • FIG. 83 is a perspective view showing the stator winding 731 and the stator core 732 in an exploded manner
  • FIG. 84 is a phase winding of each phase. It is a perspective view which shows only the structure corresponding to the U-phase winding among lines
  • FIG. 85 is a vertical sectional view of the stator 730.
  • the stator core 732 is configured as a core sheet laminate in which a plurality of core sheets 732a made of an electromagnetic steel plate which is a magnetic material are used and the plurality of core sheets 732a are laminated in the axial direction, and has a predetermined thickness in the radial direction. It has a cylindrical shape with a diameter.
  • a stator winding 731 is assembled on the radial outer side of the stator core 732 on the rotor 710 side.
  • the outer peripheral surface of the stator core 732 has a curved surface without unevenness.
  • the stator core 732 has a slotless structure and functions as a back yoke.
  • the stator core 732 is configured by, for example, a plurality of core sheets 732a punched out in an annular plate shape and laminated in the axial direction. However, a stator core 732 having a helical core structure may be used. A band-shaped core sheet is used in the stator core 732 having a helical core structure, and the core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 732 as a whole. Has been done.
  • end rings 733 are fixed to the end faces on both sides in the axial direction.
  • the end ring 733 is a positioning member having a function of holding the stator winding 731 at a predetermined position in the circumferential direction in a state where the stator winding 731 is assembled to the stator core 732.
  • the stator core 732 and the end ring 733 are the base member 736.
  • An engaging surface 734 is formed on the outer peripheral surface of the end ring 733 in a direction inclined with respect to a tangent line on a concentric circle concentric with the stator core 732 and the end ring 733.
  • the engaging surface 734 is provided by dividing the outer peripheral surface of the end ring 733 into a plurality of equal parts.
  • the same number of engaging surfaces 734 as the coil side conducting wire portions (straight line portion 744 of the coil module 740 described later) arranged in the circumferential direction are provided in the circumferential direction.
  • the direction of inclination with respect to the tangent line is opposite to each other on the engaging surfaces 734 adjacent to each other in the circumferential direction, so that a tapered engaging portion is formed on the outer peripheral surface of the end ring 733. Has been done. In this case, a recess 735 is formed between the tapered protrusions.
  • each end ring 733 on both sides in the axial direction the positions of the unevenness in the circumferential direction are the same on one end side and the other end side in the axial direction. That is, the end ring 733 on the one end side in the axial direction and the end ring 733 on the other end side in the axial direction are fixed to the stator core 732 so that the positions of the convex tops of the engaging surface 734 coincide with each other in the circumferential direction. There is.
  • the inner diameter of the end ring 733 is the same as the inner diameter of the stator core 732. Further, the outer diameter of the end ring 733 is the same as the outer diameter of the stator core 732 at the portion where the maximum diameter is reached, and is smaller than the outer diameter of the stator core 732 at the portion where the minimum diameter is reached.
  • the end ring 733 is made of a non-magnetic material such as aluminum or copper.
  • the end ring 733 is fixed to the stator core 732 by welding.
  • the end ring 733 may be mechanically fixed by pin insertion, key press fitting, or bolt fastening. By such mechanical fixing, the displacement of the end ring 733 with respect to the stator core 732 in the circumferential direction is suppressed.
  • the stator 730 has a portion corresponding to the coil side CS that faces the magnet 722 in the rotor 710 in the axial direction in the axial direction, and a coil end CE1 that is outside the coil side CS in the axial direction. , It has a part corresponding to CE2.
  • the stator core 732 is provided in the axial direction in a range corresponding to the coil side CS
  • the end ring 733 is provided in the coil end CE1 on one end side in the axial direction and the coil end CE2 on the other end side, respectively. ..
  • the coil end CE1 corresponds to the first coil end
  • the coil end CE2 corresponds to the second coil end.
  • the configuration in which the end ring 733 is engaged with the stator winding 731 will be described later.
  • the stator winding 731 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction to form a cylindrical shape (annular shape).
  • a stator core 732 is assembled inside the stator winding 731 in the radial direction.
  • the stator winding 731 has a configuration having three-phase phase windings.
  • each phase winding of each phase has a plurality of partial windings 741 (see FIG. 86), and the partial windings 741 are individually provided as coil modules 740. That is, the coil module 740 is integrally provided with partial windings 741 in the phase windings of each phase.
  • the conductor portions of each phase are arranged in a predetermined order on the coil side of the stator winding 731.
  • FIG. 82 shows the arrangement order of the U-phase, V-phase, and W-phase conductors on the coil side.
  • FIG. 84 only the coil module 740 constituting the U-phase winding is extracted and shown from the three-phase windings.
  • the number of magnetic poles is 24, but the number is arbitrary.
  • FIG. 86 is a circuit diagram showing a connection state of the partial winding 741 in each of the three-phase windings.
  • FIG. 86 shows a state in which the partial windings 741 in the phase windings of each phase are connected in parallel.
  • the coil module 740 is assembled on the radial outer side of the stator core 732.
  • the stator winding 731 has a portion corresponding to the coil side CS and a portion corresponding to the coil ends CE1 and CE2.
  • the coil module 740 is assembled in a state in which both ends in the axial direction are projected outward in the axial direction (that is, the coil end side) from the stator core 732.
  • the coil module 740 is formed in a substantially L shape by bending one of both ends in the axial direction in the radial direction, and the bending suppresses interference between adjacent coil modules 740 in the circumferential direction.
  • the coil module 740A is arranged so that the portion on the one end side in the axial direction faces outward in the axial direction
  • the coil module 740A is arranged so that the portion on one end side in the axial direction faces inward in the radial direction.
  • restraint rings 760 are attached at two positions in the axial direction on the radial outer side of the coil module 740. ..
  • the restraint ring 760 is a restraint member that restrains each coil module 740 (stator winding 731) in the radial direction.
  • the restraint ring 760 is, for example, a metal annular ring.
  • a C ring or multiple rings having both ends as free ends may be used as the restraint ring 760, and the ends of the restraint ring 760 may be connected to each other by welding, adhesion, or the like.
  • the restraint ring 760 is preferably elastic and has a diameter smaller than that of the stator winding 731 in a natural state.
  • a linear member such as a thread, a string, or a wire may be used as a restraining member, and the restraining member may be spirally wound around the outer peripheral side of the stator winding 731.
  • a string impregnated with varnish may be used to strengthen the string fixing with the varnish.
  • the coil module 740A among the coil module 740A and the coil module 740B will be described.
  • the coil module 740 is a subassembly having a partial winding 741 and a winding holder 742.
  • the partial winding 741 of the coil module 740A is also referred to as “partial winding 741A”
  • the winding holder 742 is also referred to as “winding holder 742A”
  • the partial winding 741 of the coil module 740B is referred to as "partial winding 741B”.
  • the winding holder 742 is also referred to as "winding holder 742B”.
  • the partial winding 741A corresponds to the first partial winding
  • the partial winding 741B corresponds to the second partial winding.
  • FIG. 87 (a) is a perspective view of the coil module 740A
  • FIG. 87 (b) is a perspective view showing only the partial winding 741A in the coil module 740A
  • FIG. 87 (c) is a perspective view of the coil module 740A. It is a perspective view which shows only the winding holder 742A
  • FIG. 87 (d) is a side view of the coil module 740A.
  • 88 (a) and 88 (b) are cross-sectional views showing a cross section of the coil module 740A
  • FIG. 88 (a) is a cross-sectional view taken along the line 88A-88A of FIG. 87 (d), FIG. 88 (b).
  • FIG. 87 (d) Is a sectional view taken along line 88B-88B of FIG. 87 (d).
  • the left side of the coil module 740A is the stator core 732 side
  • the lower side of the coil module 740A is the stator core 732 side.
  • the coil module 740A has a partial winding 741A formed by multiple winding of the conducting wire 743, and an insulating winding holder 742A integrally provided with the partial winding 741A.
  • the winding holder 742A is provided to insulate the partial winding 741A from the surroundings, and in particular, is provided to insulate between the partial winding 741A and the stator core 732.
  • the coil module 740A is formed in an elongated annular shape having a longitudinal direction in the axial direction.
  • the coil module 740A has a pair of straight portions 744 extending parallel to each other in the axial direction, and has bent portions 745 extending in a direction orthogonal to the axial direction at one ends on both sides in the axial direction.
  • the coil module 740A has a structure formed in a substantially L shape as a whole.
  • the partial winding 741A includes a pair of intermediate conductors 746 provided in parallel and linearly with each other, a first crossover 747 that connects the pair of intermediate conductors 746 on one end side in the axial direction, and a pair of intermediate conductors 746.
  • the pair of intermediate conductors 746 are provided so as to be separated by a predetermined coil pitch, and the intermediate conductors 746 of the partial winding 741 of the other phase can be arranged between the pair of intermediate conductors 746 in the circumferential direction. It has become.
  • the pair of intermediate conductors 746 are provided so as to be separated by two coil pitches, and the intermediate conductors 746 of the other two-phase partial windings 741 are arranged one by one between the pair of intermediate conductors 746. It has a structure of
  • the first crossover portion 747 and the second crossover portion 748 are provided as portions corresponding to the coil ends CE1 and CE2 (see FIG. 85), respectively. That is, these crossover portions 747 and 748 are provided as coil end conductor portions that connect the intermediate conductor portions 746 of the same phase at two positions different in the circumferential direction in the coil ends CE1 and CE2.
  • the first crossover portion 747 is a portion corresponding to the bent portion 745 in the coil module 740A, and is bent in a direction orthogonal to the intermediate conductor portion 746, that is, in a direction orthogonal to the axial direction. It is provided as.
  • the second crossover portion 748 is provided so as to extend in the same direction as the intermediate conductor portion 746 on the inner side in the axial direction, that is, linearly in the axial direction.
  • the partial winding 741A has a structure formed in a substantially L shape as a whole.
  • the boundary portion BD between the coil side CS and the coil ends CE1 and CE2 is shown by a broken line.
  • an outer bending portion Y1 that is bent outward in the radial direction is provided at the first crossing portion 747 (the first crossing portion 747 on the coil end CE1 side in the partial winding 741A).
  • the partial winding 741A has a configuration in which an outer bent portion Y1 is provided on the coil end CE1 side and is not bent in the radial direction on the coil end CE2 side.
  • the partial winding 741A is formed by winding the conducting wires 743 in multiple directions so that the cross section has a quadrangular shape.
  • FIG. 88A shows a cross section of the coil module 740A at the intermediate conducting wire portion 746, and the conducting wires 743 are multiplely wound around the intermediate conducting wire portion 746 so as to be aligned in the circumferential direction and the radial direction.
  • the circumferential length on the outer diameter side and the circumferential length on the inner diameter side are the same.
  • the conducting wires 743 are wound in multiple directions so as to be aligned in the axial direction and the radial direction.
  • the partial winding 741A is formed by winding the conducting wire 743 by concentric winding.
  • the winding method of the conductor 743 is arbitrary, and instead of the concentric winding, the conductor 743 may be wound multiple times by the alpha winding.
  • the cross section of the partial winding 741A may have a substantially trapezoidal shape in which the circumferential length on the outer diameter side is larger than the circumferential length on the inner diameter side.
  • the end of the conducting wire 743 is axially pulled out from the side of the first crossover 747, specifically from the tip of the bent portion 745, and the end thereof.
  • the portions are winding end portions 743a and 743b.
  • the winding end portions 743a and 743b are the winding start and winding end of the conducting wire 743, respectively.
  • the winding end 743a is connected to the current input / output terminal, and the winding end 743b is connected to the neutral point.
  • the partial winding 741A is preferably configured so that a higher potential is applied toward the outer side in the radial direction. That is, in the partial winding 741A, when the radial outer side and the radial inner side are compared, the distance between the pair of intermediate lead wire portions 746 becomes longer as the radial outer side increases. It is desirable that the configuration is such that a high potential is applied.
  • FIG. 99 shows the winding order of the conductor 743 in the partial winding 741A. In FIG. 99, the intermediate conductor portion 746 in the same partial winding 741A is shown by a solid line, and the intermediate conductor portion 746 in a different partial winding 741B (that is, the different phase partial winding 741B) is shown by a broken line.
  • the conducting wire 743 is wound so as to shift from the outer side in the radial direction to the inner side in the radial direction, and the winding start on the outer side in the radial direction is the winding end portion 743a. Further, the winding end on the inner side in the radial direction is the winding end portion 743b.
  • the winding end portion 743a is connected to the current input / output terminal, and the winding end portion 743b is connected to the neutral point, so that a higher potential is applied toward the outer side in the radial direction.
  • the winding order itself of the conducting wire 743 may be such that the winding start and the winding end are reversed on the radial outer side and the radial inner side.
  • the separation distance between the intermediate conducting wire portions 746 of the different phases adjacent to each other in the circumferential direction is different between the radial outer side and the radial inner side.
  • K1 the separation distance on the outer side in the radial direction
  • K1 the separation distance on the inner side in the radial direction
  • K1> K2 the separation distance between the intermediate conducting wire portions 746 of the different phases adjacent to each other in the circumferential direction.
  • the winding holder 742A has a bobbin shape and is made of an insulating material such as synthetic resin. Like the partial winding 741A, the winding holder 742A has a structure formed in a substantially L shape as a whole, and a portion provided along the intermediate conductor portion 746 of the partial winding 741A and each crossover portion 747. , 748.
  • the winding holder 742A is provided so as to surround the partial winding 741A from three sides in the cross section of the partial winding 741A, and is a first wall on the stator core 732 side. It has a portion 751, a second wall portion 752 on the anti-stator core side, and a third wall portion 753 connecting the first wall portion 751 and the second wall portion 752.
  • the first wall portion 751 corresponds to the back yoke side insulating wall
  • the second wall portion 752 corresponds to the anti-back yoke side insulating wall
  • the third wall portion 753 corresponds to the circumferential insulating wall.
  • the third wall portion 753 is provided on the inner side in the circumferential direction in a pair of straight line portions 744 arranged in the circumferential direction.
  • the third wall portion 753 is provided so as to extend toward the center of the circle of the stator core 732.
  • the winding holder 742A has an accommodating portion 754 formed by the first to third wall portions 751 to 753, and the partial winding 741A is provided in a state of being accommodating in the accommodating portion 754.
  • the partial winding 741A is insulated by the wall portions 751 to 753 on the stator core 732 side, the anti-stator core side, and one side in the circumferential direction. That is, the first wall portion 751 insulates the intermediate conductor portion 746 from the stator core 732.
  • the second wall portion 752 covers the intermediate conductor portion 746 so as not to be exposed to the rotor 710 side (air gap side).
  • the third wall portion 753 insulates the intermediate conductor portions 746 from each other in the circumferential direction.
  • the thickness dimension of the first wall portion 751 in the wall thickness direction (radial direction) is T11
  • the thickness dimension of the second wall portion 752 in the wall thickness direction (radial direction) is T12, the third.
  • the thickness dimension of the wall portion 753 in the wall thickness direction (circumferential direction) is T13
  • the thickness dimension T12 of the second wall portion 752 is smaller than the thickness dimension T11 of the first wall portion 751 ( T11> T12). That is, the second wall portion 752 is an insulating wall on the magnet 722 side (air gap side), and the thin insulating wall reduces the distance between the magnet 722 and the partial winding 741, specifically, the distance on the magnetic circuit.
  • T11> T12 by making the thickness dimension T11 of the first wall portion 751 thicker and thinning the thickness dimension T12 of the second wall portion 752 as compared with the configuration of FIG. 88 (a). The configuration is shown.
  • the insulation distance between the first wall portion 751 and the stator core 732 can be secured, and the insulation performance thereof can be improved. it can.
  • T11 T12 may be used.
  • the thickness dimension T13 of the third wall portion 753 may be the same as, for example, the thickness dimension T11 of the first wall portion 751. However, T13> T11 or T13 ⁇ T11 may be satisfied.
  • the thickness dimension T13 is made different at each position of the radial inner side and the radial outer side so that the thickness dimension T13 is larger on the radial outer side.
  • the third wall portion 753 has a tapered cross section that is wider toward the outer side in the radial direction.
  • the thickness dimension T13 of the third wall portion 753 is set to be larger on the radial outer side than on the radial inner side, so that the circumferential length differs between the radial inner side and the radial outer side. It is possible to appropriately arrange each intermediate lead wire portion 746 arranged in the circumferential direction while taking into consideration the above.
  • the thickness dimension T13 of the third wall portion 753 is made uniform in the radial direction, when the cross section of the partial winding 741A is made into a quadrangular shape, the two intermediate conductor portions 746 adjacent to each other in the circumferential direction are formed.
  • the side of the third wall portion 753 is too close, and the opposite side is too far away. Therefore, there is a concern that the rotating magnetic flux becomes uneven in the circumferential direction.
  • the rotational magnetic flux can be equalized in the circumferential direction. In addition, it is possible to make the insulation performance uniform in the circumferential direction.
  • the intermediate conductor portion 746 (partial winding 741A) is positioned. It is also suitable for fixing and fixing.
  • the first wall portion 751 is the wall portion (the wall portion on the inner side in the axial direction) opposite to the bent portion 745, and is the first wall portion.
  • the two wall portion 752 is a wall portion (a wall portion on the outer side in the axial direction) on the bent portion 745 side.
  • the partial winding 741A is provided in the accommodating portion 754 in a state of being in contact with or close to each of the wall portions 751 to 753 on three sides, and is opposite to the third wall portion 753 in the circumferential direction, and the first wall portion 751 and It is arranged in an area inside the end of the second wall portion 752. That is, in the winding holder 742A, the third wall portion 753 is provided on one side of both sides of the intermediate conductor portion 746 in the first wall portion 751 and the second wall portion 752 in the circumferential direction, and the other side is provided with the third wall portion 753. Protruding portions 751a and 752a protruding in the circumferential direction from the intermediate conductor portion 746 are provided.
  • the protruding portions 751a and 752a are surplus portions that are surplus in the circumferential direction with respect to the partial winding 741A.
  • an empty area SZ in which the partial winding 741A is not accommodated is provided on one side in the circumferential direction in the accommodating portion 754.
  • the free area SZ prevents the partial winding 741A in the accommodating portion 754 from protruding outside the winding holder 742.
  • first wall portion 751 and the second wall portion 752 have extension portions extending in the circumferential direction from the intermediate conductor portion 746 on both sides of the intermediate conductor portion 746 of the partial winding 741A in the circumferential direction.
  • a third wall portion 753 extending in the radial direction from the first wall portion 751 and the second wall portion 752 is provided on one side of the extension portions on both sides in the circumferential direction.
  • protruding portions 751a and 752a are provided on one side of the extension portions on both sides in the circumferential direction.
  • a resin material is filled in the accommodating portion 754 as an insulating material, and the partial winding 741A is accommodated in a state of being molded by the resin material.
  • the resin layer 755 is formed on the opposite side of the third wall portion 753 with the intermediate conductor portion 746 sandwiched in the accommodating portion 754.
  • the resin material also enters the gap between the conductors 743 of the partial winding 741A, so that in the partial winding 741A, the multiplely wound conductors 743 are close to each other using the mold resin as a bonding material. It is joined.
  • the conductors 743 in the partial winding 741A can be maintained in a desired proximity state because the adjacent conductors 743 that are wound multiple times in the partial winding 741A are joined to each other by a joining material. .. That is, the state of multiple windings in the partial winding 741A can be maintained in a desired state.
  • the resin layer 755 Similar to the third wall portion 753, the resin layer 755 has different thickness dimensions (circumferential dimensions) at each position of the radial inner side and the radial outer side, and the radial outer side has a larger circumferential dimension. It is preferable that the configuration is as follows (see FIG. 100).
  • the distance between the intermediate conductors 746 of the different phases adjacent to each other in the circumferential direction is different between the outer side in the radial direction and the inner side in the radial direction.
  • the intermediate conductor portions 746 that are lined up in the circumferential direction taking into consideration that the circumferential length is different between the inner side in the radial direction and the outer side in the radial direction.
  • the third wall portion 753 and the resin layer 755 correspond to the insulating portion in the circumferential direction.
  • the partial winding 741A may be hardened by impregnating the housing portion 754 with an adhesive containing varnish. Further, both the resin mold and the impregnation of the varnish may be performed. Further, when the conducting wire 743 is a coated conducting wire whose conductor is covered with an insulating coating, the conducting wires 743 may be fixed (bonded) to each other by self-welding of the insulating coating. However, the accommodating portion 754 may not be filled with a resin material or the like, that is, an empty area SZ may be provided as a space area.
  • the coil module 740A is assembled to the tubular stator core 732 from the outside in the radial direction, and the first wall portion 751 on the stator core 732 side has the same curvature as the outer peripheral surface of the stator core 732. It is formed on an arcuate surface. As a result, the adhesion of the coil module 740A to the stator core 732 is enhanced.
  • the second wall portion 752 on the anti-stator core side may be linear or arcuate, but in this example, it is formed in an arc shape concentric with the first wall portion 751. ..
  • the coil module 740A is assembled to the stator core 732 with the bent portion 745 radially outward, and the bent portion 745 is provided on the side of the second wall portion 752 (that is, the opposite side of the first wall portion 751). Have. Further, in this case, the circumferential distance including the two second wall portions 752 in the pair of straight portions 744 is longer than the circumferential distance including the two first wall portions 751, and the longer circumferential distance thereof.
  • a bent portion 745 having the same dimensions as the above and which is outward in the radial direction is provided.
  • the side opposite to the bent portion 745 that is, Protruding portions 756 projecting inward in the radial direction (on the stator core 732 side) are provided at two upper and lower positions.
  • the coil end CE1 on the first crossover 747 side and the protruding portion 756 are provided at a position outside the boundary portion BD in the axial direction, and the coil end CE2 on the second crossover 748 side.
  • the protruding portion 756 is provided at a position outside the boundary portion BD in the axial direction.
  • the first wall portion 751 has a portion (yoke outer portion) extending axially outward from the axial end face of the stator core 732, and the stator core is in that portion.
  • a protruding portion 756 projecting toward the stator core 732 side from the surface facing the 732 in the circumferential direction is integrally molded.
  • the protrusion 756 is formed at the same time as the first wall portion 751 by, for example, injection molding of a resin material.
  • the protruding portion 756 is provided so as to protrude from the first wall portion 751 on the stator core 732 side.
  • the protruding portion 756 is configured to have an inclined surface 756a that is inclined to one side in the range from one end in the circumferential direction to the other end in the circumferential direction of the first wall portion 751.
  • the protruding portion 756 is formed so that the inner end portion (inside in the circumferential direction) of the first wall portion 751 becomes higher in the pair of left and right straight portions 744.
  • the protruding portion 756 is formed so that the outer end portion (outside in the circumferential direction) of the first wall portion 751 is raised in the pair of left and right straight portions 744. Good.
  • the direction in which the bent portion 745 extends in the radial direction is different from that of the coil module 740A, and although there is a difference in the configuration due to this, the basic configuration is the same as that of the coil module 740A. The differences from the 740A will be mainly described.
  • FIG. 89A is a perspective view of the coil module 740B
  • FIG. 89B is a side view of the coil module 740B
  • 90 (a) and 90 (b) are cross-sectional views showing a cross section of the coil module 740B
  • FIG. 90 (a) is a cross-sectional view taken along the line 90A-90A of FIG. 89 (b) and FIG. 90 (b).
  • the left side of the coil module 740B is the stator core 732 side
  • FIGS. 90 (a) and 90 (b) the lower side of the coil module 740B is the stator core 732 side.
  • the coil module 740B has a partial winding 741B formed by multiple winding of the conducting wire 743, and an insulating winding holder 742B integrally provided with the partial winding 741B. Further, the coil module 740B has a pair of straight portions 744 extending parallel to each other in the axial direction, and has bent portions 745 extending in a direction orthogonal to the axial direction on one end side on both sides in the axial direction as a whole. It has a structure formed in a substantially L shape.
  • the configuration of the partial winding 741B is basically the same as that of the partial winding 741A. That is, the partial winding 741B is the same as the partial winding 741A, and has a first crossover that connects a pair of intermediate conductors 746 provided in parallel and linearly with each other and a pair of intermediate conductors 746 on one end side in the axial direction. It has a second crossing portion 748 that connects the portion 747 and the pair of intermediate conductor portions 746 on the other end side in the axial direction, and the pair of intermediate conductor portions 746, the first crossing portion 747, and the second crossing portion 748. It is formed in a ring shape.
  • the coil module 740A and the coil module 740B have different extending directions of the bent portion 745 when assembled to the stator core 732, and the axial directions are opposite to each other. As a result, the coil modules 740A and 740B have different configurations.
  • the first crossover 747 (the first crossover 747 on the coil end CE2 side in the partial winding 741B) is provided with an inwardly bent portion Y2 that is bent inward in the radial direction.
  • the partial winding 741B has an inwardly bent portion Y2 provided on the coil end CE2 side and is not bent in the radial direction on the coil end CE1 side.
  • the winding end portions 743a and 743b are pulled out from the side of the second crossover portion 748, specifically from the tip opposite to the bending portion 745.
  • the winding end portions 743a and 743b are pulled out on the same side in the axial direction (coil end CE1 side).
  • the winding holder 742B has a first wall portion 751 on the stator core 732 side and a first wall portion 751 on the anti-stator core side, similarly to the configuration of the winding holder 742A. It has two wall portions 752 and a third wall portion 753 connecting the first wall portion 751 and the second wall portion 752. Further, in the winding holder 742B, unlike the configuration of the winding holder 742A, in the pair of straight portions 744, the first wall portion 751 becomes the wall portion on the bent portion 745 side (the wall portion on the inner side in the axial direction), and the second wall portion 751 becomes a wall portion on the inner side in the axial direction.
  • the wall portion 752 is a wall portion (a wall portion on the outer side in the axial direction) on the opposite side of the bent portion 745.
  • the coil module 740B is assembled to the stator core 732 with the bent portion 745 inside in the radial direction, and has the bent portion 745 on the side of the first wall portion 751.
  • the circumferential distance including the two first wall portions 751 in the pair of straight portions 744 is shorter than the circumferential distance including the two second wall portions 752, and the shorter circumferential distance and the circumferential distance.
  • a bent portion 745 having the same dimensions and being inward in the radial direction is provided.
  • the bent portion 745 side that is, the inside in the radial direction is located near the boundary portion BD between the coil side CS and the coil ends CE1 and CE2.
  • Protruding portions 756 protruding toward (the stator core 732 side) are provided at two upper and lower positions.
  • the protruding portion 756 is provided at the coil end CE2 on the first crossover portion 747 side and at a position outside the boundary portion BD in the axial direction, and the coil end on the second crossover portion 748 side. It is CE1 and is provided at a position outside the boundary portion BD in the axial direction.
  • the configuration of the protrusion 756 is also the same as that of the winding holder 742A (see FIG. 90B).
  • the manufacturing method of the coil module 740 will be described.
  • the method of manufacturing the coil module 740A will be described, but the same applies to the coil module 740B.
  • the partial winding 741A is manufactured as an air-core winding coil.
  • the conducting wire 743 is wound in multiple directions using a jig to produce a partial winding 741A having the shape shown in FIG. 87 (b) as an air-core winding coil.
  • the winding holder 742A is assembled to the partial winding 741A.
  • the winding holder 742A may be individually assembled to the partial winding 741A in a state of being divided into a plurality of parts. It is preferable that the winding holder 742A can be divided into two or three in the radial direction or the axial direction.
  • the coil module 740A by winding the lead wire 743 multiple times around the winding holder 742A.
  • a protrusion or a groove for guiding the conducting wire 743 may be provided on the inner peripheral surface of the accommodating portion 754 accommodating the partial winding 741A. It may be configured to be tied with the outer conductor 743 so that the partial winding 741A is not unwound.
  • the accommodating portion 754 is filled with resin.
  • the resin layer 755 is formed in the accommodating portion 754.
  • FIG. 91 is a cross-sectional view showing a vertical cross section of the stator 730
  • FIG. 92 is a cross-sectional view showing a cross section of the stator 730
  • FIG. 93 is a stator core 732 and an end ring 733 and a coil module 740A. It is sectional drawing which shows and separated from each other. Note that FIG. 92 is a cross-sectional view taken along the line 92-92 of FIG. 91.
  • the coil modules 740A and 740B are assembled to the stator core 732 so that the bending portions 745 are opposite to each other in the axial direction and the bending directions are opposite to each other in the radial direction. ing. In this case, interference between the coil modules 740A and 740B adjacent to each other in the circumferential direction is avoided depending on the position and orientation of the bent portion 745 in each coil module 740A and 740B.
  • the partial winding 741A is provided with the outer bending portion Y1 and the partial winding 741B is provided with the inner bending portion Y2, so that the partial windings 741A are adjacent to each other in the circumferential direction.
  • 741B are designed to avoid interference with each other.
  • the outer bent portion Y1 and the inner bent portion Y2 correspond to the interference avoiding portion.
  • the coil module 740B (the second crossover portion 748 of the partial winding 741B) is located outside the coil module 740A (the first crossover portion 747 of the partial winding 741A) in the axial direction. ) Is located. Further, on the coil end CE2 side, the coil module 740A (second crossing portion 748 of the partial winding 741A) is located outside the coil module 740B (first crossing portion 747 of the partial winding 741B) in the axial direction. , The partial windings 741A and 741B are arranged side by side in the circumferential direction. As a result, the partial windings 741A and 741B are appropriately arranged in the circumferential direction while avoiding mutual interference, and the physique can be reduced.
  • end rings 733 are provided at both ends in the axial direction of the stator core 732, and the end rings 733 are engaged with the upper and lower protruding portions 756, respectively.
  • Coil modules 740A and 740B are assembled to the stator core 732.
  • the protruding portions 756 of the coil modules 740A and 740B project in a state of overlapping in the axial direction with the axial end faces (upper end face and lower end face in the figure) of the stator core 732.
  • the stator core 732 is in a state of being sandwiched in the axial direction by a pair of protruding portions 756 in the coil modules 740A and 740B (that is, in a state of being pressed in the axial direction).
  • the stator core 732 is configured by laminating a plurality of core sheets 732a in the axial direction, and the stator core 732 is sandwiched by a pair of protrusions 756 in the laminating direction of the core sheets 732a. It has become.
  • the pair of projecting portions 756 function as pressing portions that press the axial end faces of the stator core 732 in the axial direction from the outside in the axial direction.
  • the laminated holding structure of the above is provided.
  • the laminated holding structure is provided at the Q position indicated by the thick broken line.
  • the core sheet 732a is joined by welding, the core sheet 732a is joined by caulking, the adhesive (including varnish) is used, and the outer cylinder member 772 (which is press-fitted inside the stator core 732 in the radial direction) is assembled. Stacking and holding due to the frictional force of the tubular member) can be considered.
  • a restraint ring 760 is attached to the outer peripheral side of the coil modules 740A and 740B. Due to the restraint of the restraint ring 760, the coil modules 740A and 740B are pressed in the direction in which the protrusion 756 engages with the end ring 733. In particular, since the restraint ring 760 is provided at a position where the end ring 733 and the protruding portion 756 overlap in the axial direction with respect to the engaging portion, the engaged state of the end ring 733 and the protruding portion 756 can be more reliably maintained. It is supposed to be done.
  • the restraint ring 760 is provided on the radial outside of the coil modules 740A and 740B, that is, on the side of the rotor 710 facing the magnet 722. Therefore, in order to avoid interference with the rotor 710 side, it is desirable that the restraint ring 760 is as thin as possible in the radial direction. Further, the coil side CS may not be provided in the axial direction, but may be provided in the coil end CE1 and CE2 regions. In this case, it is preferable that the restraint ring 760 is provided at a position within the range of the coil ends CE1 and CE2 and at a position outside the coil modules 740A and 740B in the radial direction. However, the position where the restraint ring 760 is provided and the number of restraint rings 760 are arbitrary.
  • the restraint ring 760 is attached to the outside of the second wall portion 752 of the winding holder 742. That is, the restraint ring 760 is configured to contact the winding holder 742 but not the partial winding 741. As a result, for example, even in a configuration in which a metal restraint ring 760 is used to increase the fixing strength, it is possible to suppress a decrease in the insulating property of the partial winding 741.
  • the inclined surface 756a of the protruding portion 756 is in contact with the engaging surface 734 of the end ring 733.
  • the engaging surface 734 of the end ring 733 corresponds to the first engaging portion
  • the protruding portions 756 of the coil modules 740A and 740B correspond to the second engaging portion.
  • the inclined surface 756a corresponds to the engaged surface.
  • the end ring 733 is provided with a plurality of engaging surfaces 734 continuously in the circumferential direction so that the inclination directions are staggered, and the recess 735 is provided by the two engaging surfaces 734 adjacent to each other in the circumferential direction. Is formed (see FIG. 93).
  • one protrusion 756 of each of the two coil modules 740A and 740B is inserted into the recess 735.
  • the top of the protrusion 756 reaches the bottom of the recess 735.
  • the third wall portions 753 of the coil modules 740A and 740B are in contact with each other in the circumferential direction.
  • the first wall portions 751 and the second wall portions 752 of the coil modules 740A and 740B are in contact with each other or close to each other in the circumferential direction. It is in a state.
  • the protruding portions 756 of the two coil modules 740A and 740B are guided in the circumferential direction toward each other by the two engaging surfaces 734 forming the recess 735.
  • rattling of the two partial windings 741 adjacent to each other in the circumferential direction can be suppressed, and the displacement of the stator winding 731 due to vibration or electromagnetic force can be suitably suppressed.
  • the gap between the intermediate conductors 746 can be reduced, an improvement in the space factor can be expected.
  • each of the coil modules 740A and 740B has protrusions 756 on two first wall portions 751 separated from each other in the circumferential direction, and the two protrusions 756 are inclined at the end ring 733 with respect to each other. It is in contact with two opposite engaging surfaces 734, respectively.
  • the two protrusions 756 engage with the engaging surface 734 side of the end ring 733, so that the misalignment of the coil modules 740A and 740B in the circumferential direction is less likely to occur. can do.
  • the inclined surface 756a of the protruding portion 756 comes into contact with the engaging surface 734 of the end ring 733 in a pressed state. ..
  • the coil modules 740A and 740B can be more firmly fixed to the stator core 732.
  • the partial windings 741 housed in the accommodating portion 754 are separated from each other by a predetermined interval in the circumferential direction. It is placed in position. More specifically, the peripherally adjacent partial windings 741 are isolated from each other by the third wall portion 753 of the winding holder 742, or by the free space SZ in the accommodating portion 754 of the winding holder 742. Has been done. As a result, the insulation between the partial windings 741 having different phases adjacent to each other in the circumferential direction is ensured.
  • Two third wall portions 753 are interposed between the partial windings 741 of different phases adjacent to each other in the circumferential direction. In this case, by stacking two third wall portions 753, the insulating property of the stator winding 731 is further enhanced.
  • two free areas SZ are interposed between the partial windings 741 of different phases adjacent to each other in the circumferential direction. In this case, the free areas SZ in the accommodating portion 754 are continuous in the circumferential direction, and moreover, the free areas SZ are resin-molded, so that the insulation property of the stator winding 731 is further enhanced. ing.
  • the third wall portion 753 of the different winding holder 742 is continuously provided in the circumferential direction between the intermediate conductor portions 746 adjacent to each other in the circumferential direction, or the different winding holder 742 protrudes.
  • the portions 751a and 752a are continuously provided in the circumferential direction.
  • the thickness dimension T13 of the third wall portion 753 is the thickness of the first wall portion 751. It should be larger than the dimension T11. That is, it is preferable that 2 ⁇ T13> T11. In this case, even if a larger potential difference occurs between the intermediate conductors 746s arranged in the circumferential direction than between the stator core 732 and the intermediate conductors 746, appropriate interphase insulation is performed.
  • the first wall portion 751 and the second wall portion 752 have the third wall portion 753 on one of the circumferential directions of the intermediate conductor portions 746 of the partial windings 741A and 741B, and the other.
  • the protruding portions 751a and 752a are provided on the side. Further, in the first wall portion 751 and the second wall portion 752, the portion to which the third wall portion 753 is connected and the protruding portions 751a and 752a correspond to extension portions extending in the circumferential direction from the intermediate conductor portion 746, respectively.
  • Extensions of different coil modules 740A and 740B are provided so as to face each other in the circumferential direction between the intermediate conductors 746 that are adjacent to each other in the circumferential direction.
  • the intermediate conductor portions 746 adjacent to each other in the circumferential direction are separated from each other by the extension portion of the first wall portion 751 in the coil modules 740A and 740B, so that mutual insulation is ensured.
  • interphase insulation in the circumferential direction can be suitably realized.
  • the third wall portions 753 of the different coil modules 740A and 740B are provided in a state of facing each other in the circumferential direction on one side in the circumferential direction of each of the intermediate conductor portions 746 arranged in the circumferential direction, and in the circumferential direction.
  • the third wall portion 753 is absent and separated by the protruding portions 751a and 752a.
  • one first wall portion 751 is provided between the stator cores 732 arranged in the radial direction and the intermediate conductor portion 746, while the two first wall portions 746 are provided between the intermediate conductor portions 746 arranged in the circumferential direction.
  • the protruding portions 756 and the end ring 733 of the coil modules 740A and 740B may be fixed to each other by an adhesive such as varnish. Further, rattling may be suppressed by filling a synthetic resin or varnish between the protruding portion 756 of the coil modules 740A and 740B and the end ring 733.
  • the plurality of partial windings 741A and 741B have the same conductor cross-sectional area in the state of multiple winding and the number of multiple windings.
  • the interlinkage magnetic flux of each of the partial windings 741A and 741B constituting the parallel circuit can be made uniform.
  • the mutual potential difference between the partial windings 741A and 741B can be eliminated, and the generation of circulating current in the parallel circuit can be suppressed.
  • the interlinkage magnetic flux can be made uniform including the leakage flux at the coil ends CE1 and CE2.
  • the potential difference between the partial windings 741A and 741B can be eliminated, and the circulating current in the parallel circuit can be suppressed.
  • the stator 730 may use any of the following (A) to (C).
  • the saturation magnetic flux density of the conductor-to-conductor member is Bs
  • the width dimension of the magnet 722 at one magnetic pole in the circumferential direction is Wm
  • the residual magnetic flux density of the magnet 722 is Br
  • the magnetic relationship is Wt ⁇ Bs ⁇ Wm ⁇ Br.
  • the material is used.
  • stator 730 In the stator 730, a conductor-to-conductor member is provided between each conductor portion (intermediate conductor portion 746) in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
  • the stator 730 has a configuration in which no interconductor member is provided between each conductor portion (intermediate conductor portion 746) in the circumferential direction.
  • FIG. 95 shows a state in which bearings 791 and 792 that support the rotating shaft 701 are assembled to the inner unit 770.
  • the bearing 791 will also be referred to as a first bearing 791
  • the bearing 792 will also be referred to as a second bearing 792.
  • the first bearing 791 is a bearing provided on the base end side in the axial direction of the rotating shaft 701, that is, on the connecting shaft 705 side
  • the second bearing 792 is a bearing provided on the tip end side of the rotating shaft 701.
  • the inner unit 770 has an inner housing 771.
  • the inner housing 771 has a cylindrical outer cylinder member 772, and an inner cylinder member 773 having an outer peripheral diameter smaller than that of the outer cylinder member 772 and arranged inside the outer cylinder member 772 in the radial direction. It has a substantially disk-shaped end plate 774 fixed to one end side in the axial direction of the outer cylinder member 772 and the inner cylinder member 773.
  • Each of these members 772 to 774 is preferably made of a conductive material, for example, made of carbon fiber reinforced plastic (CFRP).
  • CFRP carbon fiber reinforced plastic
  • the outer cylinder member 772 and the end plate 774 have the same external dimensions, and the inner cylinder member 773 is provided in the space formed by the outer cylinder member 772 and the end plate 774.
  • the inner cylinder member 773 is fixed to the outer cylinder member 772 and the end plate 774 by fasteners 775 such as bolts, respectively.
  • the stator core 732 is fixed to the radial outer side of the outer cylinder member 772 of the inner housing 771. As a result, the stator 730 and the inner unit 770 are integrated.
  • a refrigerant passage 777 for circulating a refrigerant such as cooling water is formed between the outer cylinder member 772 and the inner cylinder member 773.
  • the refrigerant passage 777 is provided in an annular shape in the circumferential direction of the inner housing 771.
  • a refrigerant pipe is connected to the refrigerant passage 777, and the refrigerant flowing from the refrigerant pipe exchanges heat in the refrigerant passage 777 and then flows out to the refrigerant pipe again.
  • An annular space is formed inside the inner cylinder member 773 in the radial direction, and it is preferable that, for example, an electric component constituting an inverter as a power converter is arranged in the annular space.
  • the electric component is, for example, an electric module in which a semiconductor switching element or a capacitor is packaged.
  • the outer cylinder member 772 has a cylindrical boss portion 780 radially inside the inner cylinder member 773.
  • the boss portion 780 is provided in a hollow tubular shape, and the rotating shaft 701 is inserted into the hollow portion.
  • the boss portion 780 is a bearing holding portion that holds the bearings 791 and 792, and the bearings 791 and 792 are fixed to the hollow portion thereof (see FIG. 95).
  • the bearings 791 and 792 are, for example, radial ball bearings having a tubular inner ring, a tubular outer ring arranged radially outside the inner ring, and a plurality of balls arranged between the inner ring and the outer ring.
  • the outer ring is fixed to the boss portion 780 and is assembled to the inner unit 770.
  • the hollow portion of the boss portion 780 is provided with a first fixing portion 781 for fixing the first bearing 791 and a second fixing portion 782 for fixing the second bearing 792.
  • the first bearing 791 and the second bearing 792 have different physiques depending on the support position on the rotary shaft 701 in consideration of the vibration and the centrifugal load of the rotor 710, and support the proximal end side of the rotary shaft 701.
  • 1 Bearing 791 is a bearing having a larger size, that is, a bearing having a larger bearing load. Therefore, the first fixed portion 781 is formed to have a larger diameter than the second fixed portion 782.
  • the first bearing 791 Comparing the first bearing 791 and the second bearing 792, the first bearing 791 has a larger radial internal gap, that is, a radial gap than the second bearing 792.
  • the radial gap is the amount of play in the axial direction between the inner ring, the outer ring, and the ball of the bearing.
  • the first bearing 791 is a bearing that is more susceptible to vibration and centrifugal load of the rotor 710 than the second bearing 792, and by increasing the radial gap of the first bearing 791, the effect of load absorption can be obtained. Can be enhanced. 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 end side of the rotating shaft 701 is suppressed.
  • the first fixed portion 781 is formed by a parallel surface 781a parallel to the axial direction and an orthogonal surface 781b orthogonal to the axial direction in the boss portion 780, and the first bearing 791 is in contact with each of these surfaces. It is fixed.
  • the second fixed portion 782 is formed by a parallel surface 782a parallel to the axial direction and an orthogonal surface 782b orthogonal to the axial direction in the boss portion 780, and the second bearing is in contact with each of these surfaces. 792 is fixed.
  • a third fixing portion 783 for fixing the resolver 800 as a rotation sensor is provided on the side of the second fixing portion 782 of the first fixing portion 781 and the second fixing portion 782.
  • the third fixed portion 783 is formed by expanding the diameter of the second fixed portion 782 in a stepped shape.
  • the resolver 800 includes a resolver rotor 801 fixed to a rotating shaft 701 and a resolver stator 802 arranged so as to face each other on the radial outer side of the resolver rotor 801.
  • the resolver rotor 801 has a disk ring shape, and is provided coaxially with the rotating shaft 701 in a state where the rotating shaft 701 is inserted.
  • the resolver stator 802 has a stator core and a stator coil (not shown), and is fixed to a third fixing portion 783 of the boss portion 780.
  • the hollow portion of the boss portion 780 has a diameter smaller than that of each of the fixed portions 781 and 782 at a position between the first fixed portion 781 and the second fixed portion 782 in the axial direction.
  • Diameter portions 784 and 785 are provided.
  • the reduced diameter portion 784 is a hole having a smaller diameter than the first fixed portion 781
  • the reduced diameter portion 785 is a hole having a smaller diameter than the second fixed portion 782.
  • the third fixing portion 783 for fixing the resolver 800 is wider than the second fixing portion 782 at a position outside the second fixing portion 782 in the axial direction, in other words, at a position at the tip end side of the rotating shaft 701. It is provided as a diameterd part.
  • the second fixed portion 782 and the third fixed portion 783 are provided at positions adjacent to each other in the axial direction.
  • the second fixing portion 782 and the third fixing portion 783 can be continuously machined coaxially from the same direction. Therefore, the coaxiality between the second bearing 792 fixed to the second fixed portion 782 and the resolver stator 802 fixed to the third fixed portion 783 is increased, and the coaxiality between the resolver rotor 801 and the resolver stator 802 is increased. Will be. In this case, the runout of the resolver stator 802 with respect to the resolver rotor 801 is reduced, and the angle detection error in the resolver 800 is reduced.
  • the bus bar module 810 is electrically connected to the partial winding 741 of each coil module 740 in the stator winding 731, and one end of the partial winding 741 of each phase is connected in parallel for each phase, and each of these partial windings is connected in parallel. It is a winding connecting member that connects the other end of 741 at a neutral point.
  • FIG. 96 is a perspective view of the bus bar module 810
  • FIG. 97 is a cross-sectional view showing a part of a vertical cross section of the bus bar module 810.
  • the bus bar module 810 is connected to an annular portion 811 forming an annular shape, a plurality of connection terminals 812 extending from the annular portion 811, three input / output terminals 813 provided for each phase winding, and a current sensor for each phase. It has a current detection terminal 814.
  • the annular portion 811 is formed in an annular shape by, for example, an insulating member such as a resin, and a plurality of bus bars 821 to 824 are provided in a state of being embedded therein.
  • Each bus bar 821 to 824 is composed of a U-phase bus bar 821, a V-phase bus bar 822, a W-phase bus bar 823, and a neutral point bus bar 824 so that the plate surfaces face each other. They are arranged side by side in the axial direction.
  • the connection terminals 812 are connected to the bus bars 821 to 824 so as to project radially outward from the annular portion 811.
  • the connection terminals 812 are provided so as to be arranged in the circumferential direction of the annular portion 811 and to extend in the axial direction on the outer side in the radial direction.
  • FIG. 98 shows the connection positions of the connection terminals 812 for each bus bar 821 to 824 as a schematic diagram.
  • the left-right direction corresponds to the circumferential direction of the annular portion 811.
  • U indicates a connection terminal 812 connected to the U-phase winding
  • V indicates a connection terminal 812 connected to the V-phase winding
  • W indicates a connection terminal connected to the W-phase winding.
  • 812 is indicated
  • NE indicates a connection terminal 812 connected to the neutral point.
  • connection terminals 812 (NE) connected to the neutral point are arranged every other in the circumferential direction, and the connection terminals 812 (U), V connected to the U-phase winding are in between.
  • a connection terminal 812 (V) connected to the phase winding and a connection terminal 812 (W) connected to the W phase winding are arranged one by one.
  • These connection terminals 812 are provided in the same number as the winding ends 743a and 743b of each partial winding 741 in the coil module 740, and the connection terminals 812 and the winding ends 743a and 743b are connected one by one. It has become so.
  • connection terminal 812 and the winding end portions 743a and 743b is bent or curved in the radial direction and is brought into contact with each other as necessary, and in the contact state, joining by welding, adhesion or the like is performed. It should be done.
  • the annular portion 811 has a plurality of fixed portions 815 on the inner peripheral side, and by assembling fasteners such as bolts to the fixed portion 815, the bus bar module is attached to the end plate 774 of the inner housing 771.
  • the 810 is fixed.
  • the input / output terminals 813 are input / output terminals 813U for U phase, input / output terminals 813V for V phase, and input / output terminals 813W for W phase, and these are bus bars 821 to 823 for each phase in the annular portion 811. Are each connected to. Through each of these input / output terminals 813, power is input / output from an inverter (not shown) to the phase windings of each phase of the stator winding 731.
  • the annular portion 811 is provided with a current sensor 816 for each phase, and the detection result of the current sensor 816 is output to a control device (not shown) through the current detection terminal 814.
  • the partial winding 741 is configured by winding the conducting wire 743 multiple times between the conducting wires having the same phase provided apart from each other in the circumferential direction. Further, the phase windings of each phase are configured by connecting a plurality of partial windings 741 in parallel.
  • the cross-sectional area of the stator winding 731 can be subdivided, the occurrence of copper vortex loss can be suppressed, and the motor efficiency and the thermal rating performance can be improved.
  • the number of poles of the magnetic poles is P and the number of partial windings 741A and the number of partial windings 741B per phase are N
  • the number of poles P is 4 ⁇ N
  • N partial windings 741A and N partial windings 741B are all connected in parallel for each phase.
  • the number (N) of the partial windings 741A and 741B per phase is 6, and the number of poles P is 24, respectively.
  • FIG. 84 shows a coil module 740 of one of the three phases, as a coil module 740A having a partial winding 741A, as a coil module 740A having six coil modules 740A, and as a coil module 740B having a partial winding 741B.
  • Six coil modules 740B are shown. In each phase winding, six partial windings 741A and six partial windings 741B are all connected in parallel for each phase.
  • the number of parallel windings 741 is 12 in each case.
  • the number of parallel windings 741 is 12 in each case.
  • FIG. 101 is a vertical cross-sectional view of the inner rotor type rotary electric machine 900
  • FIG. 102 is a horizontal vertical cross-sectional view of the rotary electric machine 900
  • FIG. 103 is a cross section showing a part of the configuration shown in FIG. 102 in an enlarged manner. It is a top view.
  • the rotary electric machine 900 has a rotor 910 provided so as to be rotatable integrally with the rotary shaft 901, and a stator 920 provided on the radial outer side of the rotor 910. An air gap is formed between the rotor 910 and the stator 920 in the radial direction.
  • the rotary shaft 901 is rotatably supported by bearings (not shown) as in the above-described configuration.
  • the rotor 910 corresponds to the "field magnet” and the stator 920 corresponds to the "armature”.
  • the rotor 910 has a rotor carrier 911 formed in a hollow tubular shape and an annular magnet unit 912 fixed to the outside in the radial direction of the rotor carrier 911.
  • the rotor carrier 911 is fixed to the rotating shaft 901 and has a function as a magnet holding member.
  • the magnet unit 912 has a plurality of magnetic poles having alternating polarities in the circumferential direction of the rotor 910.
  • the magnet unit 912 corresponds to the "magnet portion".
  • the magnet unit 912 has a plurality of magnets 913 (permanent magnets) arranged side by side in the circumferential direction, and a plurality of magnetic poles having polarities alternating in the circumferential direction due to each of the magnets 913. Is formed.
  • the magnet 913 is a sintered neodymium magnet having an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more.
  • each magnet 913 the stator 920 side (upper side in the figure) of both sides in the radial direction is the magnetic flux acting surface 913a, and the magnetic flux is concentrated in the region near the d-axis which is the center of the magnetic pole on the magnetic flux acting surface 913a. Is to occur.
  • each magnet 913 is a polar anisotropy magnet, and the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the side of the q-axis, which is the magnetic pole boundary. It is configured so that it is oriented so as to be.
  • the direction of the easy-to-magnetize axis is different between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis), and the direction of the easy-to-magnetize axis is parallel to the d-axis on the d-axis side.
  • the direction of the easy-to-magnetize axis is close to the direction orthogonal to the q-axis. Then, an arcuate magnet magnetic path is formed by the orientation according to the direction of the easily magnetized axis.
  • the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side, and the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side.
  • the direction of the easy-magnetizing axis is oblique to the d-axis between the magnetic flux acting surfaces on both sides in the radial direction, the stator 920 side approaches the d-axis in the circumferential direction, and the d-axis is on the anti-stator side. It may be linearly oriented so as to be oriented away from. Even with this configuration, magnetic flux can be intensively generated in the region near the d-axis on the magnetic flux acting surface 913a on the stator 920 side of the magnet 913.
  • the configuration of the magnet 913 can be changed to other than the above.
  • a radial anisotropy permanent magnet whose magnetization direction is the radial direction and a parallel anisotropy permanent magnet whose magnetization direction is parallel can be changed. It is also possible to use.
  • the rotor 910 may have an embedded magnet type rotor structure in addition to the surface magnet type rotor structure.
  • the stator 920 has a multi-phase stator winding 921 and a stator core 922 integrally provided with the stator winding 921.
  • the stator core 922 is configured as a core sheet laminate in which a plurality of core sheets made of electrical steel sheets are laminated in the axial direction.
  • the stator core 922 has a cylindrical yoke 923 and a plurality of teeth 924 provided at predetermined intervals in the circumferential direction inside the yoke 923 in the radial direction, and is provided between the teeth 924 in the radial direction.
  • a slot 925 extending into is formed.
  • the slots 925 are formed in a substantially rectangular shape having a longitudinal direction in the radial direction, and each slot 925 opens inward in the radial direction.
  • the stator winding 921 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction.
  • the stator winding 921 has a configuration having three-phase phase windings.
  • the stator 920 has a portion corresponding to a coil side CS that faces the magnet unit 912 in the rotor 910 in the axial direction in the axial direction, and a coil end that is outside the coil side CS in the axial direction. It has a part corresponding to CE.
  • the stator core 922 is provided in a range corresponding to the coil side CS in the axial direction.
  • the coil end CE is a portion axially outside of the axial end face of the stator core 922.
  • the phase winding of each phase has two types of partial windings 931 having different coil end shapes.
  • the partial winding 931 is an annular coil formed by winding a conducting wire material in multiple directions
  • FIG. 104 (a) is a perspective view showing the configuration of a first partial winding 931A which is one partial winding 931, FIG. 104.
  • (B) is a perspective view which shows the structure of the 2nd partial winding 931B which is the other partial winding 931.
  • FIG. 105 is a side view showing the partial windings 931A and 931B side by side for comparison.
  • the partial windings 931A and 931B have different axial lengths and different end shapes on both sides in the axial direction.
  • the first partial winding 931A has a substantially C shape in the side view
  • the second partial winding 931B has a substantially I shape in the side view.
  • the first partial winding 931A is a pair of intermediate conductors 932 provided parallel to each other and linearly connected to each other and a pair of intermediate conductors 932 connected at both ends in the axial direction. It has a crossover portion 933, and is formed in an annular shape by the pair of intermediate conductor portions 932 and the pair of crossover portions 933.
  • Each intermediate conductor portion 932 is provided as a coil side conductor portion arranged in the circumferential direction in the coil side CS.
  • each crossover portion 933 is provided as a coil end lead wire portion for connecting the intermediate lead wire portions 932 having two positions different in the circumferential direction in the coil end CE.
  • the pair of crossovers 933 have the same shape on both sides in the axial direction, and both are provided as portions corresponding to the coil end CE (see FIG. 105). Each crossover 933 is provided so as to bend in a direction orthogonal to the intermediate conductor 932, that is, in a direction orthogonal to the axial direction.
  • the shape of the crossover 933 is different between the first partial winding 931A and the second partial winding 931B, and in order to clarify the distinction, the crossover 933 of the first partial winding 931A is referred to as "the first”.
  • 1 Crossover 933A ”and the crossover 933 of the second partial winding 931B are also referred to as“ second crossover 933B ”.
  • FIG. 106 is a cross-sectional view taken along the line 106-106 in FIG. 104 (a).
  • the pair of intermediate lead wire portions 932 are provided so as to be separated by a predetermined slot pitch.
  • the distance D between the centers in the circumferential direction corresponds to a three-slot pitch. That is, the distance corresponds to the slot pitch of the number of phases.
  • the slot positions between the pair of intermediate conductors 932 are shown by virtual lines. Each slot 925 between the pair of intermediate conductors 932 accommodates the intermediate conductor 932 of the other phase partial winding 931.
  • the partial winding 931 is arranged so as to straddle the three teeth 924 in the stator core 922.
  • the partial winding 931 is a centralized winding coil for all nodes, and is provided one for each phase in a one-pole pair.
  • the first partial winding 931A is formed by winding the conducting wire material CR multiple times so that the cross section of the conducting wire gathering portion becomes a quadrangle.
  • a conductor assembly having a rectangular cross section is formed by winding a conductor CR composed of flat wires having a rectangular cross section in a plurality of directions so as to be arranged in the circumferential direction and the radial direction. It is configured. That is, the first partial winding 931A is configured by winding the square wires multiple times, and the cross section of the conducting wire collecting portion, which is an aggregate of the square wires, has a quadrangular shape.
  • the pair of intermediate conductors 932 has a rectangular shape whose cross-sectional shape is the longitudinal side in the radial direction (vertical direction in the figure), and the center lines L1 and L2 of the intermediate conductors 932 are in the longitudinal direction. They are parallel to each other.
  • the tip of the first crossover 933A is configured to be multiplely wound so that the conductor CRs are aligned in the axial direction and the radial direction due to the bending in the radial direction.
  • the first partial winding 931A is configured by winding the conductor CR by concentric winding.
  • the method of winding the conductor CR is arbitrary, and instead of concentric winding, the conductor CR may be wound multiple times by alpha winding.
  • the second partial winding 931B connects a pair of intermediate conductor portions 932 provided in parallel and linearly with each other and a pair of intermediate conductor portions 932 at both ends in the axial direction. It has a pair of second crossover portions 933B, and is formed in an annular shape by the pair of intermediate conductor portions 932 and the pair of second crossover portions 933B.
  • the pair of intermediate conductors 932 in the second partial winding 931B has the same configuration as the intermediate conductor 932 of the first partial winding 931A.
  • the pair of second crossover portions 933B has a different configuration from the first crossover portion 933A of the first partial winding 931A.
  • the second crossover portion 933B of the second partial winding 931B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 932 without being bent in the radial direction.
  • the first partial winding 931A and the second partial winding 931B have the same configuration except that the coil end shape is different, and in FIG. 105, the differences between the partial windings 931A and 931B are clearly shown in comparison. There is.
  • Each partial winding 931A, 931B may be configured by covering a part or all of the partial windings with an insulating material such as synthetic resin.
  • the partial windings 931A and 931B may be integrated with an insulating winding holder as shown in FIG. 87, for example.
  • the partial windings 931A and 931B are assembled to the stator core 922 by accommodating each intermediate conductor portion 932 in the slot 925 of the stator core 922. Since each of the partial windings 931A and 931B has two types of coil end shapes, interference between the partial windings 931 adjacent to each other in the circumferential direction is suppressed.
  • the first crossing portion 933A of the first partial winding 931A is provided so as to be bent in a direction (diameter direction) orthogonal to the intermediate conductor portion 932.
  • the second crossing portion 933B of the second partial winding 931B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 932 without being bent in the radial direction.
  • the partial windings 931A and 931B are assembled to the stator core 922 in a state where the partial windings 931A and 931B partially overlap each other in the circumferential direction, but the crossover portions 933A and 933B are separated from each other in the axial direction. Interference between the crossovers 933A and 933B is avoided.
  • each of the partial windings 931A and 931B has a crossover portion 933, when the partial windings 931A and 931B are assembled to the stator core 922, the partial windings 931A and 931B are used. , Is inserted into the slot 925 from the inside in the radial direction instead of the axial direction. Further, each of the partial windings 931A and 931B has a pair of intermediate conductor portions 932, and it is desirable that each of the intermediate conductor portions 932 is accommodated in the slot 925 without causing a wasteful dead space. ..
  • the configuration for assembling the partial windings 931A and 931B to the stator core 922 will be described below.
  • FIG. 107 is a schematic view showing a configuration in which an arbitrary partial winding 931X is assembled to the stator core 922.
  • a plurality of slots 925 are formed in the stator core 922 at predetermined intervals in the circumferential direction, and two of the slots 925A and 925B are slots where the partial winding 931X is assembled.
  • Each of these slots 925A and 925B corresponds to a slot pair SP accommodating a pair of intermediate lead portions 932 of the partial winding 931X.
  • the slot 925A is referred to as "first slot 925A” and the slot 925B is referred to as "first slot 925A”.
  • Second slot 925B “.
  • the slot-to-SP is provided so as to straddle two other slots 925 for each partial winding 931.
  • the slot walls that are inside each other in the circumferential direction are referred to as an inner side wall 941
  • the slot walls that are outside each other in the circumferential direction are referred to as an outer wall 942.
  • the slots 925A and 925B are provided so that the inner side walls 941 are parallel to each other and the outer walls 942 are parallel to each other.
  • the slots 925A and 925B are parallel to each other, and the side surfaces of the pair of intermediate conductors 932 in the circumferential direction are parallel to each other. That is, the slots 925A and 925B are provided as parallel slots having a uniform width in the circumferential direction. Further, each intermediate conductor portion 932 of the partial winding 931X is provided as a parallel conductor having a uniform width in the circumferential direction.
  • a straight line passing through the circumferential center position in the range from the first slot 925A to the second slot 925B and the stator center point CP in the slot vs. SP is drawn at the first center line L11, the first slot 925A and the second slot 925B.
  • the straight line passing through each circumferential center position and parallel to the first center line L1 is defined as the second center line L12.
  • the second center lines L12 of the slots 925A and 925B are parallel to each other, and the slots 925A and 925B are provided line-symmetrically in the circumferential direction with respect to the second center line L12.
  • the first slot 925A is the left slot of the two left and right slots 925 constituting the slot vs. SP, and another slot 925 next to the first slot 925A is the right slot of the other slot vs. SP (specifically). See FIG. 108 for the arrangement of the various slots. Therefore, in each of the teeth 924 between the slots, the teeth 924 (first teeth 924A) between the two inner side walls 941 and the teeth 924 (second teeth 924B) between the two outer walls 942 alternate. It will be lined up. In this case, since the slots 925A and 925B are provided line-symmetrically in the circumferential direction with respect to the second center line L12, the sizes of the teeth 924 arranged in the circumferential direction can be equalized.
  • the shapes of the teeth 924 arranged in the circumferential direction are not uniform. That is, the stator core 922 has a first tooth 924A in which the circumferential width W11 of the base end portion on the yoke 923 side is smaller than the circumferential width W12 of the tip end portion on the anti-yoke side, and the circumferential width W11 of the base end portion.
  • the second teeth 924B which is larger than the circumferential width W12 of the tip portion, is included, and the teeth 924A and 924B are arranged alternately in the circumferential direction.
  • the circumferential width W11 of the base end portion in the first teeth 924A and the circumferential width W12 of the tip end portion in the second teeth 924B are the same.
  • the magnetic characteristics of the teeth 924A and 924B are made equal.
  • FIG. 108 is a schematic view for explaining the assembly of the partial windings 931A and 931B to each slot 925 of the stator core 922.
  • reference numerals 1 to 8 are attached to each slot 925 for the sake of assistance in explanation.
  • the 1st-4th slots, the 3rd-6th slots, and the 5th-8th slots are slot pairs SP1, SP2, SP3, respectively, and each of these slots pairs SP1 to SP3 is partially wound.
  • Lines 931A and 931B are assembled.
  • the first partial winding 931A and the second partial winding 931B the first partial winding 931A in which the crossing portion 933 is bent toward the yoke 923 side is first assembled to the slot vs. SP2, and then.
  • the second partial winding 931B is assembled to the slot pairs SP1 and SP3.
  • the partial windings 931A and 931B are preferably assembled into the slots 925A and 925B by sliding in the radial direction.
  • the first partial windings 931A are arranged side by side so that the first partial windings 931A do not overlap each other in the circumferential direction, and the second partial windings 931B have the second partial windings 931B overlapping each other in the circumferential direction. They are arranged side by side so as not to. The first partial winding 931A and the second partial winding 931B overlap each other in the circumferential direction.
  • the partial winding 931 can be assembled from the radial direction to the slot pair SP in which the pair of intermediate conductors 932 of the partial winding 931 are accommodated.
  • the inner side walls 941 and the outer wall 942 of each of the slots 925A and 925B are parallel to each other, and the yoke 923 side of each slot 925.
  • the circumferential width W1 of the above and the circumferential width W2 on the anti-yoke side are made the same.
  • the inner side walls 941 are provided so as to be separated from each other on the anti-yoke side
  • the outer walls 942 are provided so as to be close to each other on the anti-yoke side
  • the yoke 923 side in each slot 925 is provided.
  • the pair of intermediate conductors 932 do not interfere with the corners on the tip side of the teeth.
  • the pair of intermediate conductors 932 can be accommodated in the slots 925A and 925B without creating a wasteful dead space in the slot 925. That is, it is possible to accommodate the pair of intermediate conductors 932 in each slot 925 in a state of being close to the inner side wall 941 and the outer wall 942.
  • each partial winding 931 is arranged so as to straddle two or more teeth 924, and interference at the coil end portion in each partial winding 931 arranged adjacent to each other in the circumferential direction and partially overlapping.
  • the crossing portions 933 of the partial windings 931 are separated from each other in the axial direction, the partial windings 931 can be arranged without causing interference between the partial windings 931.
  • the conductor space factor in the slot 925 can be improved, and the loss of the rotary electric machine 900 can be reduced and the amount of heat generated can be suppressed.
  • the partial winding 931 is assembled to the slot vs. SP. It can be preferably realized. That is, the partial winding 931 can be suitably assembled by sliding the partial winding 931 in parallel along the first center line L11. Further, by providing the first slot 925A and the second slot 925B in line symmetry in the circumferential direction with respect to the second center line L12 parallel to the first center line L11, each teeth arranged in the circumferential direction in the stator core 922. It has an advantageous configuration for equalizing the size of the 924.
  • each slot 925 is provided as a parallel slot having a uniform width in the circumferential direction and each intermediate conductor portion 932 of the partial winding 931 is provided as a parallel conductor having a uniform width in the circumferential direction, the stator winding 921 is occupied.
  • the product ratio can be improved.
  • each slot 925 is a parallel slot, it is possible to match the shape and size of the teeth 924 between the slots 925, which is an advantageous configuration for equalizing the amount of iron in each tooth 924. It has become.
  • the partial winding 931 has a configuration in which square wires having a quadrangular cross section of the conductor are wound in multiple directions, and the cross section of the conductor assembly portion, which is an aggregate of the square wires, has a quadrangular shape. In this case, the space factor of the stator winding 921 can be further improved.
  • the second teeth 924B which becomes "W12" will be included.
  • the first crossover 933A of the first partial winding 931A is bent radially outward, and the second crossover 933B of the second partial winding 931B is shafted with respect to the first crossover 933A of the first partial winding 931A. It is configured to be provided at a position separated in the direction. As a result, interference between the crossover portions 933A and 933B can be suitably avoided in each of these partial windings 931A and 931B, and a configuration excellent in assembling property can be realized.
  • the inner side walls 941 are provided so as to approach each other on the anti-yoke side, and the outer walls 942 are provided so as to be separated from each other on the anti-yoke side. It may have been. Further, in the slots 925A and 925B shown in FIG. 109, either the inner side wall 941 or the outer wall 942 may be provided so as to be parallel to each other. In the configuration of FIG. 109, in each slot 925, the circumferential width W1 on the yoke 923 side and the circumferential width W2 on the anti-yoke side are W1 ⁇ W2.
  • the back side wall 943 on the yoke 923 side of the slot 915 may be provided in a direction along the circular CL concentric with the inner peripheral surface SA on the anti-yoke side of the stator core 922.
  • the slot center line (second center line L12) Is in a direction different from the normal direction of the core inner peripheral surface SA, but as described above, by providing the inner side wall 943 of the slot 915 in the direction along the circular CL, the radial dimension (depth dimension) of the slot 925 can be rotated. Can be the same in direction.
  • Each slot 925 has a substantially parallelogram in cross-sectional shape.
  • the cross section of the intermediate conductor portion 932 has a substantially parallel four-sided shape according to the slot shape.
  • the partial winding 931 can be suitably arranged in the slot 925 without creating an excess space. That is, in the configuration in which the radial dimensions of the slots 925 are the same in the circumferential direction, the radial outer diameter or the diameter in the slot 925 is different from that in the configuration in which the radial dimensions of the slots 925 are different in the circumferential direction (for example, the configuration of FIG. 107). It is possible to make it difficult to generate excess space inside in the direction, and it is possible to make the assembly of the partial winding 931 more suitable.
  • a flange portion 951 extending in the circumferential direction is provided at the tip of the teeth 924 in the stator core 922 so as to narrow the opening of the slot 925.
  • the collar portion 951 is provided in a state in which the plastically deformed portion 952 at the tip of the tooth is plastically deformed.
  • the flange portion 951 may be formed by fixing the flange forming member 953 to the tip of the teeth of the stator core 922.
  • the flange portion 951 provided at the tip of the tooth can prevent the partial winding 931 from falling off. Further, the collar portion 951 is formed in a state where the plastically deformed portion 952 at the tip of the tooth is plastically deformed or a flange forming member 953 is fixed to the tip of the tooth, and is partially wound with respect to the stator core 922. A desired collar structure can be provided without causing any trouble in assembling the 931 from the radial direction.
  • the first teeth 924A having "the circumferential width W11 of the base end portion ⁇ the circumferential width W12 of the tip portion” and “the circumferential width W11 of the base end portion> the circumferential direction of the tip portion".
  • the circumferential width W11 of the first teeth 924A and the circumferential width W12 of the second teeth 924B are made the same, but this may be changed.
  • all the teeth 924 may have the same circumferential width W12 at the tip, or all the teeth 924 may have the same circumferential width W11 at the base end.
  • the configuration shown below can be used as a configuration for suppressing mutual interference between the partial windings 931.
  • the upper crossover portion shown in the drawing is provided so as to extend in the axial direction, and the lower crossover portion shown in the drawing is provided so as to be bent toward the radial core side.
  • the upper crossover portion is provided so as to be bent toward the radial opposite core side, and the lower crossover portion is provided so as to extend in the axial direction.
  • the upper crossover portion is provided so as to be bent toward the radial opposite core side, and the lower crossover portion is provided on the radial core side. It is bent and provided.
  • the partial windings 931A and 931B are assembled to the stator core 922 in a state of being offset from each other in the axial direction, and in that state, the crossovers are separated from each other in the axial direction, and the crossovers interfere with each other. Is designed to be avoided.
  • the upper crossover portion and the lower crossover portion are provided so as to be bent toward the radial core side.
  • the upper crossover portion and the lower crossover portion are provided so as to be bent toward the opposite core side in the radial direction.
  • the crossovers are separated from each other in the radial direction so that the crossovers do not interfere with each other.
  • the rotor 910 has a skew structure in which the magnetic pole positions of the magnet unit 912 are different in the circumferential direction in the axial direction. As a result, it is possible to realize a rotary electric machine 900 in which the cogging torque is suppressed while improving the space factor.
  • Specific skew structures for the rotor 910 are shown in FIGS. 113 (a) and 113 (b).
  • FIGS. 113 (a) and 113 (b) are front views of the rotor 910, and the figure shows only one pole of the magnet 913 of the magnet unit 912.
  • the rotor 910 shown in FIG. 113A has an oblique skew structure, and a magnet 913 is provided so as to obliquely change the circumferential position in the axial direction. Further, the rotor 910 shown in FIG. 113B has a step skew structure, and a magnet 913 is provided so as to change the circumferential position in the axial direction in a stepped manner.
  • the rotary electric machine 900 may be an outer rotor type rotary electric machine.
  • the outer rotor type in the stator 920, a plurality of teeth 924 are provided on the radial outside of the cylindrical yoke 923, and each partial winding 931 is assembled from the radial outside to the slot 925 between the teeth. Be done.
  • the stator winding may have a configuration having two-phase phase windings (U-phase winding and V-phase winding).
  • a pair of intermediate conductors 932 are provided at a distance corresponding to a two-slot pitch in the distance between the centers in the circumferential direction, and the pair of intermediate conductors 932 are provided. It suffices that one intermediate conducting wire portion 932 in the other one-phase partial winding 931 is arranged between the two.
  • rotating electric machines 700 and 900 it is also possible to adopt a rotating armature type rotating electric machine having an armature as a rotor instead of a rotating field type rotating electric machine using a field magnet as a rotor.
  • disclosure in this specification is not limited to the illustrated embodiments.
  • the disclosure includes exemplary embodiments and modifications by those skilled in the art based on them.
  • disclosure is not limited to the parts and / or element combinations shown in the embodiments. Disclosure can be carried out in various combinations.
  • the disclosure can have additional parts that can be added to the embodiments. Disclosures include those in which the parts and / or elements of the embodiment are omitted. Disclosures include the replacement or combination of parts and / or elements between one embodiment and another.
  • the technical scope disclosed is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims statement.

Abstract

An armature core (922) comprises a cylindrical yoke (923) and a plurality of teeth (924), with a slot (925) formed between the teeth. In the armature core, a set of two slots, i.e., a first slot (925A) and a second slot (925B), is a slot pair (SP) in which a pair of intermediate conductor wire portions (932) of a partial winding are respectively accommodated. The first slot and the second slot are provided such that inner walls (941) thereof that are both on the inside in a circumferential direction are parallel or closer to each other on an anti-yoke side, and outer walls (942) thereof that are both on the outside in the circumferential direction are parallel to each other or farther from each other on the anti-yoke side, wherein each of the slots has a yoke-side circumferential width (W1) less than or equal to an anti-yoke-side circumferential width (W2). The pair of intermediate conductor wire portions are accommodated in the first slot and the second slot in proximity to and opposing the inner walls and the outer walls.

Description

回転電機Rotating machine 関連出願の相互参照Cross-reference of related applications
　本出願は、２０１９年１１月２７日に出願された日本出願番号２０１９－２１４０９８号に基づくもので、ここにその記載内容を援用する。 This application is based on Japanese application number 2019-214098, which was filed on November 27, 2019, and the contents of the description are incorporated herein by reference.
　この明細書における開示は、回転電機に関する。 The disclosure in this specification relates to a rotary electric machine.
　従来、周方向に極性が交互となる複数の磁極を有する磁石部を含む界磁子と、多相の電機子巻線を有する電機子と、を備える回転電機が知られている。また、例えば特許文献１には、相ごとに設けられた集中巻コイル（短節集中巻コイル）を電機子コアに取り付ける構成として、周方向に設けられた複数のティース間に、径方向内側に開口するスロット（溝）を形成し、そのスロットに対してコイルを組み入れるようにした構成が開示されている。具体的には回転電機において、ティースを、１つおきにそれぞれ長方形断面形状、台形断面形状とし、そのティース間に形成されたスロットに長方形断面のコイルを組み入れることで、スロット内の隙間を残さずにコイルを収容する構成としている。 Conventionally, a rotary electric machine including a field magnet including a magnet portion having a plurality of magnetic poles having alternating polarities in the circumferential direction and an armature having a multi-phase armature winding is known. Further, for example, in Patent Document 1, a concentrated winding coil (short-section concentrated winding coil) provided for each phase is attached to the armature core, and is provided in the radial direction between a plurality of teeth provided in the circumferential direction. A configuration is disclosed in which a slot (groove) to be opened is formed and a coil is incorporated in the slot. Specifically, in a rotary electric machine, every other tooth has a rectangular cross-sectional shape and a trapezoidal cross-sectional shape, and a coil having a rectangular cross section is incorporated in a slot formed between the teeth so as not to leave a gap in the slot. It is configured to accommodate the coil.
特表２００９－５２８８１１号公報Special Table 2009-528811
　ところで、上記特許文献１に記載の回転電機は、電機子コアの単一のティースに対して、１つの集中巻コイルを巻装する構成であり、それら各コイルが周方向において互いに干渉することなく並べて配置される。しかしながら、電機子巻線として分布巻コイル（例えば全節集中巻コイル）を用いる場合には、それら各コイルを径方向に組み付ける際に、各コイルのコイルエンド部分が互いに干渉することが考えられる。つまり、分布巻コイルを用いる場合には、各コイルが２以上のティースを跨ぐように配置されることになり、周方向における互いの干渉が懸念される。そのため、電機子巻線として分布巻コイルを用いる回転電機において、技術改善の余地があると考えられる。 By the way, the rotary electric machine described in Patent Document 1 has a configuration in which one centralized winding coil is wound around a single tooth of an armature core, and the coils do not interfere with each other in the circumferential direction. Arranged side by side. However, when a distributed winding coil (for example, a centralized winding coil for all nodes) is used as the armature winding, it is conceivable that the coil end portions of the coils interfere with each other when the coils are assembled in the radial direction. That is, when a distributed winding coil is used, each coil is arranged so as to straddle two or more teeth, and there is a concern about mutual interference in the circumferential direction. Therefore, it is considered that there is room for technical improvement in a rotary electric machine that uses a distributed winding coil as an armature winding.
　本開示は、上記事情に鑑みてなされたものであり、電機子コアに対して電機子巻線を好適に組み付けることができる回転電機を提供することを目的とする。 The present disclosure has been made in view of the above circumstances, and an object of the present disclosure is to provide a rotary electric machine capable of suitably assembling an armature winding to an armature core.
　この明細書における開示された複数の態様は、それぞれの目的を達成するために、互いに異なる技術的手段を採用する。この明細書に開示される目的、特徴、および効果は、後続の詳細な説明、および添付の図面を参照することによってより明確になる。 The plurality of aspects disclosed herein employ different technical means to achieve their respective objectives. The objectives, features, and effects disclosed herein will be made clearer by reference to the subsequent detailed description and accompanying drawings.
　手段１は、
　周方向に極性が交互となる複数の磁極を含む磁石部を有する界磁子と、
　相あたり複数の部分巻線からなる相巻線を有する多相の電機子巻線と、前記電機子巻線に一体に設けられる電機子コアとを備える電機子と、
を備える回転電機であって、
　前記電機子コアは、円筒状のヨークと、該ヨークの径方向内側又は径方向外側において周方向に所定間隔で設けられた複数のティースとを有し、前記各ティースどうしの間に、径方向に延びるスロットが形成されており、
　前記部分巻線は、周方向に所定間隔を離して設けられる一対の中間導線部と、軸方向一端側及び他端側に設けられ前記一対の中間導線部を環状に接続する渡り部とを有し、前記スロットに前記中間導線部が収容され、かつ２以上の前記ティースを跨ぐように配置されるものであり、
　前記電機子コアにおいて２つ一組のスロットである第１スロット及び第２スロットが前記一対の中間導線部がそれぞれ収容されるスロット対であり、
　前記第１スロット及び前記第２スロットは、周方向に互いに内側となる内側壁どうしが平行又は反ヨーク側で互いに近づき、かつ周方向に互いに外側となる外側壁どうしが平行又は反ヨーク側で互いに遠ざかるように設けられ、それら各スロットにおける前記ヨーク側の周方向幅が、反ヨーク側の周方向幅以下の大きさとなっており、
　前記一対の中間導線部が、前記内側壁及び前記外側壁に近接対向した状態で前記第１スロット及び前記第２スロットに収容されており、
　周方向に隣り合いかつ一部が重複した状態で並べて配置された前記各部分巻線において前記渡り部が軸方向又は径方向に互いに離間している。 Means 1
A field magnet having a magnet portion containing a plurality of magnetic poles having alternating polarities in the circumferential direction,
An armature having a multi-phase armature winding having a phase winding composed of a plurality of partial windings per phase, and an armature core integrally provided with the armature winding.
It is a rotary electric machine equipped with
The armature core has a cylindrical yoke and a plurality of teeth provided at predetermined intervals in the circumferential direction on the radial inner side or the radial outer side of the yoke, and between the respective teeth in the radial direction. A slot extending to is formed,
The partial winding has a pair of intermediate conductor portions provided at predetermined intervals in the circumferential direction, and a crossover portion provided on one end side and the other end side in the axial direction to connect the pair of intermediate conductor portions in an annular shape. However, the intermediate conducting wire portion is housed in the slot, and is arranged so as to straddle two or more of the teeth.
In the armature core, the first slot and the second slot, which are a set of two slots, are a pair of slots in which the pair of intermediate conductors are housed.
In the first slot and the second slot, the inner side walls that are inside each other in the circumferential direction are parallel to each other or close to each other on the anti-yoke side, and the outer walls that are outward to each other in the circumferential direction are parallel to each other or on the anti-yoke side. It is provided so as to move away from each other, and the circumferential width of the yoke side in each of these slots is smaller than the circumferential width of the anti-yoke side.
The pair of intermediate conductors are housed in the first slot and the second slot in a state of being close to the inner side wall and the outer wall.
In each of the partial windings arranged side by side in a circumferential direction adjacent to each other and partially overlapping, the crossovers are separated from each other in the axial direction or the radial direction.
　上記構成の回転電機では、電機子コアにおいて、円筒状のヨークの径方向内側又は径方向外側には周方向に所定間隔で複数のティースが設けられており、各ティースどうしの間に、径方向に延びるスロットが形成されている。また、電機子巻線は、相ごとに、一対の中間導線部と渡り部とを含む複数の部分巻線を有し、その部分巻線は、スロットに中間導線部が収容され、かつ２以上のティースを跨ぐように配置されるものとなっている。この場合特に、部分巻線の一対の中間導線部が収容されるスロットは、２つ一組のスロット（第１スロット及び第２スロット）からなるスロット対であり、このスロット対に対して、径方向からの部分巻線の組み付けが可能となっている。具体的には、第１スロット及び第２スロットは、それら各スロットの内側壁どうしが平行又は反ヨーク側で互いに近づき、かつ外側壁どうしが平行又は反ヨーク側で互いに遠ざかるように設けられ、それら各スロットにおけるヨーク側の周方向幅（Ｗ１）が、反ヨーク側の周方向幅（Ｗ２）以下の大きさとなっている（図１０７参照）。そのため、内側壁どうしが反ヨーク側で互いに遠ざかるように設けられている構成や、外側壁どうしが反ヨーク側で互いに近づくように設けられている構成、各スロットにおけるヨーク側の周方向幅が反ヨーク側の周方向幅よりも大きい構成（Ｗ１＞Ｗ２の構成）とは異なり、一対の中間導線部を、ティース先端側の角部との干渉を生じさせることなく、さらにスロット内に無駄なデッドスペースを生じさせることなく、一対の中間導線部を、スロット対の第１スロット及び第２スロットに収容することが可能になっている。つまり、各スロットにおいて内側壁及び外側壁に近接対向した状態で一対の中間導線部を収容することが可能になっている。 In the rotary electric machine having the above configuration, in the armature core, a plurality of teeth are provided at predetermined intervals in the circumferential direction on the radial inner side or the radial outer side of the cylindrical yoke, and between the teeth, the radial direction is provided. A slot extending to is formed. Further, the armature winding has a plurality of partial windings including a pair of intermediate conductors and a crossover for each phase, and the partial windings include two or more intermediate conductors in slots. It is arranged so as to straddle the teeth of. In this case, in particular, the slot in which the pair of intermediate conductors of the partial winding is housed is a slot pair consisting of a pair of slots (first slot and second slot), and the diameter is relative to this slot pair. It is possible to assemble partial windings from the direction. Specifically, the first slot and the second slot are provided so that the inner side walls of each of the slots are close to each other on the parallel or anti-yoke side, and the outer walls are separated from each other on the parallel or anti-yoke side. The circumferential width (W1) on the yoke side of each slot is smaller than the circumferential width (W2) on the anti-yoke side (see FIG. 107). Therefore, the inner side walls are provided so as to be separated from each other on the anti-yoke side, the outer walls are provided so as to be close to each other on the anti-yoke side, and the circumferential width of the yoke side in each slot is opposite. Unlike the configuration (W1> W2 configuration) that is larger than the circumferential width on the yoke side, the pair of intermediate conductors does not interfere with the corners on the tip side of the teeth, and there is unnecessary dead in the slot. A pair of intermediate lead wires can be accommodated in the first slot and the second slot of the slot pair without creating a space. That is, it is possible to accommodate a pair of intermediate conductors in each slot in a state of being close to the inner side wall and the outer wall.
　また、上記構成の電機子は、各部分巻線が２以上のティースを跨ぐように配置されるものであり、周方向に隣り合いかつ一部が重複した状態で並ぶ各部分巻線においてコイルエンド部分での干渉が懸念されるが、それら各部分巻線において渡り部が軸方向又は径方向に互いに離間しているため、部分巻線どうしの干渉を招くことなく各部分巻線を配置できる。その結果、電機子コアに対して電機子巻線を好適に組み付けることができる電機子の実現が可能になっている。 Further, in the armature having the above configuration, each partial winding is arranged so as to straddle two or more teeth, and the coil end is formed in each partial winding arranged adjacent to each other in the circumferential direction and partially overlapping. Although there is a concern about interference in the parts, since the crossovers are separated from each other in the axial direction or the radial direction in each of the partial windings, the partial windings can be arranged without causing interference between the partial windings. As a result, it has become possible to realize an armature in which the armature winding can be suitably assembled to the armature core.
　手段２では、手段１において、前記スロット対における前記第１スロットから前記第２スロットまでの範囲の周方向中心位置と電機子中心点とを通る直線を第１中心線、前記第１スロット及び前記第２スロットにおいて各々の周方向中心位置を通りかつ前記第１中心線に平行な直線を第２中心線とする場合に、前記第１スロット及び前記第２スロットにおいて前記第２中心線は互いに平行であり、かつ前記第１スロット及び前記第２スロットは、前記第２中心線に対して周方向に線対称で設けられている。 In the means 2, in the means 1, the first center line, the first slot, and the straight line passing through the circumferential center position in the range from the first slot to the second slot and the armature center point in the slot pair are defined as the first center line, the first slot, and the second slot. When a straight line passing through each circumferential center position in the second slot and parallel to the first center line is set as the second center line, the second center lines are parallel to each other in the first slot and the second slot. The first slot and the second slot are provided line-symmetrically in the circumferential direction with respect to the second center line.
　上記構成では、スロット対における第１中心線と、第１スロット及び第２スロットの各々の第２中心線とを互いに平行にすることで、そのスロット対に対する部分巻線の組み付けを好適に実現できる。つまり、部分巻線を第１中心線に沿って平行にスライドさせることで、部分巻線を好適に組み付けることができる。また、第１スロット及び第２スロットを、第１中心線に平行な第２中心線に対して周方向に線対称で設けることで、電機子コアにおいて周方向に並ぶ各ティースの大きさの均等化を図る上で有利な構成となっている。 In the above configuration, by making the first center line of the slot pair and the second center line of each of the first slot and the second slot parallel to each other, it is possible to suitably realize the assembly of the partial winding to the slot pair. .. That is, the partial winding can be suitably assembled by sliding the partial winding in parallel along the first center line. Further, by providing the first slot and the second slot symmetrically in the circumferential direction with respect to the second center line parallel to the first center line, the sizes of the teeth arranged in the circumferential direction in the armature core are equalized. It has an advantageous configuration for the purpose of conversion.
　手段３では、手段２において、前記第１スロット及び前記第２スロットの各々において前記内側壁及び前記外側壁は互いに平行であり、前記一対の中間導線部の周方向の側面は互いに平行である。 In the means 3, in the means 2, the inner side wall and the outer wall are parallel to each other in each of the first slot and the second slot, and the circumferential side surfaces of the pair of intermediate conductors are parallel to each other.
　上記構成では、各スロットが、周方向の幅が均一な平行スロットとして設けられている。また、部分巻線の各中間導線部が、周方向の幅が均一な平行導線として設けられている。この場合、各スロットを平行スロットとし、かつ各中間導線部を平行導線とすることで、電機子巻線の占積率の向上を図ることができる。 In the above configuration, each slot is provided as a parallel slot having a uniform width in the circumferential direction. Further, each intermediate conductor portion of the partial winding is provided as a parallel conductor having a uniform width in the circumferential direction. In this case, by making each slot a parallel slot and each intermediate conductor portion being a parallel conductor, it is possible to improve the space factor of the armature winding.
　また、各スロットを平行スロットとした構成では、スロット間のティースの形状や大きさを合わせ込むことが可能となり、各ティースでの鉄量の均等化を図る上で有利な構成となっている。 In addition, in the configuration where each slot is a parallel slot, it is possible to match the shape and size of the teeth between the slots, which is an advantageous configuration for equalizing the amount of iron in each tooth.
　手段４では、手段３において、前記部分巻線は、導体断面が四角形形状をなす角線を多重に巻回されることで構成されており、前記角線の集合体である導線集合部の横断面が四角形形状をなしている。 In the means 4, in the means 3, the partial winding is formed by winding a plurality of square wires having a quadrangular cross section of the conductor, and crosses the conductor collecting portion which is an aggregate of the square wires. The surface has a quadrangular shape.
　上記構成では、角線を多重に巻回してなる部分巻線を用い、その部分巻線において角線の集合体である導線集合部の横断面が四角形形状をなしているため、電機子巻線における一層の占積率向上を図ることができる。 In the above configuration, a partial winding formed by winding square wires in multiple directions is used, and since the cross section of the conductor assembly portion, which is an aggregate of square wires, has a quadrangular shape in the partial winding, the armature winding It is possible to further improve the space factor in.
　手段５では、手段２～４のいずれかにおいて、前記電機子コアにおいて周方向に並ぶ前記各ティースは、前記ヨーク側の基端部の周方向幅が反ヨーク側の先端部の周方向幅よりも小さい第１ティースと、前記基端部の周方向幅が前記先端部の周方向幅よりも大きい第２ティースとを含み、前記第１ティースにおける前記基端部の周方向幅と、前記第２ティースにおける前記先端部の周方向幅とが同一である。 In the means 5, in any of the means 2 to 4, the circumferential width of the base end portion on the yoke side of each of the teeth arranged in the circumferential direction in the armature core is larger than the circumferential width of the tip end portion on the anti-yoke side. A first tooth having a small size and a second tooth having a circumferential width of the base end portion larger than the circumferential width of the tip end portion are included, and the circumferential width of the base end portion in the first tooth and the first tooth. The width of the tip in the two teeth in the circumferential direction is the same.
　上記のとおり電機子コアの各スロットに対して部分巻線（詳しくは部分巻線の一対の中間導線部）を径方向から組み付け可能にする構成では、周方向に並ぶ各ティースの形態が均一でなくなり、「基端部の周方向幅＜先端部の周方向幅」となる第１ティースと、「基端部の周方向幅＞先端部の周方向幅」となる第２ティースとが含まれることとなる。そしてかかる構成において、第１ティースにおける基端部の周方向幅と、第２ティースにおける先端部の周方向幅とを同一にしたため、各スロットの周方向の最小幅を一様に合わせることができる。これにより、電機子コアにおいて局所的に磁気飽和が生じることを抑制でき、局所的な磁気飽和に起因する性能低下を抑制することができる。 As described above, in the configuration in which the partial winding (specifically, a pair of intermediate conductors of the partial winding) can be assembled to each slot of the armature core from the radial direction, the form of each tooth arranged in the circumferential direction is uniform. It includes the first tooth, which is "the circumferential width of the base end <the circumferential width of the tip portion", and the second tooth, which is "the circumferential width of the base end portion> the circumferential width of the tip portion". It will be. In such a configuration, since the circumferential width of the base end portion in the first teeth and the circumferential width of the tip portion in the second teeth are made the same, the minimum width in the circumferential direction of each slot can be uniformly matched. .. As a result, it is possible to suppress the occurrence of local magnetic saturation in the armature core, and it is possible to suppress the deterioration in performance due to the local magnetic saturation.
　手段６では、手段２～５のいずれかにおいて、前記スロットの前記ヨーク側の奥側壁が、前記電機子コアの反ヨーク側の内周面と同心の円に沿う向きで設けられている。 In the means 6, in any of the means 2 to 5, the back side wall on the yoke side of the slot is provided so as to be oriented along a circle concentric with the inner peripheral surface on the anti-yoke side of the armature core.
　上記構成によれば、スロットの径方向寸法（奥行き寸法）を周方向に同一にすることができる。これにより、スロット内において余剰スペースを生じさせることなく好適に部分巻線を配置することができる。 According to the above configuration, the radial dimension (depth dimension) of the slot can be made the same in the circumferential direction. As a result, the partial winding can be suitably arranged without creating an excess space in the slot.
　手段７では、手段１～６のいずれかにおいて、周方向に隣り合いかつ一部が重複した状態で並べて配置される前記各部分巻線として第１部分巻線及び第２部分巻線を用い、前記第１部分巻線では、前記渡り部が径方向内側又は径方向外側に折り曲げられ、前記第２部分巻線では、前記渡り部が、前記第１部分巻線の渡り部に対して軸方向又は径方向に離間する位置に設けられている。 In the means 7, in any of the means 1 to 6, the first partial winding and the second partial winding are used as the partial windings that are arranged side by side in a state of being adjacent to each other in the circumferential direction and partially overlapping. In the first partial winding, the cross section is bent radially inward or radially outward, and in the second partial winding, the cross section is axially relative to the cross section of the first partial winding. Alternatively, it is provided at a position separated in the radial direction.
　上記構成では、少なくとも第１部分巻線の渡り部が径方向内側又は径方向外側に折り曲げられ、第２部分巻線の渡り部が、第１部分巻線の渡り部に対して軸方向又は径方向に離間する位置に設けられているため、これら各部分巻線において渡り部どうしの干渉を好適に回避でき、組み付け性に優れる構成を実現できる。 In the above configuration, at least the crossover of the first partial winding is bent radially inward or radially outward, and the crossover of the second partial winding is axially or radially relative to the crossover of the first partial winding. Since it is provided at a position separated in the direction, interference between the crossovers can be suitably avoided in each of these partial windings, and a configuration excellent in assembling property can be realized.
　手段８では、手段１～７のいずれかにおいて、前記ティースの先端に、前記スロットの開口部を狭めるように周方向に延びる鍔部を有しており、前記鍔部は、ティース先端の塑性変形部が塑性変形された状態、又はティース先端に鍔形成部材が固定された状態で形成されている。 In the means 8, in any of the means 1 to 7, the tip of the tooth has a flange portion extending in the circumferential direction so as to narrow the opening of the slot, and the flange portion is plastically deformed at the tip of the tooth. The portion is plastically deformed, or the flange forming member is fixed to the tip of the tooth.
　上記構成では、ティース先端に設けられた鍔部によりスロットの開口部が狭められており、部分巻線の脱落等を抑制できるものとなっている。また、鍔部は、ティース先端の塑性変形部が塑性変形された状態、又はティース先端に鍔形成部材が固定された状態で形成されており、電機子コアに対して部分巻線が径方向から組み付けられることに何ら支障を及ぼすことなく所望の鍔構造を設けることができる。 In the above configuration, the opening of the slot is narrowed by the flange provided at the tip of the tooth, and it is possible to prevent the partial winding from falling off. Further, the collar portion is formed in a state where the plastically deformed portion at the tip of the tooth is plastically deformed, or a state where the collar forming member is fixed to the tip of the tooth, and the partial winding is from the radial direction with respect to the armature core. A desired collar structure can be provided without any hindrance to assembly.
　手段９では、手段１～８のいずれかにおいて、前記部分巻線は、１極対において相ごとに１つずつ設けられている。 In the means 9, in any of the means 1 to 8, the partial winding is provided one for each phase in a one-pole pair.
　上記構成では、１極対において相ごとに１つずつの割合で部分巻線が設けられており、電機子コアで言えば、周方向において１相１極あたり１個の割合でスロットが設けられるシングルスロット仕様となっている。この場合、例えばダブルスロット仕様とする構成とは異なり、少なくとも２種類の部分巻線を用いれば、部分巻線どうしの干渉の回避が可能となり、製造の観点からしても有利な構成を実現することができる。 In the above configuration, one partial winding is provided for each phase in one pole pair, and in the armature core, one slot is provided for each phase in the circumferential direction. It is a single slot specification. In this case, for example, unlike the configuration of the double slot specification, if at least two types of partial windings are used, it is possible to avoid interference between the partial windings, and a configuration advantageous from the viewpoint of manufacturing is realized. be able to.
　手段１０では、手段９において、前記界磁子は、軸方向において、前記磁石部における磁極位置を周方向に異ならせたスキュー構造を有している。 In the means 10, in the means 9, the field magnet has a skew structure in which the magnetic pole positions in the magnet portion are different in the circumferential direction in the axial direction.
　シングルスロット仕様の電機子ではコギングトルクが課題となるが、界磁子がスキュー構造を有していることにより、コギングトルクの低減が可能となる。これにより、占積率を向上しつつコギングトルクを抑制した回転電機を実現できる。 Cogging torque is an issue for single-slot armatures, but the field magnet has a skew structure, which makes it possible to reduce cogging torque. As a result, it is possible to realize a rotary electric machine in which the cogging torque is suppressed while improving the space factor.
　界磁子のスキュー構造としては、軸方向において周方向位置を斜めに変化させるようにして永久磁石を設けた斜めスキュー構造、又は軸方向において周方向位置を段差状に変化させるようにして永久磁石を設けた段スキュー構造とするとよい。 As the skew structure of the field magnet, a diagonal skew structure in which a permanent magnet is provided so as to change the circumferential position diagonally in the axial direction, or a permanent magnet in which the circumferential position is changed in a stepped shape in the axial direction. It is preferable to use a step skew structure provided with.
　本開示についての上記目的およびその他の目的、特徴や利点は、添付の図面を参照しながら下記の詳細な記述により、より明確になる。その図面は、
図１は、回転電機の縦断面斜視図であり、 図２は、回転電機の縦断面図であり、 図３は、図２のIII－III線断面図であり、 図４は、図３の一部を拡大して示す断面図であり、 図５は、回転電機の分解図であり、 図６は、インバータユニットの分解図であり、 図７は、固定子巻線のアンペアターンとトルク密度との関係を示すトルク線図であり、 図８は、回転子及び固定子の横断面図であり、 図９は、図８の一部を拡大して示す図であり、 図１０は、固定子の横断面図であり、 図１１は、固定子の縦断面図であり、 図１２は、固定子巻線の斜視図であり、 図１３は、導線の構成を示す斜視図であり、 図１４は、素線の構成を示す模式図であり、 図１５は、ｎ層目における各導線の形態を示す図であり、 図１６は、ｎ層目とｎ＋１層目の各導線を示す側面図であり、 図１７は、実施形態の磁石について電気角と磁束密度との関係を示す図であり、 図１８は、比較例の磁石について電気角と磁束密度との関係を示す図であり、 図１９は、回転電機の制御システムの電気回路図であり、 図２０は、制御装置による電流フィードバック制御処理を示す機能ブロック図であり、 図２１は、制御装置によるトルクフィードバック制御処理を示す機能ブロック図であり、 図２２は、第２実施形態における回転子及び固定子の横断面図であり、 図２３は、図２２の一部を拡大して示す図であり、 図２４は、磁石ユニットにおける磁束の流れを具体的に示す図であり、 図２５は、変形例１における固定子の断面図であり、 図２６は、変形例１における固定子の断面図であり、 図２７は、変形例２における固定子の断面図であり、 図２８は、変形例３における固定子の断面図であり、 図２９は、変形例４における固定子の断面図であり、 図３０は、変形例７における回転子及び固定子の横断面図であり、 図３１は、変形例８において操作信号生成部の処理の一部を示す機能ブロック図であり、 図３２は、キャリア周波数変更処理の手順を示すフローチャートであり、 図３３は、変形例９において導線群を構成する各導線の接続形態を示す図であり、 図３４は、変形例９において４対の導線が積層配置されている構成を示す図であり、 図３５は、変形例１０においてインナロータ型の回転子及び固定子の横断面図であり、 図３６は、図３５の一部を拡大して示す図であり、 図３７は、インナロータ型の回転電機の縦断面図であり、 図３８は、インナロータ型の回転電機の概略構成を示す縦断面図であり、 図３９は、変形例１１においてインナロータ構造の回転電機の構成を示す図であり、 図４０は、変形例１１においてインナロータ構造の回転電機の構成を示す図であり、 図４１は、変形例１２において回転電機子形の回転電機の構成を示す図であり、 図４２は、変形例１４における導線の構成を示す断面図であり、 図４３は、リラクタンストルク、磁石トルク及びＤＭの関係を示す図であり、 図４４は、ティースを示す図であり、 図４５は、インホイールモータ構造の車輪及びその周辺構造を示す斜視図であり、 図４６は、車輪及びその周辺構造の縦断面図であり、 図４７は、車輪の分解斜視図であり、 図４８は、回転電機を回転軸の突出側から見た側面図であり、 図４９は、図４８の４９－４９線断面図であり、 図５０は、図４９の５０－５０線断面図であり、 図５１は、回転電機の分解断面図であり、 図５２は、回転子の部分断面図であり、 図５３は、固定子巻線及び固定子コアの斜視図であり、 図５４は、固定子巻線を平面状に展開して示す正面図であり、 図５５は、導線のスキューを示す図であり、 図５６は、インバータユニットの分解断面図であり、 図５７は、インバータユニットの分解断面図であり、 図５８は、インバータハウジングでの各電気モジュールの配置の状態を示す図であり、 図５９は、電力変換器の電気的構成を示す回路図であり、 図６０は、スイッチモジュールの冷却構造例を示す図であり、 図６１は、スイッチモジュールの冷却構造例を示す図であり、 図６２は、スイッチモジュールの冷却構造例を示す図であり、 図６３は、スイッチモジュールの冷却構造例を示す図であり、 図６４は、スイッチモジュールの冷却構造例を示す図であり、 図６５は、冷却水通路に対する各電気モジュールの配列順序を示す図であり、 図６６は、図４９の６６－６６線断面図であり、 図６７は、図４９の６７－６７線断面図であり、 図６８は、バスバーモジュールを単体で示す斜視図であり、 図６９は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７０は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７１は、各電気モジュールとバスバーモジュールとの電気的な接続状態を示す図であり、 図７２は、インホイールモータにおける変形例１を説明するための構成図であり、 図７３は、インホイールモータにおける変形例２を説明するための構成図であり、 図７４は、インホイールモータにおける変形例３を説明するための構成図であり、 図７５は、インホイールモータにおける変形例４を説明するための構成図であり、 図７６は、変形例１５における回転電機の全体を示す斜視図であり、 図７７は、回転電機の縦断面図であり、 図７８は、回転電機の分解断面図であり、 図７９は、回転子の断面図であり、 図８０は、磁石ユニットの断面構造を示す部分断面図であり、 図８１は、磁石ユニットの一部を拡大して示す部分断面図であり、 図８２は、固定子の構成を示す斜視図であり、 図８３は、固定子巻線と固定子コアとを分解して示す斜視図であり、 図８４は、各相の相巻線のうちＵ相巻線に相当する構成のみを示す斜視図であり、 図８５は、固定子の縦断面図であり、 図８６は、３相の各相巻線における部分巻線の接続状態を示す回路図であり、 図８７は、コイルモジュールの構成を示す図であり、 図８８は、コイルモジュールの構成を示す図であり、 図８９は、コイルモジュールの構成を示す図であり、 図９０は、コイルモジュールの構成を示す図であり、 図９１は、固定子の縦断面を示す断面図であり、 図９２は、固定子の横断面を示す断面図であり、 図９３は、固定子コア及びエンドリングとコイルモジュールとを互いに分離して示す断面図であり、 図９４は、インナユニットの縦断面図であり、 図９５は、インナユニットの縦断面図であり、 図９６は、バスバーモジュールの斜視図であり、 図９７は、バスバーモジュールの縦断面の一部を示す断面図であり、 図９８は、各バスバーに対する接続端子の接続位置を示す略図であり、 図９９は、部分巻線における導線の巻回順序を示す図であり、 図１００は、コイルモジュールの構成を示す図であり、 図１０１は、変形例１６における回転電機の構成を示す縦断面図であり、 図１０２は、回転電機の横断面図であり、 図１０３は、回転電機の構成の一部を拡大して示す横断面図であり、 図１０４は、部分巻線の構成を示す斜視図であり、 図１０５は、第１部分巻線及び第２部分巻線を横に並べて対比して示す側面図であり、 図１０６は、図１０４（ａ）における１０６－１０６線断面図であり、 図１０７は、固定子コアに対する部分巻線の組み付けの構成を示す概略図であり、 図１０８は、固定子コアに対する部分巻線の組み付けを説明するための概略図であり、 図１０９は、固定子コアに対する部分巻線の組み付けの構成を示す概略図であり、 図１１０は、固定子コアに対する部分巻線の組み付けの構成を示す概略図であり、 図１１１は、固定子コアに対する部分巻線の組み付けの構成を示す概略図であり、 図１１２は、部分巻線の構成を説明するための概略図であり、 図１１３は、回転子のスキュー構造を説明するための概略図である。 The above objectives and other objectives, features and advantages of the present disclosure will be clarified by the following detailed description with reference to the accompanying drawings. The drawing is
FIG. 1 is a vertical cross-sectional perspective view of a rotary electric machine. FIG. 2 is a vertical cross-sectional view of the rotary electric machine. FIG. 3 is a sectional view taken along line III-III of FIG. FIG. 4 is a cross-sectional view showing a part of FIG. 3 in an enlarged manner. FIG. 5 is an exploded view of the rotary electric machine. FIG. 6 is an exploded view of the inverter unit. FIG. 7 is a torque diagram showing the relationship between the ampere turn of the stator winding and the torque density. FIG. 8 is a cross-sectional view of the rotor and the stator. FIG. 9 is an enlarged view of a part of FIG. FIG. 10 is a cross-sectional view of the stator. FIG. 11 is a vertical cross-sectional view of the stator. FIG. 12 is a perspective view of the stator winding. FIG. 13 is a perspective view showing the configuration of the conducting wire. FIG. 14 is a schematic view showing the configuration of the strands. FIG. 15 is a diagram showing the morphology of each conducting wire in the nth layer. FIG. 16 is a side view showing the conductors of the nth layer and the n + 1th layer. FIG. 17 is a diagram showing the relationship between the electric angle and the magnetic flux density of the magnet of the embodiment. FIG. 18 is a diagram showing the relationship between the electric angle and the magnetic flux density of the magnet of the comparative example. FIG. 19 is an electric circuit diagram of the control system of the rotary electric machine. FIG. 20 is a functional block diagram showing a current feedback control process by the control device. FIG. 21 is a functional block diagram showing torque feedback control processing by the control device. FIG. 22 is a cross-sectional view of the rotor and the stator according to the second embodiment. FIG. 23 is an enlarged view of a part of FIG. 22. FIG. 24 is a diagram specifically showing the flow of magnetic flux in the magnet unit. FIG. 25 is a cross-sectional view of the stator in the first modification. FIG. 26 is a cross-sectional view of the stator in the first modification. FIG. 27 is a cross-sectional view of the stator in the modified example 2. FIG. 28 is a cross-sectional view of the stator in the modified example 3. FIG. 29 is a cross-sectional view of the stator in the modified example 4. FIG. 30 is a cross-sectional view of the rotor and the stator in the modified example 7. FIG. 31 is a functional block diagram showing a part of the processing of the operation signal generation unit in the modified example 8. FIG. 32 is a flowchart showing the procedure of the carrier frequency change process. FIG. 33 is a diagram showing a connection form of each of the conductors constituting the conductor group in the modified example 9. FIG. 34 is a diagram showing a configuration in which four pairs of conducting wires are stacked and arranged in the modified example 9. FIG. 35 is a cross-sectional view of the inner rotor type rotor and stator in the modified example 10. FIG. 36 is an enlarged view of a part of FIG. 35. FIG. 37 is a vertical sectional view of an inner rotor type rotary electric machine. FIG. 38 is a vertical cross-sectional view showing a schematic configuration of an inner rotor type rotary electric machine. FIG. 39 is a diagram showing a configuration of a rotary electric machine having an inner rotor structure in the modified example 11. FIG. 40 is a diagram showing a configuration of a rotary electric machine having an inner rotor structure in the modified example 11. FIG. 41 is a diagram showing a configuration of a rotary armature type rotary electric machine in the modified example 12. FIG. 42 is a cross-sectional view showing the configuration of the conducting wire in the modified example 14. FIG. 43 is a diagram showing the relationship between the reluctance torque, the magnet torque, and the DM. FIG. 44 is a diagram showing teeth. FIG. 45 is a perspective view showing a wheel having an in-wheel motor structure and its peripheral structure. FIG. 46 is a vertical cross-sectional view of the wheel and its peripheral structure. FIG. 47 is an exploded perspective view of the wheel. FIG. 48 is a side view of the rotary electric machine as viewed from the protruding side of the rotating shaft. FIG. 49 is a cross-sectional view taken along the line 49-49 of FIG. 48. FIG. 50 is a cross-sectional view taken along the line 50-50 of FIG. 49. FIG. 51 is an exploded sectional view of the rotary electric machine. FIG. 52 is a partial cross-sectional view of the rotor. FIG. 53 is a perspective view of the stator winding and the stator core. FIG. 54 is a front view showing the stator winding developed in a plane. FIG. 55 is a diagram showing the skew of the conductor. FIG. 56 is an exploded sectional view of the inverter unit. FIG. 57 is an exploded sectional view of the inverter unit. FIG. 58 is a diagram showing a state of arrangement of each electric module in the inverter housing. FIG. 59 is a circuit diagram showing the electrical configuration of the power converter. FIG. 60 is a diagram showing an example of a cooling structure of the switch module. FIG. 61 is a diagram showing an example of a cooling structure of the switch module. FIG. 62 is a diagram showing an example of a cooling structure of the switch module. FIG. 63 is a diagram showing an example of a cooling structure of the switch module. FIG. 64 is a diagram showing an example of a cooling structure of the switch module. FIG. 65 is a diagram showing the arrangement order of each electric module with respect to the cooling water passage. FIG. 66 is a cross-sectional view taken along the line 66-66 of FIG. 49. FIG. 67 is a cross-sectional view taken along the line 67-67 of FIG. 49. FIG. 68 is a perspective view showing the bus bar module as a single unit. FIG. 69 is a diagram showing an electrical connection state between each electric module and the bus bar module. FIG. 70 is a diagram showing an electrical connection state between each electric module and the bus bar module. FIG. 71 is a diagram showing an electrical connection state between each electric module and the bus bar module. FIG. 72 is a configuration diagram for explaining a modification 1 of the in-wheel motor. FIG. 73 is a configuration diagram for explaining a modification 2 of the in-wheel motor. FIG. 74 is a configuration diagram for explaining a modification 3 of the in-wheel motor. FIG. 75 is a configuration diagram for explaining a modification 4 of the in-wheel motor. FIG. 76 is a perspective view showing the entire rotary electric machine in the modified example 15. FIG. 77 is a vertical cross-sectional view of the rotary electric machine. FIG. 78 is an exploded sectional view of the rotary electric machine. FIG. 79 is a cross-sectional view of the rotor. FIG. 80 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit. FIG. 81 is a partial cross-sectional view showing a part of the magnet unit in an enlarged manner. FIG. 82 is a perspective view showing the configuration of the stator. FIG. 83 is a perspective view showing the stator winding and the stator core in an exploded manner. FIG. 84 is a perspective view showing only the configuration corresponding to the U-phase winding among the phase windings of each phase. FIG. 85 is a vertical cross-sectional view of the stator. FIG. 86 is a circuit diagram showing a connection state of partial windings in each of the three-phase windings. FIG. 87 is a diagram showing the configuration of the coil module. FIG. 88 is a diagram showing the configuration of the coil module. FIG. 89 is a diagram showing the configuration of the coil module. FIG. 90 is a diagram showing the configuration of the coil module. FIG. 91 is a cross-sectional view showing a vertical cross section of the stator. FIG. 92 is a cross-sectional view showing a cross section of the stator. FIG. 93 is a cross-sectional view showing the stator core, the end ring, and the coil module separated from each other. FIG. 94 is a vertical sectional view of the inner unit. FIG. 95 is a vertical sectional view of the inner unit. FIG. 96 is a perspective view of the bus bar module. FIG. 97 is a cross-sectional view showing a part of the vertical cross section of the bus bar module. FIG. 98 is a schematic diagram showing the connection positions of the connection terminals for each bus bar. FIG. 99 is a diagram showing the winding order of the conducting wires in the partial winding. FIG. 100 is a diagram showing the configuration of the coil module. FIG. 101 is a vertical cross-sectional view showing the configuration of the rotary electric machine in the modified example 16. FIG. 102 is a cross-sectional view of the rotary electric machine. FIG. 103 is an enlarged cross-sectional view showing a part of the configuration of the rotary electric machine. FIG. 104 is a perspective view showing the configuration of the partial winding. FIG. 105 is a side view showing the first partial winding and the second partial winding side by side in comparison. FIG. 106 is a cross-sectional view taken along the line 106-106 in FIG. 104 (a). FIG. 107 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core. FIG. 108 is a schematic view for explaining the assembly of the partial winding with respect to the stator core. FIG. 109 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core. FIG. 110 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core. FIG. 111 is a schematic view showing the configuration of the assembly of the partial winding with respect to the stator core. FIG. 112 is a schematic view for explaining the configuration of the partial winding. FIG. 113 is a schematic view for explaining the skew structure of the rotor.
　図面を参照しながら、複数の実施形態を説明する。複数の実施形態において、機能的におよび／または構造的に対応する部分および／または関連付けられる部分には同一の参照符号、または百以上の位が異なる参照符号が付される場合がある。対応する部分および／又は関連付けられる部分については、他の実施形態の説明を参照することができる。 A plurality of embodiments will be described with reference to the drawings. In a plurality of embodiments, functionally and / or structurally corresponding parts and / or related parts may be designated with the same reference code or reference codes having a hundreds or more different digits. References can be made to the description of other embodiments for the corresponding and / or associated parts.
　本実施形態における回転電機は、例えば車両動力源として用いられるものとなっている。ただし、回転電機は、産業用、車両用、家電用、ＯＡ機器用、遊技機用などとして広く用いられることが可能となっている。なお、以下の各実施形態相互において、互いに同一又は均等である部分には、図中、同一符号を付しており、同一符号の部分についてはその説明を援用する。 The rotary electric machine in this embodiment is used as a vehicle power source, for example. However, the rotary electric machine can be widely used for industrial use, vehicle use, home appliance use, OA equipment use, game machine use, and the like. In each of the following embodiments, parts that are the same or equal to each other are designated by the same reference numerals in the drawings, and the description thereof will be incorporated for the parts having the same reference numerals.
　（第１実施形態）
　本実施形態に係る回転電機１０は、同期式多相交流モータであり、アウタロータ構造（外転構造）のものとなっている。回転電機１０の概要を図１乃至図５に示す。図１は、回転電機１０の縦断面斜視図であり、図２は、回転電機１０の回転軸１１に沿う方向での縦断面図であり、図３は、回転軸１１に直交する方向での回転電機１０の横断面図（図２のIII－III線断面図）であり、図４は、図３の一部を拡大して示す断面図であり、図５は、回転電機１０の分解図である。なお、図３では、図示の都合上、回転軸１１を除き、切断面を示すハッチングを省略している。以下の記載では、回転軸１１が延びる方向を軸方向とし、回転軸１１の中心から放射状に延びる方向を径方向とし、回転軸１１を中心として円周状に延びる方向を周方向としている。 (First Embodiment)
The rotary electric machine 10 according to the present embodiment is a synchronous multi-phase AC motor and has an outer rotor structure (abduction structure). The outline of the rotary electric machine 10 is shown in FIGS. 1 to 5. FIG. 1 is a vertical sectional perspective view of the rotary electric machine 10, FIG. 2 is a vertical sectional view of the rotary electric machine 10 in a direction along the rotation axis 11, and FIG. 3 is a vertical sectional view in a direction orthogonal to the rotation axis 11. It is a cross-sectional view of the rotary electric machine 10 (a cross-sectional view taken along line III-III of FIG. 2), FIG. 4 is an enlarged cross-sectional view of a part of FIG. 3, and FIG. Is. In FIG. 3, for convenience of illustration, the hatching indicating the cut surface is omitted except for the rotating shaft 11. In the following description, the direction in which the rotating shaft 11 extends is the axial direction, the direction extending radially from the center of the rotating shaft 11 is the radial direction, and the direction extending radially around the rotating shaft 11 is the circumferential direction.
　回転電機１０は、大別して、軸受ユニット２０と、ハウジング３０と、回転子４０と、固定子５０と、インバータユニット６０とを備えている。これら各部材は、いずれも回転軸１１と共に同軸上に配置され、所定順序で軸方向に組み付けられることで回転電機１０が構成されている。本実施形態の回転電機１０は、「界磁子」としての回転子４０と、「電機子」としての固定子５０とを有する構成となっており、回転界磁形の回転電機として具体化されるものとなっている。 The rotary electric machine 10 is roughly classified into 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 rotary electric machine 10 of the present embodiment has a configuration having a rotor 40 as a "field magnet" and a stator 50 as an "armature", and is embodied as a rotary field type rotary electric machine. It has become a thing.
　軸受ユニット２０は、軸方向に互いに離間して配置される２つの軸受２１，２２と、その軸受２１，２２を保持する保持部材２３とを有している。軸受２１，２２は、例えばラジアル玉軸受であり、それぞれ外輪２５と、内輪２６と、それら外輪２５及び内輪２６の間に配置された複数の玉２７とを有している。保持部材２３は円筒状をなしており、その径方向内側に軸受２１，２２が組み付けられている。そして、軸受２１，２２の径方向内側に、回転軸１１及び回転子４０が回転自在に支持されている。軸受２１，２２により、回転軸１１を回転可能に支持する一組の軸受が構成されている。 The bearing unit 20 has two bearings 21 and 22 arranged apart from each other in the axial direction, and a holding member 23 for holding the bearings 21 and 22. The bearings 21 and 22 are, for example, radial ball bearings, each of which has an outer ring 25, an inner ring 26, and a plurality of balls 27 arranged between the outer ring 25 and the inner ring 26. The holding member 23 has a cylindrical shape, and bearings 21 and 22 are assembled inside the holding member 23 in the radial direction. The rotating shaft 11 and the rotor 40 are rotatably supported inside the bearings 21 and 22 in the radial direction. Bearings 21 and 22 form a set of bearings that rotatably support the rotating shaft 11.
　各軸受２１，２２では、不図示のリテーナにより玉２７が保持され、その状態で各玉同士のピッチが保たれている。軸受２１，２２は、リテーナの軸方向上下部に封止部材を有し、その内部に非導電性グリース（例えば非導電性のウレア系グリース）が充填されている。また、内輪２６の位置がスペーサにより機械的に保持され、内側から上下方向に凸となる定圧予圧が施されている。 In each bearing 21 and 22, the balls 27 are held by retainers (not shown), and the pitch between the balls is maintained in that state. The bearings 21 and 22 have sealing members at the upper and lower portions in the axial direction of the retainer, and the inside thereof is filled with non-conductive grease (for example, non-conductive urea-based grease). Further, the position of the inner ring 26 is mechanically held by the spacer, and a constant pressure preload that is convex in the vertical direction from the inside is applied.
　ハウジング３０は、円筒状をなす周壁３１を有する。周壁３１は、その軸方向に対向する第１端と第２端を有する。周壁３１は、第１端に端面３２と有するとともに、第２端に開口３３を有する。開口３３は、第２端の全体において開放されている。端面３２には、その中央に円形の孔３４が形成されており、その孔３４に挿通させた状態で、ネジやリベット等の固定具により軸受ユニット２０が固定されている。また、ハウジング３０内、すなわち周壁３１及び端面３２により区画された内部スペースには、中空円筒状の回転子４０と中空円筒状の固定子５０とが収容されている。本実施形態では回転電機１０がアウタロータ式であり、ハウジング３０内には、筒状をなす回転子４０の径方向内側に固定子５０が配置されている。回転子４０は、軸方向において端面３２の側で回転軸１１に片持ち支持されている。 The housing 30 has a cylindrical peripheral wall 31. The peripheral wall 31 has a first end and a second end facing each other in the axial direction thereof. The peripheral wall 31 has an end face 32 at the first end and an opening 33 at the second end. The opening 33 is open throughout the second end. A circular hole 34 is formed in the center of the end surface 32, and the bearing unit 20 is fixed by a fixing tool such as a screw or a rivet while being inserted through the hole 34. Further, a hollow cylindrical rotor 40 and a hollow cylindrical stator 50 are housed in the housing 30, that is, in the internal space partitioned by the peripheral wall 31 and the end surface 32. In the present embodiment, the rotary electric machine 10 is an outer rotor type, and a stator 50 is arranged inside the housing 30 in the radial direction of the cylindrical rotor 40. The rotor 40 is cantilevered by the rotating shaft 11 on the side of the end face 32 in the axial direction.
　回転子４０は、中空筒状に形成された磁石ホルダ４１と、その磁石ホルダ４１の径方向内側に設けられた環状の磁石ユニット４２とを有している。磁石ホルダ４１は、略カップ状をなし、磁石保持部材としての機能を有する。磁石ホルダ４１は、円筒状をなす円筒部４３と、同じく円筒状をなしかつ円筒部４３よりも小径の固定部（attachment）４４と、それら円筒部４３及び固定部４４を繋ぐ部位となる中間部４５とを有している。円筒部４３の内周面に磁石ユニット４２が取り付けられている。 The rotor 40 has a magnet holder 41 formed in a hollow tubular shape 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 has a function as a magnet holding member. The magnet holder 41 has a cylindrical portion 43 having a cylindrical shape, an attachment 44 having a cylindrical shape and a diameter smaller than that of the cylindrical portion 43, and an intermediate portion serving as a portion connecting the cylindrical portion 43 and the fixed portion 44. It has 45 and. A magnet unit 42 is attached to the inner peripheral surface of the cylindrical portion 43.
　なお、磁石ホルダ４１は、機械強度が充分な冷間圧延鋼板（ＳＰＣＣ）や、鍛造用鋼、炭素繊維強化プラスチック（ＣＦＲＰ）等により構成されている。 The magnet holder 41 is made of a cold-rolled steel plate (SPCC) having sufficient mechanical strength, forging steel, carbon fiber reinforced plastic (CFRP), or the like.
　固定部４４の貫通孔４４ａには回転軸１１が挿通される。貫通孔４４ａ内に配置された回転軸１１に対して固定部４４が固定されている。つまり、固定部４４により、回転軸１１に対して磁石ホルダ４１が固定されている。なお、固定部４４は、凹凸を利用したスプライン結合やキー結合、溶接、又はかしめ等により回転軸１１に対して固定されているとよい。これにより、回転子４０が回転軸１１と一体に回転する。 The rotating shaft 11 is inserted through the through hole 44a of the fixing portion 44. The fixing portion 44 is fixed to the rotating shaft 11 arranged in the through hole 44a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing portion 44. The fixing portion 44 may be fixed to the rotating shaft 11 by spline coupling, key coupling, welding, caulking, or the like using unevenness. As a result, the rotor 40 rotates integrally with the rotating shaft 11.
　また、固定部４４の径方向外側には、軸受ユニット２０の軸受２１，２２が組み付けられている。上述のとおり軸受ユニット２０はハウジング３０の端面３２に固定されているため、回転軸１１及び回転子４０は、ハウジング３０に回転可能に支持されるものとなっている。これにより、ハウジング３０内において回転子４０が回転自在となっている。 Further, bearings 21 and 22 of the bearing unit 20 are assembled on the radial outer side of the fixing portion 44. As described above, since the bearing unit 20 is fixed to the end surface 32 of the housing 30, the rotating shaft 11 and the rotor 40 are rotatably supported by the housing 30. As a result, the rotor 40 is rotatable in the housing 30.
　回転子４０には、その軸方向に対向する二つの端部の一方にのみ固定部４４が設けられており、これにより、回転子４０が回転軸１１に片持ち支持されている。ここで、回転子４０の固定部４４は、軸受ユニット２０の軸受２１，２２により、軸方向に異なる２位置で回転可能に支持されている。すなわち、回転子４０は、磁石ホルダ４１の、その軸方向に対向する二つの端部の一方において、その軸方向に離間する二つの軸受２１，２２により回転可能に支持されている。そのため、回転子４０が回転軸１１に片持ち支持される構造であっても、回転子４０の安定回転が実現されるようになっている。この場合、回転子４０の軸方向中心位置に対して片側にずれた位置で、回転子４０が軸受２１，２２により支持されている。 The rotor 40 is provided with a fixing portion 44 only on one of its two end portions facing in the axial direction, whereby the rotor 40 is cantilevered and supported by the rotating shaft 11. Here, the fixing portion 44 of the rotor 40 is rotatably supported by bearings 21 and 22 of the bearing unit 20 at two positions different in the axial direction. That is, the rotor 40 is rotatably supported by two bearings 21 and 22 which are separated from each other in the axial direction at one of the two end portions of the magnet holder 41 which face each other in the axial direction. Therefore, even if the rotor 40 is cantilevered and supported by the rotating shaft 11, stable rotation of the rotor 40 can be realized. In this case, the rotor 40 is supported by the bearings 21 and 22 at a position shifted to one side with respect to the axial center position of the rotor 40.
　また、軸受ユニット２０において回転子４０の中心寄り（図の下側）の軸受２２と、その逆側（図の上側）の軸受２１とは、外輪２５及び内輪２６と玉２７との間の隙間寸法が相違しており、例えば回転子４０の中心寄りの軸受２２の方が、その逆側の軸受２１よりも隙間寸法が大きいものとなっている。この場合、回転子４０の中心寄りの側において、回転子４０の振れや、部品公差に起因するインバランスによる振動が軸受ユニット２０に作用しても、その振れや振動の影響が良好に吸収される。具体的には、回転子４０の中心寄り（図の下側）の軸受２２において予圧により遊び寸法（隙間寸法）を大きくしていることで、片持ち構造において生じる振動がその遊び部分により吸収される。前記予圧は、定位置予圧、又は定圧予圧のいずれであっても良い。定位置予圧の場合、軸受２１と軸受２２の外輪２５はいずれも保持部材２３に対して、圧入、又は接着等の方法を用いて接合されている。また、軸受２１と軸受２２の内輪２６はいずれも回転軸１１に対して、圧入、又は接着等の方法を用いて接合されている。ここで軸受２１の外輪２５を軸受２１の内輪２６に対して軸方向に異なる位置に配置する事で予圧を発生させることができる。軸受２２の外輪２５を軸受２２の内輪２６に対して軸方向に異なる位置に配置する事でも予圧を発生させることができる。 Further, in the bearing unit 20, the bearing 22 near the center of the rotor 40 (lower side in the figure) and the bearing 21 on the opposite side (upper side in the figure) are the gaps between the outer ring 25 and the inner ring 26 and the ball 27. The dimensions are different. For example, the bearing 22 near the center of the rotor 40 has a larger clearance dimension than the bearing 21 on the opposite side. In this case, even if vibration of the rotor 40 or vibration due to imbalance caused by component tolerance acts on the bearing unit 20 on the side closer to the center of the rotor 40, the influence of the vibration or vibration is well absorbed. Tolerant. Specifically, by increasing the play dimension (gap dimension) by preloading the bearing 22 near the center of the rotor 40 (lower side of the figure), the vibration generated in the cantilever structure is absorbed by the play portion. To. The preload may be either a fixed position preload or a constant pressure 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 rotating shaft 11 by a method such as press fitting or adhesion. Here, the preload can be generated by arranging the outer ring 25 of the bearing 21 at different positions in the axial direction with respect to the inner ring 26 of the bearing 21. Preload can also be generated by arranging the outer ring 25 of the bearing 22 at different positions in the axial direction with respect to the inner ring 26 of the bearing 22.
　また定圧予圧を採用する場合には、軸方向において、軸受２２と軸受２１に挟まれた領域から軸受２２の外輪２５に向けて予圧が発生する様に予圧用バネ、例えばウェーブワッシャ２４等を軸受２２と軸受２１に挟まれた同領域に配置する。この場合も、軸受２１と軸受２２の内輪２６はいずれも回転軸１１に対して、圧入、又は接着等の方法を用いて接合されている。軸受２１、又は軸受２２の外輪２５は、保持部材２３に対して所定のクリアランスを介して配置される。このような構成とすることで、軸受２２の外輪２５には軸受２１から離れる方向に予圧用バネのバネ力が作用する。そして、この力が回転軸１１を伝わることで、軸受２１の内輪２６を軸受２２の方向に押し付ける力が作用する。これにより、軸受２１，２２ともに、外輪２５と内輪２６の軸方向の位置がずれ、前述した定位置予圧と同様に２つのベアリングに予圧を掛けることができる。 When a constant pressure preload is adopted, a preload spring, for example, a wave washer 24 or the like is bearing so that a preload is generated from the region sandwiched between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22 in the axial direction. It is arranged in the same region sandwiched between the 22 and the bearing 21. 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 bonding. The bearing 21 or the outer ring 25 of the bearing 22 is arranged with respect to the holding member 23 via a predetermined clearance. With such a configuration, the spring force of the preload spring acts on the outer ring 25 of the bearing 22 in the direction away from the bearing 21. Then, when this force is transmitted through the rotating shaft 11, a force that presses the inner ring 26 of the bearing 21 in the direction of the bearing 22 acts. As a result, the positions of the outer ring 25 and the inner ring 26 in the axial direction of both the bearings 21 and 22 are displaced, and the preload can be applied to the two bearings in the same manner as the above-mentioned fixed position preload.
　なお、定圧予圧を発生させる際には、必ずしも図２に示す様に軸受２２の外輪２５にバネ力を印加する必要は無い。例えば、軸受２１の外輪２５にバネ力を印加しても良い。また軸受２１，２２のいずれかの内輪２６を回転軸１１に対して所定のクリアランスを介して配置し、軸受２１，２２の外輪２５を保持部材２３に対して圧入、又は接着等の方法を用いて接合することで、２つのベアリングに予圧を掛けても良い。 When generating the constant pressure preload, it is not always necessary to apply the spring force to the outer ring 25 of the bearing 22 as shown in FIG. For example, a spring force may be applied to the outer ring 25 of the bearing 21. Further, the inner ring 26 of any of the bearings 21 and 22 is arranged with respect to the rotating shaft 11 through a predetermined clearance, and the outer ring 25 of the bearings 21 and 22 is press-fitted or bonded to the holding member 23. Preload may be applied to the two bearings by joining them together.
　更には、軸受２１の内輪２６が軸受２２に対して離れるように力を作用させる場合には、軸受２２の内輪２６も軸受２１に対して離れるように力を作用させる方が良い。逆に、軸受２１の内輪２６が軸受２２に対して近づくように力を作用させる場合には、軸受２２の内輪２６も軸受２１に対して近づくように力を作用させる方が良い。 Furthermore, when a force is applied so that the inner ring 26 of the bearing 21 is separated from the bearing 22, it is better to apply a force so that the inner ring 26 of the bearing 22 is also separated from the bearing 21. On the contrary, when the force is applied so that the inner ring 26 of the bearing 21 approaches the bearing 22, it is better to apply the force so that the inner ring 26 of the bearing 22 also approaches the bearing 21.
　なお、本回転電機１０を車両動力源等の目的で車両に適用する場合には、予圧を発生させる機構に対して予圧の発生方向の成分を持つ振動が加わる可能性や、予圧を印加する対象物に掛る重力の方向が変動してしまう可能性がある。その為、本回転電機１０を車両に適用する場合には、定位置予圧を採用することが望ましい。 When the rotary electric machine 10 is applied to a vehicle for the purpose of a vehicle power source or the like, there is a possibility that vibration having a component in the direction in which the preload is generated is applied to the mechanism for generating the preload, and a target to which the preload is applied. The direction of gravity on an object may fluctuate. Therefore, when applying the rotary electric machine 10 to a vehicle, it is desirable to adopt a fixed position preload.
　また、中間部４５は、環状の内側肩部４９ａと環状の外側肩部４９ｂを有する。外側肩部４９ｂは、中間部４５の径方向において内側肩部４９ａの外側に位置している。内側肩部４９ａと外側肩部４９ｂは、中間部４５の軸方向において互いに離間している。これにより、中間部４５の径方向において、円筒部４３と固定部４４とは部分的に重複している。つまり、固定部４４の基端部（図の下側の奥側端部）よりも軸方向外側に、円筒部４３が突出するものとなっている。本構成では、中間部４５が段差無しで平板状に設けられる場合に比べて、回転子４０の重心近くの位置で、回転軸１１に対して回転子４０を支持させることが可能となり、回転子４０の安定動作が実現できるものとなっている。 Further, the intermediate portion 45 has an annular inner shoulder portion 49a and an annular outer shoulder portion 49b. The outer shoulder portion 49b is located outside the inner shoulder portion 49a in the radial direction of the intermediate portion 45. The inner shoulder portion 49a and the outer shoulder portion 49b are separated from each other in the axial direction of the intermediate portion 45. As a result, the cylindrical portion 43 and the fixed portion 44 partially overlap in the radial direction of the intermediate portion 45. That is, the cylindrical portion 43 protrudes outward in the axial direction from the base end portion (lower end portion on the lower side of the figure) of the fixed portion 44. In this configuration, the rotor 40 can be supported with respect to the rotating shaft 11 at a position near the center of gravity of the rotor 40, as compared with the case where the intermediate portion 45 is provided in a flat plate shape without a step. The stable operation of 40 can be realized.
　上述した中間部４５の構成によれば、回転子４０には、径方向において固定部４４を囲みかつ中間部４５の内寄りとなる位置に、軸受ユニット２０の一部を収容する軸受収容凹部４６が環状に形成されるとともに、径方向において軸受収容凹部４６を囲みかつ中間部４５の外寄りとなる位置に、後述する固定子５０の固定子巻線５１のコイルエンド５４を収容するコイル収容凹部４７が形成されている。そして、これら各収容凹部４６，４７が、径方向の内外で隣り合うように配置されるようになっている。つまり、軸受ユニット２０の一部と、固定子巻線５１のコイルエンド５４とが径方向内外に重複するように配置されている。これにより、回転電機１０において軸方向の長さ寸法の短縮が可能となっている。 According to the configuration of the intermediate portion 45 described above, the rotor 40 has a bearing accommodating recess 46 that accommodates a part of the bearing unit 20 at a position that surrounds the fixing portion 44 in the radial direction and is inward of the intermediate portion 45. Is formed in an annular shape, and a coil accommodating recess that accommodates the coil end 54 of the stator winding 51 of the stator 50, which will be described later, at a position that surrounds the bearing accommodating recess 46 in the radial direction and is located on the outer side of the intermediate portion 45. 47 is formed. The accommodating recesses 46 and 47 are arranged so as to be adjacent to each other inside and outside in the radial direction. That is, a part of the bearing unit 20 and the coil end 54 of the stator winding 51 are arranged so as to overlap in and out in the radial direction. This makes it possible to shorten the axial length dimension in the rotary electric machine 10.
　中間部４５は、回転軸１１側から径方向外側に張り出すように設けられている。そして、その中間部４５に、軸方向に延び、固定子５０の固定子巻線５１のコイルエンド５４に対する接触を回避する接触回避部が設けられている。中間部４５が張出部に相当する。 The intermediate portion 45 is provided so as to project radially outward from the rotation shaft 11 side. The intermediate portion 45 is provided with a contact avoiding portion that extends in the axial direction and avoids contact of the stator winding 51 of the stator 50 with respect to the coil end 54. The intermediate portion 45 corresponds to the overhanging portion.
　コイルエンド５４は、径方向の内側又は外側に曲げられることで、そのコイルエンド５４の軸方向寸法を小さくすることができ、固定子５０の軸長を短縮することが可能である。コイルエンド５４の曲げ方向は、回転子４０との組み付けを考慮したものであるとよい。回転子４０の径方向内側に固定子５０を組み付けることを想定すると、その回転子４０に対する挿入先端側では、コイルエンド５４が径方向内側に曲げられるとよい。コイルエンド５４の反対側のコイルエンドの曲げ方向は任意でよいが、空間的に余裕のある外側に曲げた形状が製造上好ましい。 By bending the coil end 54 inward or outward in the radial direction, the axial dimension of the coil end 54 can be reduced, and the axial length of the stator 50 can be shortened. The bending direction of the coil end 54 may be in consideration of assembly with the rotor 40. Assuming that the stator 50 is assembled inside the rotor 40 in the radial direction, the coil end 54 may be bent inward in the radial direction on the insertion tip side with respect to the rotor 40. The bending direction of the coil end on the opposite side of the coil end 54 may be arbitrary, but a shape in which the coil end is bent outward with a sufficient space is preferable in manufacturing.
　また、磁石部としての磁石ユニット４２は、円筒部４３の径方向内側において、周方向に沿って極性が交互に変わるように配置された複数の永久磁石により構成されている。これにより、磁石ユニット４２は、周方向に複数の磁極を有する。ただし、磁石ユニット４２の詳細については後述する。 Further, the magnet unit 42 as the magnet portion is composed of a plurality of permanent magnets arranged so as to alternately change the polarities along the circumferential direction inside the cylindrical portion 43 in the radial direction. As a result, the magnet unit 42 has a plurality of magnetic poles in the circumferential direction. However, the details of the magnet unit 42 will be described later.
　固定子５０は、回転子４０の径方向内側に設けられている。固定子５０は、略筒状（環状）に巻回形成された固定子巻線５１と、その径方向内側に配置されたベース部材としての固定子コア５２とを有しており、固定子巻線５１が、所定のエアギャップを挟んで円環状の磁石ユニット４２に対向するように配置されている。固定子巻線５１は複数の相巻線よりなる。それら各相巻線は、周方向に配列された複数の導線が所定ピッチで互いに接続されることで構成されている。本実施形態では、Ｕ相、Ｖ相及びＷ相の３相巻線と、Ｘ相、Ｙ相及びＺ相の３相巻線とを用い、それら３相の巻線を２つ用いることで、固定子巻線５１が６相の相巻線として構成されている。 The stator 50 is provided inside the rotor 40 in the radial direction. The stator 50 has a stator winding 51 formed by winding in a substantially tubular shape (annular shape) and a stator core 52 as a base member arranged radially inside the stator winding. The wire 51 is arranged so as to face the annular magnet unit 42 with a predetermined air gap in between. The stator winding 51 is composed of a plurality of phase windings. Each of these phase windings is configured by connecting a plurality of conductors arranged in the circumferential direction to each other at a predetermined pitch. In the present embodiment, a U-phase, V-phase, and W-phase three-phase winding and an X-phase, Y-phase, and Z-phase three-phase winding are used, and two of these three-phase windings are used. The stator winding 51 is configured as a 6-phase phase winding.
　固定子コア５２は、軟磁性材である電磁鋼板が積層された積層鋼板により円環状に形成されており、固定子巻線５１の径方向内側に組み付けられている。電磁鋼板は、例えば鉄に数％程度（例えば３％）の珪素を添加した珪素鋼板である。固定子巻線５１が電機子巻線に相当し、固定子コア５２が電機子コアに相当する。 The stator core 52 is formed in an annular shape by laminated steel plates on which electromagnetic steel plates which are soft magnetic materials are laminated, and is assembled inside the stator winding 51 in the radial direction. The electromagnetic steel sheet is, for example, a silicon steel sheet in which about several% (for example, 3%) of silicon is added to iron. The stator winding 51 corresponds to the armature winding, and the stator core 52 corresponds to the armature core.
　固定子巻線５１は、径方向において固定子コア５２に重複する部分であり、かつ固定子コア５２の径方向外側となるコイルサイド部５３と、軸方向において固定子コア５２の一端側及び他端側にそれぞれ張り出すコイルエンド５４，５５とを有している。コイルサイド部５３は、径方向において固定子コア５２と回転子４０の磁石ユニット４２にそれぞれ対向している。回転子４０の内側に固定子５０が配置された状態では、軸方向両側のコイルエンド５４，５５のうち軸受ユニット２０の側（図の上側）となるコイルエンド５４が、回転子４０の磁石ホルダ４１により形成されたコイル収容凹部４７に収容されている。ただし、固定子５０の詳細については後述する。 The stator winding 51 is a portion that overlaps the stator core 52 in the radial direction, and is a coil side portion 53 that is radially outside the stator core 52, and one end side of the stator core 52 and others in the axial direction. It has coil ends 54 and 55 overhanging on the end side, respectively. The coil side portion 53 faces the stator core 52 and the magnet unit 42 of the rotor 40 in the radial direction, respectively. When the stator 50 is arranged inside the rotor 40, the coil end 54 on the side of the bearing unit 20 (upper side in the figure) of the coil ends 54 and 55 on both sides in the axial direction is the magnet holder of the rotor 40. It is housed in the coil accommodating recess 47 formed by 41. However, the details of the stator 50 will be described later.
　インバータユニット６０は、ハウジング３０に対してボルト等の締結具により固定されるユニットベース６１と、そのユニットベース６１に組み付けられる複数の電気コンポーネント６２とを有している。ユニットベース６１は、例えば炭素繊維強化プラスチック（ＣＦＲＰ）により構成されている。ユニットベース６１は、ハウジング３０の開口３３の縁に対して固定されるエンドプレート６３と、そのエンドプレート６３に一体に設けられ、軸方向に延びるケーシング６４とを有している。エンドプレート６３は、その中心部に円形の開口６５を有しており、開口６５の周縁部から起立するようにしてケーシング６４が形成されている。 The inverter unit 60 has a unit base 61 fixed to the housing 30 by fasteners such as bolts, and a plurality of electrical components 62 assembled to the unit base 61. The unit base 61 is made of, for example, carbon fiber reinforced plastic (CFRP). The unit base 61 has an end plate 63 fixed to the edge of the opening 33 of the housing 30, and a casing 64 integrally provided with the end plate 63 and extending in the axial direction. The end plate 63 has a circular opening 65 at the center thereof, and the casing 64 is formed so as to stand up from the peripheral edge of the opening 65.
　ケーシング６４の外周面には固定子５０が組み付けられている。つまり、ケーシング６４の外径寸法は、固定子コア５２の内径寸法と同じか、又は固定子コア５２の内径寸法よりも僅かに小さい寸法になっている。ケーシング６４の外側に固定子コア５２が組み付けられることで、固定子５０とユニットベース６１とが一体化されている。また、ユニットベース６１がハウジング３０に固定されることからすると、ケーシング６４に固定子コア５２が組み付けられた状態では、固定子５０がハウジング３０に対して一体化された状態となっている。 A stator 50 is assembled on the outer peripheral surface of the casing 64. That is, the outer diameter of the casing 64 is the same as the inner diameter of the stator core 52, or slightly smaller than the inner diameter of the stator core 52. By assembling the stator core 52 to the outside of the casing 64, the stator 50 and the unit base 61 are integrated. Further, since the unit base 61 is fixed to the housing 30, the stator 50 is integrated with the housing 30 when the stator core 52 is assembled to the casing 64.
　なお、固定子コア５２は、ユニットベース６１に対して接着、焼きばめ、圧入等により組み付けられているとよい。これにより、ユニットベース６１側に対する固定子コア５２の周方向又は軸方向の位置ずれが抑制される。 The stator core 52 may be assembled to the unit base 61 by adhesion, shrink fitting, press fitting, or the like. As a result, the displacement of the stator core 52 in the circumferential direction or the axial direction with respect to the unit base 61 side is suppressed.
　また、ケーシング６４の径方向内側は、電気コンポーネント６２を収容する収容空間となっており、その収容空間には、回転軸１１を囲むようにして電気コンポーネント６２が配置されている。ケーシング６４は、収容空間形成部としての役目を有している。電気コンポーネント６２は、インバータ回路を構成する半導体モジュール６６や、制御基板６７、コンデンサモジュール６８を具備する構成となっている。 Further, the radial inside of the casing 64 is a storage space for accommodating the electric component 62, and the electric component 62 is arranged so as to surround the rotating shaft 11 in the accommodation space. The casing 64 has a role as a storage space forming portion. The electric component 62 includes a semiconductor module 66 constituting an inverter circuit, a control board 67, and a capacitor module 68.
　なお、ユニットベース６１が、固定子５０の径方向内側に設けられ、固定子５０を保持する固定子ホルダ（電機子ホルダ）に相当する。ハウジング３０及びユニットベース６１により、回転電機１０のモータハウジングが構成されている。このモータハウジングでは、回転子４０を挟んで軸方向の一方側においてハウジング３０に対して保持部材２３が固定されるとともに、他方側においてハウジング３０及びユニットベース６１が互いに結合されている。例えば電気自動車である電動車両等においては、その車両等の側にモータハウジングが取り付けられることで、回転電機１０が車両等に装着される。 The unit base 61 is provided 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 the motor housing of the rotary electric machine 10. In this motor housing, the holding member 23 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 are coupled to each other on the other side. For example, in an electric vehicle or the like which is an electric vehicle, the rotary electric machine 10 is attached to the vehicle or the like by attaching a motor housing to the side of the vehicle or the like.
　ここで、上記図１～図５に加え、インバータユニット６０の分解図である図６を用いて、インバータユニット６０の構成をさらに説明する。 Here, in addition to FIGS. 1 to 5 above, the configuration of the inverter unit 60 will be further described with reference to FIG. 6, which is an exploded view of the inverter unit 60.
　ユニットベース６１において、ケーシング６４は、筒状部７１と、その軸方向において対向する両端の一方（軸受ユニット２０側の端部）に設けられた端面７２とを有している。筒状部７１の軸方向両端部のうち端面７２の反対側は、エンドプレート６３の開口６５を通じて全面的に開放されている。端面７２には、その中央に円形の孔７３が形成されており、その孔７３に回転軸１１が挿通可能となっている。孔７３には、回転軸１１の外周面との間の空隙を封鎖するシール材１７１が設けられている。シール材１７１は、例えば樹脂材料よりなる摺動シールであるとよい。 In the unit base 61, the casing 64 has a tubular portion 71 and end faces 72 provided on one of both ends (ends on the bearing unit 20 side) facing each other in the axial direction thereof. Of both ends of the tubular portion 71 in the axial direction, the opposite side of the end surface 72 is completely opened through the opening 65 of the end plate 63. A circular hole 73 is formed in the center of the end surface 72, and the rotating shaft 11 can be inserted into the hole 73. The hole 73 is provided with a sealing material 171 that seals a gap between the rotating shaft 11 and the outer peripheral surface. The sealing material 171 may be, for example, a sliding seal made of a resin material.
　ケーシング６４の筒状部７１は、その径方向外側に配置される回転子４０及び固定子５０と、その径方向内側に配置される電気コンポーネント６２との間を仕切る仕切り部となっており、筒状部７１を挟んで径方向内外に、回転子４０及び固定子５０と電気コンポーネント６２とが並ぶようにそれぞれ配置されている。 The tubular portion 71 of the casing 64 is a partition portion that partitions the rotor 40 and the stator 50 arranged on the outer side in the radial direction and the electric component 62 arranged on the inner side in the radial direction. The rotor 40, the stator 50, and the electrical component 62 are arranged side by side in and out of the radial direction with the shape portion 71 in between.
　また、電気コンポーネント６２は、インバータ回路を構成する電気部品であり、固定子巻線５１の各相巻線に対して所定順序で電流を流して回転子４０を回転させる力行機能と、回転軸１１の回転に伴い固定子巻線５１に流れる３相交流電流を入力し、発電電力として外部に出力する発電機能とを有している。なお、電気コンポーネント６２は、力行機能と発電機能とのうちいずれか一方のみを有するものであってもよい。発電機能は、例えば回転電機１０が車両用動力源として用いられる場合、回生電力として外部に出力する回生機能である。 Further, the electric component 62 is an electric component constituting an inverter circuit, and has a power running function of passing a current through each phase winding of the stator winding 51 in a predetermined order to rotate the rotor 40, and a rotating shaft 11. It has a power generation function of inputting a three-phase AC current flowing through the stator winding 51 with the rotation of the stator winding 51 and outputting it to the outside as generated power. The electric component 62 may have only one of the power running function and the power generation function. The power generation function is, for example, a regenerative function that outputs regenerative power to the outside when the rotary electric machine 10 is used as a power source for a vehicle.
　電気コンポーネント６２の具体的な構成として、図４に示すように、回転軸１１の周りには、中空円筒状をなすコンデンサモジュール６８が設けられており、そのコンデンサモジュール６８の外周面上に、複数の半導体モジュール６６が周方向に並べて配置されている。コンデンサモジュール６８は、互いに並列接続された平滑用のコンデンサ６８ａを複数備えている。具体的には、コンデンサ６８ａは、複数枚のフィルムコンデンサが積層されてなる積層型フィルムコンデンサであり、横断面が台形状をなしている。コンデンサモジュール６８は、１２個のコンデンサ６８ａが環状に並べて配置されることで構成されている。 As a specific configuration of the electric component 62, as shown in FIG. 4, a hollow cylindrical capacitor module 68 is provided around the rotating shaft 11, and a plurality of capacitor modules 68 are provided on the outer peripheral surface of the capacitor module 68. The semiconductor modules 66 of the above are arranged side by side in the circumferential direction. The capacitor module 68 includes a plurality of smoothing capacitors 68a connected in parallel to each other. Specifically, the capacitor 68a is a laminated film capacitor in which a plurality of film capacitors are laminated, and has a trapezoidal cross section. The capacitor module 68 is configured by arranging twelve capacitors 68a side by side in an annular shape.
　なお、コンデンサ６８ａの製造過程においては、例えば、複数のフィルムが積層されてなる所定幅の長尺フィルムを用い、フィルム幅方向を台形高さ方向とし、かつ台形の上底と下底とが交互になるように長尺フィルムが等脚台形状に切断されることにより、コンデンサ素子が作られる。そして、そのコンデンサ素子に電極等を取り付けることでコンデンサ６８ａが作製される。 In the manufacturing process of the capacitor 68a, for example, a long film having a predetermined width in which a plurality of films are laminated is used, the film width direction is the trapezoidal height direction, and the upper bottom and the lower bottom of the trapezoid are alternately alternated. A capacitor element is made by cutting a long film into an isosceles trapezoidal shape so as to be. Then, a capacitor 68a is manufactured by attaching an electrode or the like to the capacitor element.
　半導体モジュール６６は、例えばＭＯＳＦＥＴやＩＧＢＴ等の半導体スイッチング素子を有し、略板状に形成されている。本実施形態では、回転電機１０が２組の３相巻線を備えており、その３相巻線ごとにインバータ回路が設けられていることから、計１２個の半導体モジュール６６を環状に並べて形成された半導体モジュール群６６Ａが電気コンポーネント６２に設けられている。 The semiconductor module 66 has a semiconductor switching element such as a MOSFET or an IGBT, and is formed in a substantially plate shape. In the present embodiment, since the rotary electric machine 10 includes two sets of three-phase windings and an inverter circuit is provided for each of the three-phase windings, a total of 12 semiconductor modules 66 are formed by arranging them in an annular shape. The semiconductor module group 66A is provided in the electric component 62.
　半導体モジュール６６は、ケーシング６４の筒状部７１とコンデンサモジュール６８との間に挟まれた状態で配置されている。半導体モジュール群６６Ａの外周面は筒状部７１の内周面に当接し、半導体モジュール群６６Ａの内周面はコンデンサモジュール６８の外周面に当接している。この場合、半導体モジュール６６で生じた熱は、ケーシング６４を介してエンドプレート６３に伝わり、エンドプレート６３から放出される。 The semiconductor module 66 is arranged so as to be sandwiched between the tubular portion 71 of the casing 64 and the capacitor module 68. The outer peripheral surface of the semiconductor module group 66A is in contact with the inner peripheral surface of the tubular portion 71, and the inner peripheral surface of the semiconductor module group 66A is in contact with the outer peripheral surface of the capacitor module 68. In this case, the heat generated in the semiconductor module 66 is transferred to the end plate 63 via the casing 64 and released from the end plate 63.
　半導体モジュール群６６Ａは、外周面側、すなわち径方向において半導体モジュール６６と筒状部７１との間にスペーサ６９を有しているとよい。この場合、コンデンサモジュール６８では軸方向に直交する横断面の断面形状が正１２角形である一方、筒状部７１の内周面の横断面形状が円形であるため、スペーサ６９は、内周面が平坦面、外周面が曲面となっている。スペーサ６９は、半導体モジュール群６６Ａの径方向外側において円環状に連なるように一体に設けられていてもよい。スペーサ６９は、良熱伝導体であり、例えばアルミニウム等の金属、又は放熱ゲルシート等であるとよい。なお、筒状部７１の内周面の横断面形状をコンデンサモジュール６８と同じ１２角形にすることも可能である。この場合、スペーサ６９の内周面及び外周面がいずれも平坦面であるとよい。 The semiconductor module group 66A may have a spacer 69 on the outer peripheral surface side, that is, in the radial direction between the semiconductor module 66 and the tubular portion 71. In this case, in the capacitor module 68, the cross-sectional shape of the cross section orthogonal to the axial direction is a regular dodecagon, while the cross-sectional shape of the inner peripheral surface of the tubular portion 71 is circular, so that the spacer 69 is an inner peripheral surface. Is a flat surface and the outer peripheral surface is a curved surface. The spacer 69 may be integrally provided so as to be connected in an annular shape on the radial outer side of the semiconductor module group 66A. The spacer 69 is a good thermal conductor, and may be, for example, a metal such as aluminum, a heat radiating gel sheet, or the like. It is also possible to make the cross-sectional shape of the inner peripheral surface of the tubular portion 71 into a dodecagonal shape, which is the same as that of the capacitor module 68. In this case, it is preferable that both the inner peripheral surface and the outer peripheral surface of the spacer 69 are flat surfaces.
　また、本実施形態では、ケーシング６４の筒状部７１に、冷却水を流通させる冷却水通路７４が形成されており、半導体モジュール６６で生じた熱は、冷却水通路７４を流れる冷却水に対しても放出される。つまり、ケーシング６４は水冷機構を備えている。図３や図４に示すように、冷却水通路７４は、電気コンポーネント６２（半導体モジュール６６及びコンデンサモジュール６８）を囲むように環状に形成されている。半導体モジュール６６は筒状部７１の内周面に沿って配置されており、その半導体モジュール６６に対して径方向内外に重なる位置に冷却水通路７４が設けられている。 Further, in the present embodiment, a cooling water passage 74 for flowing cooling water is formed in the tubular portion 71 of the casing 64, and the heat generated in the semiconductor module 66 is directed to the cooling water flowing through the cooling water passage 74. Even released. That is, the casing 64 is provided with a water cooling mechanism. As shown in FIGS. 3 and 4, the cooling water passage 74 is formed in an annular shape so as to surround the electrical component 62 (semiconductor module 66 and condenser module 68). The semiconductor module 66 is arranged along the inner peripheral surface of the tubular portion 71, and a cooling water passage 74 is provided at a position where the semiconductor module 66 overlaps the semiconductor module 66 in the radial direction inside and outside.
　筒状部７１の外側には固定子５０が配置され、内側には電気コンポーネント６２が配置されていることから、筒状部７１に対しては、その外側から固定子５０の熱が伝わるとともに、内側から電気コンポーネント６２の熱（例えば半導体モジュール６６の熱）が伝わることになる。この場合、固定子５０と半導体モジュール６６とを同時に冷やすことが可能となっており、回転電機１０における発熱部材の熱を効率良く放出することができる。 Since the stator 50 is arranged on the outside of the tubular portion 71 and the electrical component 62 is arranged on the inside, the heat of the stator 50 is transferred to the tubular portion 71 from the outside, and the heat of the stator 50 is transferred to the tubular portion 71. The heat of the electric component 62 (for example, the heat of the semiconductor module 66) 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.
　更に、固定子巻線５１への通電を行うことで回転電機を動作させるインバータ回路の一部、又は全部を構成する半導体モジュール６６の少なくとも一部が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置されている。望ましくは、１つの半導体モジュール６６の全体が固定子コア５２に囲まれた領域内に配置されている。更に、望ましくは、全ての半導体モジュール６６の全体が固定子コア５２に囲まれた領域内に配置されている。 Further, at least a part of the semiconductor module 66 constituting a part or the whole of the inverter circuit for operating the rotary electric machine by energizing the stator winding 51 is radially outside the tubular portion 71 of the casing 64. It is arranged in the area surrounded by the stator core 52 arranged in. Desirably, the entire semiconductor module 66 is arranged in the region surrounded by the stator core 52. Further, preferably, the entire semiconductor module 66 is arranged in the region surrounded by the stator core 52.
　また、半導体モジュール６６の少なくとも一部が、冷却水通路７４により囲まれた領域内に配置されている。望ましくは、全ての半導体モジュール６６の全体がヨーク１４１に囲まれた領域内に配置されている。 Further, at least a part of the semiconductor module 66 is arranged in the area surrounded by the cooling water passage 74. Desirably, the entire semiconductor module 66 is located in the region surrounded by the yoke 141.
　また、電気コンポーネント６２は、軸方向において、コンデンサモジュール６８の一方の端面に設けられた絶縁シート７５と、他方の端面に設けられた配線モジュール７６とを備えている。この場合、コンデンサモジュール６８は、その軸方向に対向した二つの端面、すなわち第１端面と第２端面を有している。コンデンサモジュール６８の軸受ユニット２０に近い第１端面は、ケーシング６４の端面７２に対向しており、絶縁シート７５を挟んだ状態で端面７２に重ね合わされている。また、コンデンサモジュール６８の開口６５に近い第２端面には、配線モジュール７６が組み付けられている。 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 facing each other in the axial direction, that is, a first end face and a second end face. The first end surface of the capacitor module 68 near the bearing unit 20 faces the end surface 72 of the casing 64, and is superposed on the end surface 72 with the insulating sheet 75 sandwiched between them. A wiring module 76 is assembled on the second end surface of the capacitor module 68 near the opening 65.
　配線モジュール７６は、合成樹脂材よりなり円形板状をなす本体部７６ａと、その内部に埋設された複数のバスバー７６ｂ，７６ｃを有しており、そのバスバー７６ｂ，７６ｃにより、半導体モジュール６６やコンデンサモジュール６８と電気的接続がなされている。具体的には、半導体モジュール６６は、その軸方向端面から延びる接続ピン６６ａを有しており、その接続ピン６６ａが、本体部７６ａの径方向外側においてバスバー７６ｂに接続されている。また、バスバー７６ｃは、本体部７６ａの径方向外側においてコンデンサモジュール６８とは反対側に延びており、その先端部にて配線部材７９に接続されるようになっている（図２参照）。 The wiring module 76 has a main body portion 76a made of a synthetic resin material and having a circular plate shape, and a plurality of bus bars 76b and 76c embedded therein. The bus bars 76b and 76c are used to form a semiconductor module 66 and a capacitor. It has an electrical connection with module 68. Specifically, the semiconductor module 66 has a connecting pin 66a extending from its axial end face, and the connecting pin 66a is connected to the bus bar 76b on the radial outer side of the main body portion 76a. Further, the bus bar 76c extends to the side opposite to the capacitor module 68 on the radial outer side of the main body portion 76a, and is connected to the wiring member 79 at the tip end portion thereof (see FIG. 2).
　上記のとおりコンデンサモジュール６８の軸方向に対向する第１端面に絶縁シート７５が設けられ、かつコンデンサモジュール６８の第２端面に配線モジュール７６が設けられた構成によれば、コンデンサモジュール６８の放熱経路として、コンデンサモジュール６８の第１端面および第２端面から端面７２及び筒状部７１に至る経路が形成される。すなわち、第１端面から端面７２への経路と、第２端面から筒状部７１へ至る経路が形成される。これにより、コンデンサモジュール６８において半導体モジュール６６が設けられた外周面以外の端面部からの放熱が可能になっている。つまり、径方向への放熱だけでなく、軸方向への放熱も可能となっている。 According to the configuration in which the insulating sheet 75 is provided on the first end surface of the capacitor module 68 facing the axial direction and the wiring module 76 is provided on the second end surface of the capacitor module 68 as described above, the heat dissipation path of the capacitor module 68 is provided. As a result, a path is formed from the first end face and the second end face of the capacitor module 68 to the end face 72 and the tubular portion 71. That is, a path from the first end face to the end face 72 and a path from the second end face to the 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 on which the semiconductor module 66 is provided. That is, not only heat dissipation in the radial direction but also heat dissipation in the axial direction is possible.
　また、コンデンサモジュール６８は中空円筒状をなし、その内周部には所定の隙間を介在させて回転軸１１が配置されることから、コンデンサモジュール６８の熱はその中空部からも放出可能となっている。この場合、回転軸１１の回転により空気の流れが生じることにより、その冷却効果が高められるようになっている。 Further, since the capacitor module 68 has a hollow cylindrical shape and the rotating shaft 11 is arranged on the inner peripheral portion thereof with a predetermined gap interposed therebetween, the heat of the capacitor module 68 can be released from the hollow portion as well. ing. In this case, the rotation of the rotating shaft 11 causes an air flow to enhance the cooling effect.
　配線モジュール７６には、円板状の制御基板６７が取り付けられている。制御基板６７は、所定の配線パターンが形成されたプリントサーキットボード（ＰＣＢ）を有しており、そのボード上には各種ＩＣや、マイコン等からなる制御部に相当する制御装置７７が実装されている。制御基板６７は、ネジ等の固定具により配線モジュール７６に固定されている。制御基板６７は、その中央部に、回転軸１１を挿通させる挿通孔６７ａを有している。 A disk-shaped control board 67 is attached to the wiring module 76. The control board 67 has a printed circuit board (PCB) on which a predetermined wiring pattern is formed, and a control device 77 corresponding to a control unit including various ICs and a microcomputer is mounted on the board. There is. The control board 67 is fixed to the wiring module 76 by a fixture such as a screw. The control board 67 has an insertion hole 67a in which the rotation shaft 11 is inserted in the central portion thereof.
　なお、配線モジュール７６は、軸方向に互いに対向する、すなわち、その厚み方向において互いに対向する第１面と第２面を有する。第１面は、コンデンサモジュール６８に面する。配線モジュール７６は、その第２面に、制御基板６７を設けている。制御基板６７の両面の一方側から他方側に配線モジュール７６のバスバー７６ｃが延びる構成となっている。かかる構成において、制御基板６７には、バスバー７６ｃとの干渉を回避する切欠が設けられているとよい。例えば、円形状をなす制御基板６７の外縁部の一部が切り欠かれているとよい。 The wiring module 76 has a first surface and a second surface that face each other in the axial direction, that is, face each other in the thickness direction thereof. The first surface faces the capacitor module 68. The wiring module 76 is provided with a control board 67 on the second surface thereof. The bus bar 76c 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 76c. For example, it is preferable that a part of the outer edge portion of the control board 67 having a circular shape is cut out.
　上述のとおり、ケーシング６４に囲まれた空間内に電気コンポーネント６２が収容され、その外側に、ハウジング３０、回転子４０及び固定子５０が層状に設けられている構成によれば、インバータ回路で生じる電磁ノイズが好適にシールドされるようになっている。すなわち、インバータ回路では、所定のキャリア周波数によるＰＷＭ制御を利用して各半導体モジュール６６でのスイッチング制御が行われ、そのスイッチング制御により電磁ノイズが生じることが考えられるが、その電磁ノイズを、電気コンポーネント６２の径方向外側のハウジング３０、回転子４０、固定子５０等により好適にシールドできる。 As described above, according to the configuration in which the electric component 62 is housed in the space surrounded by the casing 64 and the housing 30, the rotor 40 and the stator 50 are provided in layers on the outside thereof, the electric component 62 is generated in the inverter circuit. Electromagnetic noise is suitably shielded. That is, in the inverter circuit, switching control is performed in each semiconductor module 66 by utilizing PWM control by a predetermined carrier frequency, and it is conceivable that electromagnetic noise is generated by the switching control. It can be suitably shielded by the housing 30, the rotor 40, the stator 50, etc. on the radial outer side of the 62.
　更に、半導体モジュール６６の少なくとも一部が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置することで、半導体モジュール６６と固定子巻線５１とが固定子コア５２を介さずに配置されている構成に比べて、半導体モジュール６６から磁束が発生したとしても、固定子巻線５１に影響を与えにくい。また、固定子巻線５１から磁束が発生したとしても、半導体モジュール６６に影響を与えにくい。なお、半導体モジュール６６の全体が、ケーシング６４の筒状部７１の径方向外側に配置された固定子コア５２に囲まれた領域内に配置されると更に効果的である。また、半導体モジュール６６の少なくとも一部が、冷却水通路７４により囲まれている場合、固定子巻線５１や磁石ユニット４２からの発熱が半導体モジュール６６に届きにくいという効果を得ることができる。 Further, at least a part of the semiconductor module 66 is arranged in the region surrounded by the stator core 52 arranged radially outside the tubular portion 71 of the casing 64, whereby the semiconductor module 66 and the stator winding are arranged. Compared to the configuration in which 51 and 51 are arranged without the stator core 52, even if magnetic flux is generated from the semiconductor module 66, it is less likely to affect the stator winding 51. Further, even if the magnetic flux is generated from the stator winding 51, it is unlikely to affect the semiconductor module 66. It is more effective if the entire semiconductor module 66 is arranged in a region surrounded by the stator core 52 arranged on the radial outer side of the tubular portion 71 of the casing 64. Further, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, it is possible to obtain the effect that the heat generated from the stator winding 51 and the magnet unit 42 is difficult to reach the semiconductor module 66.
　筒状部７１においてエンドプレート６３の付近には、その外側の固定子５０と内側の電気コンポーネント６２とを電気的に接続する配線部材７９（図２参照）を挿通させる貫通孔７８が形成されている。図２に示すように、配線部材７９は、圧着、溶接などにより、固定子巻線５１の端部と配線モジュール７６のバスバー７６ｃとにそれぞれ接続されている。配線部材７９は、例えばバスバーであり、その接合面は平たく潰されていることが望ましい。貫通孔７８は、１カ所又は複数箇所に設けられているとよく、本実施形態では２カ所に貫通孔７８が設けられている。２カ所に貫通孔７８が設けられる構成では、２組の３相巻線から延びる巻線端子を、それぞれ配線部材７９により容易に結線することが可能となり、多相結線を行う上で好適なものとなっている。 In the tubular portion 71, a through hole 78 is formed in the vicinity of the end plate 63 through which a wiring member 79 (see FIG. 2) for electrically connecting the outer stator 50 and the inner electrical component 62 is inserted. There is. As shown in FIG. 2, the wiring member 79 is connected to the end of the stator winding 51 and the bus bar 76c of the wiring module 76 by crimping, welding, or the like. The wiring member 79 is, for example, a bus bar, and it is desirable that the joint surface thereof be flattened. The through holes 78 are preferably provided at one place or a plurality of places, and in the present embodiment, the through holes 78 are provided at two places. In a configuration in which through holes 78 are provided at two locations, winding terminals extending from two sets of three-phase windings can be easily connected by wiring members 79, which is suitable for multi-phase connection. It has become.
　上述のとおりハウジング３０内には、図４に示すように径方向外側から順に回転子４０、固定子５０が設けられ、固定子５０の径方向内側にインバータユニット６０が設けられている。ここで、ハウジング３０の内周面の半径をｄとした場合に、回転子４０の回転中心からｄ×０．７０５の距離よりも径方向外側に回転子４０と固定子５０とが配置されている。この場合、回転子４０及び固定子５０のうち径方向内側の固定子５０の内周面（すなわち固定子コア５２の内周面）から径方向内側となる領域を第１領域Ｘ１、径方向において固定子５０の内周面からハウジング３０までの間の領域を第２領域Ｘ２とすると、第１領域Ｘ１の横断面の面積は、第２領域Ｘ２の横断面の面積よりも大きい構成となっている。また、径方向において回転子４０の磁石ユニット４２及び固定子巻線５１が重複する範囲で見て、第１領域Ｘ１の容積が第２領域Ｘ２の容積よりも大きい構成となっている。 As described above, as shown in FIG. 4, a rotor 40 and a stator 50 are provided in the housing 30 in this order from the outside in the radial direction, and an inverter unit 60 is provided inside the stator 50 in the radial direction. Here, assuming that the radius of the inner peripheral surface of the housing 30 is d, the rotor 40 and the stator 50 are arranged radially outside the distance of d × 0.705 from the center of rotation of the rotor 40. There is. In this case, the region of the rotor 40 and the stator 50 that is radially inward from the inner peripheral surface of the stator 50 that is radially inner (that is, the inner peripheral surface of the stator core 52) is the first region X1 in the radial direction. Assuming that the region between the inner peripheral surface of the stator 50 and the housing 30 is the second region X2, the cross-sectional area of the first region X1 is larger than the cross-sectional area of the second region X2. There is. Further, the volume of the first region X1 is larger than the volume of the second region X2 when viewed in the range where the magnet unit 42 of the rotor 40 and the stator winding 51 overlap in the radial direction.
　なお、回転子４０及び固定子５０を磁気回路コンポーネントアッセンブリとすると、ハウジング３０内において、その磁気回路コンポーネントアッセンブリの内周面から径方向内側となる第１領域Ｘ１が、径方向において磁気回路コンポーネントアッセンブリの内周面からハウジング３０までの間の第２領域Ｘ２よりも容積が大きい構成となっている。 When the rotor 40 and the stator 50 are magnetic circuit component assemblies, the first region X1 radially inside from the inner peripheral surface of the magnetic circuit component assembly in the housing 30 is the magnetic circuit component assembly in the radial direction. The volume is larger than that of the second region X2 between the inner peripheral surface of the above and the housing 30.
　次いで、回転子４０及び固定子５０の構成をより詳しく説明する。 Next, the configurations of the rotor 40 and the stator 50 will be described in more detail.
　一般に、回転電機における固定子の構成として、積層鋼板よりなりかつ円環状をなす固定子コアに周方向に複数のスロットを設け、そのスロット内に固定子巻線を巻装するものが知られている。具体的には、固定子コアは、ヨークから所定間隔で径方向に延びる複数のティースを有しており、周方向に隣り合うティース間にスロットが形成されている。そして、スロット内に、例えば径方向に複数層の導線が収容され、その導線により固定子巻線が構成されている。 Generally, as a structure of a stator in a rotary electric machine, a stator core made of a laminated steel plate and forming an annular shape is provided with a plurality of slots in the circumferential direction, and a stator winding is wound in the slots. There is. Specifically, the stator core has a plurality of teeth extending in the radial direction from the yoke at predetermined intervals, and slots are formed between the teeth adjacent to each other in the circumferential direction. Then, for example, a plurality of layers of conductors are accommodated in the slot in the radial direction, and the stator winding is formed by the conductors.
　ただし、上述した固定子構造では、固定子巻線の通電時において、固定子巻線の起磁力が増加するのに伴い固定子コアのティース部分で磁気飽和が生じ、それに起因して回転電機のトルク密度が制限されることが考えられる。つまり、固定子コアにおいて、固定子巻線の通電により生じた回転磁束がティースに集中することで、磁気飽和が生じると考えられる。 However, in the above-mentioned stator structure, when the stator winding is energized, magnetic saturation occurs in the teeth portion of the stator core as the magnetomotive force of the stator winding increases, which causes magnetic saturation in the rotating electric machine. It is possible that the torque density is limited. That is, in the stator core, it is considered that magnetic saturation occurs when the rotational magnetic flux generated by the energization of the stator winding is concentrated on the teeth.
　また、一般的に、回転電機におけるＩＰＭ（Interior Permanent Magnet）ロータの構成として、永久磁石がｄ－ｑ座標系におけるｄ軸に配置され、ｑ軸にロータコアが配置されたものが知られている。このような場合、ｄ軸近傍の固定子巻線が励磁されることで、フレミングの法則により固定子から回転子のｑ軸に励磁磁束が流入される。そしてこれにより、回転子のｑ軸コア部分に、広範囲の磁気飽和が生じると考えられる。 Further, in general, as a configuration of an IPM (Interior Permanent Magnet) rotor in a rotary electric machine, a permanent magnet is arranged on the d-axis in the dq coordinate system, and a rotor core is arranged on the q-axis. In such a case, the stator winding near the d-axis is excited, so that 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 portion of the rotor.
　図７は、固定子巻線の起磁力を示すアンペアターン［ＡＴ］とトルク密度［Ｎｍ／Ｌ］との関係を示すトルク線図である。破線が一般的なＩＰＭロータ型の回転電機における特性を示す。図７に示すように、一般的な回転電機では、固定子において起磁力を増加させていくことにより、スロット間のティース部分及びｑ軸コア部分の２カ所で磁気飽和が生じ、それが原因でトルクの増加が制限されてしまう。このように、当該一般的な回転電機では、アンペアターン設計値がＡ１で制限されることになる。 FIG. 7 is a torque diagram showing the relationship between the ampere turn [AT] showing the magnetomotive force of the stator winding and the torque density [Nm / L]. The broken line shows the characteristics of a general IPM rotor type rotary electric machine. As shown in FIG. 7, in a general rotary electric machine, by increasing the magnetomotive force in the stator, magnetic saturation occurs in two places, the tooth portion between the slots and the q-axis core portion, which causes magnetic saturation. The increase in torque is limited. As described above, in the general rotary electric machine, the ampere turn design value is limited by A1.
　そこで本実施形態では、磁気飽和に起因する制限を解消すべく、回転電機１０において、以下に示す構成を付与するものとしている。すなわち、第１の工夫として、固定子において固定子コアのティースで生じる磁気飽和をなくすべく、固定子５０においてスロットレス構造を採用し、かつＩＰＭロータのｑ軸コア部分で生じる磁気飽和をなくすべく、ＳＰＭ（Surface Permanent Magnet）ロータを採用している。第１の工夫によれば、磁気飽和が生じる上記２カ所の部分をなくすことができるが、低電流域でのトルクが減少することが考えられる（図７の一点鎖線参照）。そのため、第２の工夫として、ＳＰＭロータの磁束増強を図ることでトルク減少を挽回すべく、回転子４０の磁石ユニット４２において磁石磁路を長くして磁力を高めた極異方構造を採用している。 Therefore, in the present embodiment, in order to eliminate the limitation caused by magnetic saturation, the rotary electric machine 10 is provided with the following configuration. That is, as a first device, in order to eliminate the magnetic saturation that occurs in the teeth of the stator core in the stator, a slotless structure is adopted in the stator 50, and in order to eliminate the magnetic saturation that occurs in the q-axis core portion of the IPM rotor. , SPM (Surface Permanent Magnet) rotor is used. According to the first device, it is possible to eliminate the above-mentioned two parts where magnetic saturation occurs, but it is conceivable that the torque in the low current region is reduced (see the alternate long and short dash line in FIG. 7). Therefore, as a second device, in order to recover the torque decrease by increasing the magnetic flux of the SPM rotor, the magnet unit 42 of the rotor 40 adopts a polar anisotropic structure in which the magnetic path is lengthened to increase the magnetic force. ing.
　また、第３の工夫として、固定子巻線５１のコイルサイド部５３において導線の固定子５０における径方向厚さを小さくした扁平導線構造を採用してトルク減少の挽回を図っている。ここで、上述の磁力を高めた極異方構造によって、磁石ユニット４２に対向する固定子巻線５１には、より大きな渦電流が発生することが考えられる。しかしながら、第３の工夫によれば、径方向に薄い扁平導線構造のため、固定子巻線５１における径方向の渦電流の発生を抑制することができる。このように、これら第１～第３の各構成によれば、図７に実線で示すように、磁力の高い磁石を採用してトルク特性の大幅な改善を見込みつつも、磁力の高い磁石ゆえに生じ得る大きい渦電流発生の懸念も改善できるものとなっている。 Further, as a third device, the coil side portion 53 of the stator winding 51 adopts a flat conductor structure in which the radial thickness of the stator 50 of the conductor is reduced to recover the torque reduction. Here, it is conceivable that a larger eddy current is generated in the stator winding 51 facing the magnet unit 42 due to the above-mentioned polar anisotropic structure in which the magnetic force is increased. 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 eddy current in the radial direction in the stator winding 51. As described above, according to each of the first to third configurations, as shown by the solid line in FIG. 7, a magnet having a high magnetic force is adopted to expect a significant improvement in torque characteristics, but the magnet has a high magnetic force. Concerns about the generation of large eddy currents that can occur can also be improved.
　さらに、第４の工夫として、極異方構造を利用し正弦波に近い磁束密度分布を有する磁石ユニットを採用している。これによれば、後述するパルス制御等によって正弦波整合率を高めてトルク増強を図ることができるとともに、ラジアル磁石と比べ緩やかな磁束変化のため渦電流損（渦電流による銅損：eddy current loss）もまた更に抑制することができるのである。 Furthermore, as a fourth device, a magnet unit that uses a polar anisotropic structure and has a magnetic flux density distribution close to a sine wave is adopted. According to this, the sine wave matching rate can be increased by pulse control or the like described later to increase the torque, and eddy current loss (copper loss due to eddy current: eddy current loss) due to a gentler magnetic flux change than that of a radial magnet. ) Can also be further suppressed.
　以下、正弦波整合率について説明する。正弦波整合率は、磁石の表面を磁束プローブでなぞる等して計測した表面磁束密度分布の実測波形と周期及びピーク値が同じ正弦波との比較から求める事ができる。そして、回転電機の基本波である１次波形の振幅が、実測波形の振幅、即ち基本波に他の高調波成分を加えた振幅に対して、占める割合が正弦波整合率に相当する。正弦波整合率が高くなると、表面磁束密度分布の波形が正弦波形状に近づいていく。そして、正弦波整合率を向上させた磁石を備えた回転電機に対して、インバータから１次の正弦波の電流を供給すると、磁石の表面磁束密度分布の波形が正弦波形状に近い事と相まって、大きなトルクを発生させることができる。なお、表面磁束密度分布は実測以外の方法、例えばマクスウェルの方程式を用いた電磁界解析によって推定しても良い。 The sine wave matching factor will be described below. The sine wave matching factor can be obtained by comparing the measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet with a magnetic flux probe and the sine wave having the same period and peak value. The ratio of the amplitude of the primary waveform, which is the fundamental wave of the rotating electric machine, to the amplitude of the actually measured waveform, that is, the amplitude obtained by adding other harmonic components to the fundamental wave, corresponds to the sine wave matching factor. As the sinusoidal matching factor increases, the waveform of the surface magnetic flux density distribution approaches the sinusoidal shape. Then, when a primary sine wave current is supplied from the inverter to a rotating electric machine equipped with a magnet having an improved sine wave matching rate, the waveform of the surface magnetic flux density distribution of the magnet is close to the sine wave shape. , Can generate a large torque. The surface magnetic flux density distribution may be estimated by a method other than actual measurement, for example, electromagnetic field analysis using Maxwell's equations.
　また、第５の工夫として、固定子巻線５１を複数の素線を寄せ集めて束ねた素線導体構造としている。これによれば、素線が並列結線されているため、大電流が流せるとともに、扁平導線構造で固定子５０の周方向に広がった導線で発生する渦電流の発生を、素線それぞれの断面積が小さくなるため、第３の工夫による径方向に薄くする以上に効果的に抑制することができる。そして、複数の素線を撚り合わせた構成にすることで、導体からの起磁力に対しては、電流通電方向に対して右ネジの法則で発生する磁束に対する渦電流を相殺することができる。 Further, as a fifth device, the stator winding 51 has a wire conductor structure in which a plurality of wire wires are gathered and bundled. According to this, since the strands are connected in parallel, a large current can flow, and the eddy current generated by the conductors that spread in the circumferential direction of the stator 50 in the flat conductor structure is generated by the cross-sectional area of each strand. Is smaller, so it can be suppressed more effectively than thinning in the radial direction by the third device. Then, by forming a structure in which a plurality of strands are twisted together, it is possible to cancel the eddy current with respect to the magnetic flux generated by the right-handed screw rule with respect to the current energizing direction with respect to the magnetomotive force from the conductor.
　このように、第４の工夫、第５の工夫をさらに加えると、第２の工夫である磁力の高い磁石を採用しながら、さらにその高い磁力に起因する渦電流損を抑制しながらトルク増強を図ることができる。 In this way, if the fourth and fifth devices are further added, the torque can be increased while using the magnet with a high magnetic force, which is the second device, while suppressing the eddy current loss caused by the high magnetic force. Can be planned.
　以下に、上述した固定子５０のスロットレス構造、固定子巻線５１の扁平導線構造、及び磁石ユニット４２の極異方構造について個別に説明を加える。ここではまずは、固定子５０におけるスロットレス構造と固定子巻線５１の扁平導線構造とを説明する。図８は、回転子４０及び固定子５０の横断面図であり、図９は、図８に示す回転子４０及び固定子５０の一部を拡大して示す図である。図１０は、図１１のＸ‐Ｘ線に沿った固定子５０の横断面を示す断面図であり、図１１は、固定子５０の縦断面を示す断面図である。また、図１２は、固定子巻線５１の斜視図である。なお、図８及び図９には、磁石ユニット４２における磁石の磁化方向を矢印にて示している。 Below, 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 will be individually described. Here, first, the slotless structure of the stator 50 and the flat conductor structure of the stator winding 51 will be described. FIG. 8 is a cross-sectional view of the rotor 40 and the stator 50, and FIG. 9 is an enlarged view of a part of the rotor 40 and the stator 50 shown in FIG. 10 is a cross-sectional view showing a cross section of the stator 50 along the line XX of FIG. 11, and FIG. 11 is a cross-sectional view showing a vertical cross section of the stator 50. Further, FIG. 12 is a perspective view of the stator winding 51. In addition, in FIG. 8 and FIG. 9, the magnetization direction of the magnet in the magnet unit 42 is indicated by an arrow.
　図８乃至図１１に示すように、固定子コア５２は、軸方向に複数の電磁鋼板が積層され、かつ径方向に所定の厚さを有する円筒状をなしており、回転子４０側となる径方向外側に固定子巻線５１が組み付けられるものとなっている。固定子コア５２において、回転子４０側の外周面が導線設置部（導体エリア）となっている。固定子コア５２の外周面は凹凸のない曲面状をなしており、その外周面において周方向に所定間隔で複数の導線群８１が配置されている。固定子コア５２は、回転子４０を回転させるための磁気回路の一部となるバックヨークとして機能する。この場合、周方向に隣り合う各２つの導線群８１の間には軟磁性材からなるティース（つまり、鉄心）が設けられていない構成（つまり、スロットレス構造）となっている。本実施形態において、それら各導線群８１の間隙５６には、封止部材５７の樹脂材料が入り込む構造となっている。つまり、固定子５０において、周方向における各導線群８１の間に設けられる導線間部材が、非磁性材料である封止部材５７として構成されている。封止部材５７の封止前の状態で言えば、固定子コア５２の径方向外側には、それぞれ導線間領域である間隙５６を隔てて周方向に所定間隔で導線群８１が配置されており、これによりスロットレス構造の固定子５０が構築されている。言い換えれば、各導線群８１は、後述するように二つの導線（conductor）８２からなり、固定子５０の周方向に隣り合う各二つの導線群８１の間は、非磁性材のみが占有している。この非磁性材とは、封止部材５７以外に空気などの非磁性気体や非磁性液体などをも含む。なお、以下において、封止部材５７は導線間部材（conductor-to- conductor member）ともいう。 As shown in FIGS. 8 to 11, the stator core 52 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction, and is on the rotor 40 side. The stator winding 51 is assembled on the outer side in the radial direction. In the stator core 52, the outer peripheral surface on the rotor 40 side serves as a conductor area. The outer peripheral surface of the stator core 52 has a curved surface without unevenness, and a plurality of conductor groups 81 are arranged at predetermined intervals in the circumferential direction on the outer peripheral surface thereof. The stator core 52 functions as a back yoke that 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 of the two conductor groups 81 adjacent to each other 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 groups 81. That is, in the stator 50, the interconductor member provided between each conductor group 81 in the circumferential direction is configured as a sealing member 57 which is a non-magnetic material. Speaking in the state before sealing of the sealing member 57, the conducting wire groups 81 are arranged at predetermined intervals in the circumferential direction with a gap 56 which is a region between the conducting wires, respectively, on the outer side in the radial direction of the stator core 52. As a result, the stator 50 having a slotless structure is constructed. In other words, each conductor group 81 is composed of two conductors 82 as described later, and only the non-magnetic material occupies between the two conductor groups 81 adjacent to each other in the circumferential direction of the stator 50. There is. The non-magnetic material includes a non-magnetic gas such as air, a non-magnetic liquid, and the like in addition to the sealing member 57. In the following, the sealing member 57 is also referred to as a conductor-to-conductor member.
　なお、周方向に並ぶ各導線群８１の間においてティースが設けられている構成とは、ティースが、径方向に所定厚さを有し、かつ周方向に所定幅を有することで、各導線群８１の間に磁気回路の一部、すなわち磁石磁路を形成する構成であると言える。この点において、各導線群８１の間にティースが設けられていない構成とは、上記の磁気回路の形成がなされていない構成であると言える。 The configuration in which the teeth are provided between the conductor groups 81 arranged in the circumferential direction means that the teeth have a predetermined thickness in the radial direction and a predetermined width in the circumferential direction, so that each conductor group has a predetermined width. It can be said that a part of the magnetic circuit, that is, a magnetic magnetic path is formed between 81. In this respect, it can be said that the configuration in which the teeth are not provided between the conducting wire groups 81 is the configuration in which the above-mentioned magnetic circuit is not formed.
　図１０に示すように、固定子巻線（すなわち電機子巻線）５１は、所定の厚みＴ２（以下、第１寸法とも言う）と幅Ｗ２（以下、第２寸法とも言う）を有するように形成されている。厚みＴ２は、固定子巻線５１の径方向において互いに対向する外側面と内側面との間の最短距離である。幅Ｗ２は、固定子巻線５１の多相（実施例では３相：Ｕ相、Ｖ相及びＷ相の３相あるいはＸ相、Ｙ相及びＺ相の３相）の一つとして機能する固定子巻線５１の一部分の固定子巻線５１の周方向の長さである。具体的には、図１０において、周方向に隣り合う２つの導線群８１が３相の内の一つである例えばＵ相として機能する場合、周方向において当該２つの導線群８１の端から端までの幅Ｗ２である。そして、厚みＴ２は幅Ｗ２より小さくなっている。 As shown in FIG. 10, the stator winding (that is, armature winding) 51 has a predetermined thickness T2 (hereinafter, also referred to as a first dimension) and a width W2 (hereinafter, also referred to as a second dimension). It is formed. The thickness T2 is the shortest distance between the outer surface and the inner surface facing each other in the radial direction of the stator winding 51. The width W2 is a fixation that functions as one of the polyphases of the stator winding 51 (three phases in the embodiment: three phases of U phase, V phase and W phase, or three phases of X phase, Y phase and Z phase). It is the length in the circumferential direction of the stator winding 51 which is a part of the child winding 51. Specifically, in FIG. 10, when two conductor groups 81 adjacent to each other in the circumferential direction function as one of the three phases, for example, the U phase, the two conductor groups 81 are end-to-end in the circumferential direction. Width up to W2. The thickness T2 is smaller than the width W2.
　なお、厚みＴ２は、幅Ｗ２内に存在する２つの導線群８１の合計幅寸法より小さいことが好ましい。また、仮に固定子巻線５１（より詳しくは導線８２）の断面形状が真円形状や楕円形状、又は多角形形状である場合、固定子５０の径方向に沿った導線８２の断面のうち、その断面において固定子５０の径方向の最大の長さをＷ１２、同断面のうち固定子５０の周方向の最大の長さをＷ１１としても良い。 The thickness T2 is preferably smaller than the total width dimension of the two conductor groups 81 existing in the width W2. If the cross-sectional shape of the stator winding 51 (more specifically, the wire 82) is a perfect circle, an ellipse, or a polygon, the cross section of the stator 82 along the radial direction of the stator 50. In the cross section, the maximum length of the stator 50 in the radial direction may be W12, and the maximum length of the stator 50 in the circumferential direction may be W11.
　図１０及び図１１に示すように、固定子巻線５１は、封止材（モールド材）としての合成樹脂材からなる封止部材５７により封止されている。つまり、固定子巻線５１は、固定子コア５２と共にモールド材によりモールドされている。なお樹脂は、非磁性体、又は非磁性体の均等物としてＢｓ＝０と看做すことができる。 As shown in FIGS. 10 and 11, the stator winding 51 is sealed by a sealing member 57 made of a synthetic resin material as a sealing material (molding material). That is, the stator winding 51 is molded by the molding material together with the stator core 52. The resin can be regarded as a non-magnetic material or an equivalent of the non-magnetic material as Bs = 0.
　図１０の横断面で見れば、封止部材５７は、各導線群８１の間、すなわち間隙５６に合成樹脂材が充填されて設けられており、封止部材５７により、各導線群８１の間に絶縁部材が介在する構成となっている。つまり、間隙５６において封止部材５７が絶縁部材として機能する。封止部材５７は、固定子コア５２の径方向外側において、各導線群８１を全て含む範囲、すなわち径方向の厚さ寸法が各導線群８１の径方向の厚さ寸法よりも大きくなる範囲で設けられている。 Looking at the cross section of FIG. 10, the sealing member 57 is provided between the conductor groups 81, that is, the gap 56 is filled with the synthetic resin material, and the sealing member 57 between the conductor groups 81. Insulation member is interposed in the structure. That is, the sealing member 57 functions as an insulating member in the gap 56. The sealing member 57 is provided on the radial outer side of the stator core 52 in a range including all of the lead wire groups 81, that is, in a range in which the radial thickness dimension is larger than the radial thickness dimension of each lead wire group 81. It is provided.
　また、図１１の縦断面で見れば、封止部材５７は、固定子巻線５１のターン部８４を含む範囲で設けられている。固定子巻線５１の径方向内側では、固定子コア５２の軸方向に対向する端面の少なくとも一部を含む範囲で封止部材５７が設けられている。この場合、固定子巻線５１は、各相の相巻線の端部、すなわちインバータ回路との接続端子を除く略全体で樹脂封止されている。 Further, when viewed in the vertical cross section of FIG. 11, the sealing member 57 is provided in a range including the turn portion 84 of the stator winding 51. Inside the stator winding 51 in the radial direction, a sealing member 57 is provided within a range including at least a part of the end faces of the stator core 52 facing in the axial direction. In this case, the stator winding 51 is resin-sealed almost entirely except for the ends of the phase windings of each phase, that is, the connection terminals with the inverter circuit.
　封止部材５７が固定子コア５２の端面を含む範囲で設けられた構成では、封止部材５７により、固定子コア５２の積層鋼板を軸方向内側に押さえ付けることができる。これにより、封止部材５７を用いて、各鋼板の積層状態を保持することができる。なお、本実施形態では、固定子コア５２の内周面を樹脂封止していないが、これに代えて、固定子コア５２の内周面を含む固定子コア５２の全体を樹脂封止する構成であってもよい。 In the configuration in which the sealing member 57 is provided in a range including the end face of the stator core 52, the laminated steel plate of the stator core 52 can be pressed inward in the axial direction by the sealing member 57. Thereby, the laminated state of each steel plate can be maintained by using the sealing member 57. In the present embodiment, the inner peripheral surface of the stator core 52 is not resin-sealed, but instead, the entire stator core 52 including the inner peripheral surface of the stator core 52 is resin-sealed. It may be a configuration.
　回転電機１０が車両動力源として使用される場合には、封止部材５７が、高耐熱のフッ素樹脂や、エポキシ樹脂、ＰＰＳ樹脂、ＰＥＥＫ樹脂、ＬＣＰ樹脂、シリコン樹脂、ＰＡＩ樹脂、ＰＩ樹脂等により構成されていることが好ましい。また、膨張差による割れ抑制の観点から線膨張係数を考えると、固定子巻線５１の導線の外被膜と同じ材質であることが望ましい。すなわち、線膨張係数が、一般的に他樹脂の倍以上であるシリコン樹脂は望ましくは除外される。なお、電気車両の如く、燃焼を利用した機関を持たない電気製品においては、１８０℃程度の耐熱性を持つＰＰＯ樹脂やフェノール樹脂、ＦＲＰ樹脂も候補となる。回転電機の周囲温度が１００℃未満と見做せる分野においては、この限りではない。 When the rotary electric machine 10 is used as a vehicle power source, the sealing member 57 is made of a highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, or the like. It is preferably configured. Further, considering the coefficient of linear expansion from the viewpoint of suppressing cracks due to the difference in expansion, it is desirable that the material is the same as the outer coating of the conductor of the stator winding 51. That is, a silicon resin having a coefficient of linear expansion that is generally more than double that of other resins is preferably excluded. For electric products that do not have an engine that utilizes combustion, such as electric vehicles, PPO resin, phenol resin, and FRP resin that have heat resistance of about 180 ° C. are also candidates. This does not apply in the field where the ambient temperature of the rotary electric machine can be regarded as less than 100 ° C.
　回転電機１０のトルクは磁束の大きさに比例する。ここで、固定子コアがティースを有している場合には、固定子での最大磁束量がティースでの飽和磁束密度に依存して制限されるが、固定子コアがティースを有していない場合には、固定子での最大磁束量が制限されない。そのため、固定子巻線５１に対する通電電流を増加して回転電機１０のトルク増加を図る上で、有利な構成となっている。 The torque of the rotary 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 in the stator is limited depending on the saturation magnetic flux density in the teeth, but the stator core does not have teeth. In this case, the maximum amount of magnetic flux in the stator is not limited. Therefore, the configuration is advantageous in increasing the energizing current for the stator winding 51 to increase the torque of the rotary electric machine 10.
　本実施形態では、固定子５０においてティースを無くした構造（スロットレス構造）を用いたことにより、固定子５０のインダクタンスが低減される。具体的には、複数のティースにより仕切られた各スロットに導線が収容される一般的な回転電機の固定子ではインダクタンスが例えば１ｍＨ前後であるのに対し、本実施形態の固定子５０ではインダクタンスが５～６０μＨ程度に低減される。本実施形態では、アウタロータ構造の回転電機１０としつつも、固定子５０のインダクタンス低減により機械的時定数Ｔｍを下げることが可能となっている。つまり、高トルク化を図りつつ、機械的時定数Ｔｍの低減が可能となっている。なお、イナーシャをＪ、インダクタンスをＬ、トルク定数をＫｔ、逆起電力定数をＫｅとすると、機械的時定数Ｔｍは、次式により算出される。
Ｔｍ＝（Ｊ×Ｌ）／（Ｋｔ×Ｋｅ）
この場合、インダクタンスＬの低減により機械的時定数Ｔｍが低減されることが確認できる。 In the present embodiment, the inductance of the stator 50 is reduced by using a structure (slotless structure) in which the stator 50 has no teeth. Specifically, in the stator of a general rotary electric machine in which a conducting wire is accommodated in each slot partitioned by a plurality of teeth, the inductance is, for example, around 1 mH, whereas in the stator 50 of the present embodiment, the inductance is high. It is reduced to about 5 to 60 μH. In the present embodiment, it is possible to reduce the mechanical time constant Tm by reducing the inductance of the stator 50 while using the rotary electric machine 10 having an outer rotor structure. That is, it is possible to reduce the mechanical time constant Tm while increasing the torque. Assuming that the inertia is J, the inductance is L, the torque constant is Kt, and the counter electromotive force constant is Ke, the mechanical time constant Tm is calculated by the following equation.
Tm = (J × L) / (Kt × Ke)
In this case, it can be confirmed that the mechanical time constant Tm is reduced by reducing the inductance L.
　固定子コア５２の径方向外側における各導線群８１は、断面が扁平矩形状をなす複数の導線８２が固定子コア５２の径方向に並べて配置されて構成されている。各導線８２は、横断面において「径方向寸法＜周方向寸法」となる向きで配置されている。これにより、各導線群８１において径方向の薄肉化が図られている。また、径方向の薄肉化を図るとともに、導体領域が、ティースが従来あった領域まで平らに延び、扁平導線領域構造となっている。これにより、薄肉化により断面積が小さくなることで懸念される導線の発熱量の増加を、周方向に扁平化して導体の断面積を稼ぐことで抑えている。なお、複数の導線を周方向に並べ、かつそれらを並列結線とする構成であっても、導体被膜分の導体断面積低下は起こるものの、同じ理屈に依る効果が得られる。なお、以下において、導線群８１のそれぞれ、および導線８２のそれぞれを、伝導部材（conductive member）とも言う。 Each conductor group 81 on the radial outer side of the stator core 52 is configured by arranging a plurality of conductors 82 having a flat rectangular cross section side by side in the radial direction of the stator core 52. Each of the conductors 82 is arranged in a direction such that "diameter dimension <circumferential dimension" in the cross section. As a result, the thickness of each conductor group 81 is reduced in the radial direction. In addition, the thickness in the radial direction is reduced, and the conductor region extends flat to the region where the teeth have been conventionally, forming a flat conductor region structure. As a result, the increase in the calorific value of the conducting wire, which is a concern because the cross-sectional area becomes smaller due to the thinning, is suppressed by flattening in the circumferential direction to increase the cross-sectional area of the conductor. Even if a plurality of conductors are arranged in the circumferential direction and connected in parallel, the conductor cross-sectional area of the conductor coating is reduced, but the same reasoning effect can be obtained. In the following, each of the conductor group 81 and each of the conductor 82 will also be referred to as a conductive member.
　スロットがないことから、本実施形態における固定子巻線５１では、その周方向の一周における固定子巻線５１が占める導体領域を、固定子巻線５１が存在しない導体非占有領域より大きく設計することができる。なお、従来の車両用回転電機は、固定子巻線の周方向の一周における導体領域／導体非占有領域は１以下であるのが当然であった。一方、本実施形態では、導体領域が導体非占有領域と同等又は導体領域が導体非占有領域よりも大きくなるようにして、各導線群８１が設けられている。ここで、図１０に示すように、周方向において導線８２（つまり、後述する直線部８３）が配置された導線領域をＷＡ、隣り合う導線８２の間となる導線間領域をＷＢとすると、導線領域ＷＡは、導線間領域ＷＢより周方向において大きいものとなっている。 Since there is no slot, in the stator winding 51 in the present embodiment, the conductor region occupied by the stator winding 51 in one circumference in the circumferential direction is designed to be larger than the conductor non-occupied region in which the stator winding 51 does not exist. be able to. In the conventional rotary electric machine for vehicles, it is natural that the conductor region / conductor non-occupied region in one circumference of the stator winding in the circumferential direction is 1 or less. On the other hand, in the present embodiment, each conductor group 81 is provided so that the conductor region is equal to the conductor non-occupied region or the conductor region is larger than the conductor non-occupied region. Here, as shown in FIG. 10, assuming that the conductor region in which the conductor 82 (that is, the straight line portion 83 described later) is arranged in the circumferential direction is WA and the region between the conductors 82 between the adjacent conductors 82 is WB, the conductor The region WA is larger in the circumferential direction than the interconductor region WB.
　固定子巻線５１における導線群８１の構成として、その導線群８１の径方向の厚さ寸法は、１磁極内における１相分の周方向の幅寸法よりも小さいものとなっている。すなわち、導線群８１が径方向に２層の導線８２よりなり、かつ１磁極内に１相につき周方向に２つの導線群８１が設けられる構成では、各導線８２の径方向の厚さ寸法をＴｃ、各導線８２の周方向の幅寸法をＷｃとした場合に、「Ｔｃ×２＜Ｗｃ×２」となるように構成されている。なお、他の構成として、導線群８１が２層の導線８２よりなり、かつ１磁極内に１相につき周方向に１つの導線群８１が設けられる構成では、「Ｔｃ×２＜Ｗｃ」の関係となるように構成されるとよい。要するに、固定子巻線５１において周方向に所定間隔で配置される導線部（導線群８１）は、その径方向の厚さ寸法が、１磁極内における１相分の周方向の幅寸法よりも小さいものとなっている。 As a configuration of the conductor group 81 in the stator winding 51, the thickness dimension of the conductor group 81 in the radial direction is smaller than the width dimension of one phase in one magnetic pole in the circumferential direction. That is, in a configuration in which the conductor group 81 is composed of two layers of conductors 82 in the radial direction and two conductor groups 81 are provided in the circumferential direction for each phase in one magnetic pole, the thickness dimension of each conductor 82 in the radial direction is set. When Tc and the width dimension of each conducting wire 82 in the circumferential direction are Wc, it is configured to be "Tc × 2 <Wc × 2". As another configuration, in a configuration in which the conductor group 81 is composed of two layers of conductors 82 and one conductor group 81 is provided in one magnetic pole in the circumferential direction for each phase, the relationship of "Tc × 2 <Wc" is provided. It is preferable that it is configured so as to be. In short, the conductor portions (conductor group 81) arranged at predetermined intervals in the circumferential direction in the stator winding 51 have a thickness dimension in the radial direction that is larger than the width dimension in the circumferential direction for one phase in one magnetic pole. It is small.
　言い換えると、１本１本の各導線８２は、径方向の厚さ寸法Ｔｃが周方向の幅寸法Ｗｃよりも小さいとよい。またさらに、径方向に２層の導線８２よりなる導線群８１の径方向の厚さ寸法（２Ｔｃ）、すなわち導線群８１の径方向の厚さ寸法（２Ｔｃ）が周方向の幅寸法Ｗｃよりも小さいとよい。 In other words, it is preferable that the thickness dimension Tc in the radial direction of each conductor 82 is smaller than the width dimension Wc in the circumferential direction. Furthermore, the radial thickness dimension (2Tc) of the conductor group 81 composed of two layers of conductors 82 in the radial direction, that is, the radial thickness dimension (2Tc) of the conductor group 81 is larger than the circumferential width dimension Wc. It should be small.
　回転電機１０のトルクは、導線群８１の固定子コア５２の径方向の厚さに略反比例する。この点、固定子コア５２の径方向外側において導線群８１の厚さを薄くしたことにより、回転電機１０のトルク増加を図る上で有利な構成となっている。その理由としては、回転子４０の磁石ユニット４２から固定子コア５２までの距離（つまり鉄の無い部分の距離）を小さくして磁気抵抗を下げることができるためである。これによれば、永久磁石による固定子コア５２の鎖交磁束を大きくすることができ、トルクを増強することができる。 The torque of the rotary electric machine 10 is substantially inversely proportional to the radial thickness of the stator core 52 of the conductor group 81. In this respect, the thickness of the conductor group 81 is reduced on the radial outer side of the stator core 52, which is advantageous in increasing the torque of the rotary electric 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 iron-free portion). 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.
　また、導線群８１の厚さを薄くしたことにより、導線群８１から磁束が漏れても固定子コア５２に回収されやすくなり、磁束がトルク向上のために有効に利用されずに外部に漏れることを抑制することができる。つまり、磁束漏れにより磁力が低下することを抑制でき、永久磁石による固定子コア５２の鎖交磁束を大きくして、トルクを増強することができる。 Further, by reducing the thickness of the conductor group 81, even if the magnetic flux leaks from the conductor group 81, it is easily collected by the stator core 52, and the magnetic flux is not effectively used for improving torque and leaks to the outside. Can be suppressed. That is, it is possible to suppress a decrease in magnetic force due to magnetic flux leakage, and it is possible to increase the interlinkage magnetic flux of the stator core 52 by the permanent magnet to increase the torque.
　導線８２(conductor)は、導体(conductor body)８２ａの表面が絶縁被膜８２ｂにより被覆された被覆導線よりなり、径方向に互いに重なる導線８２同士の間、及び導線８２と固定子コア５２との間においてそれぞれ絶縁性が確保されている。この絶縁被膜８２ｂは、後述する素線８６が自己融着被覆線であるならその被膜、又は、素線８６の被膜とは別に重ねられた絶縁部材で構成されている。なお、導線８２により構成される各相巻線は、接続のための露出部分を除き、絶縁被膜８２ｂによる絶縁性が保持されるものとなっている。露出部分としては、例えば、入出力端子部や、星形結線とする場合の中性点部分である。導線群８１では、樹脂固着や自己融着被覆線を用いて、径方向に隣り合う各導線８２が相互に固着されている。これにより、導線８２同士が擦れ合うことによる絶縁破壊や、振動、音が抑制される。 The conductor 82 is composed of a coated conductor whose surface is coated with an insulating coating 82b, and is between the conductors 82 that overlap each other in the radial direction and between the conductor 82 and the stator core 52. Insulation is ensured in each. The insulating coating 82b is composed of a coating thereof if the strand 86 described later is a self-bonding coated wire, or an insulating member laminated separately from the coating of the strand 86. Each phase winding composed of the conducting wire 82 retains the insulating property by the insulating coating 82b except for the exposed portion for connection. The exposed portion is, for example, an input / output terminal portion or a neutral point portion in the case of a star-shaped connection. In the conductor group 81, the conductors 82 adjacent to each other in the radial direction are fixed to each other by using resin fixing or self-bonding coated wire. As a result, dielectric breakdown, vibration, and sound due to the rubbing of the conducting wires 82 against each other are suppressed.
　本実施形態では、導体８２ａが複数の素線(wire)８６の集合体として構成されている。具体的には、図１３に示すように、導体８２ａは、複数の素線８６を撚ることで撚糸状に形成されている。また、図１４に示すように、素線８６は、細い繊維状の導電材８７を束ねた複合体として構成されている。例えば、素線８６はＣＮＴ（カーボンナノチューブ）繊維の複合体であり、ＣＮＴ繊維として、炭素の少なくとも一部をホウ素で置換したホウ素含有微細繊維を含む繊維が用いられている。炭素系微細繊維としては、ＣＮＴ繊維以外に、気相成長法炭素繊維（ＶＧＣＦ）等を用いることができるが、ＣＮＴ繊維を用いることが好ましい。なお、素線８６の表面は、エナメルなどの高分子絶縁層で覆われている。また、素線８６の表面は、ポリイミドの被膜やアミドイミドの被膜からなる、いわゆるエナメル被膜で覆われていることが好ましい。 In this embodiment, the conductor 82a is configured as an aggregate of a plurality of wires 86. Specifically, as shown in FIG. 13, the conductor 82a is formed in a twisted state by twisting a plurality of strands 86. Further, as shown in FIG. 14, the wire 86 is configured as a composite in which thin fibrous conductive materials 87 are bundled. For example, the wire 86 is a composite of CNT (carbon nanotube) fibers, and as the CNT fiber, a fiber containing boron-containing fine fibers in which at least a part of carbon is replaced with boron is used. As the carbon-based fine fiber, a vapor phase growth method carbon fiber (VGCF) or the like can be used in addition to the CNT fiber, but it is preferable to use the CNT fiber. The surface of the wire 86 is covered with a polymer insulating layer such as enamel. Further, it is preferable that the surface of the wire 86 is covered with a so-called enamel film made of a polyimide film or an amidimide film.
　導線８２は、固定子巻線５１においてｎ相の巻線を構成する。そして導線８２（すなわち、導体８２ａ）の各々の素線８６は、互いに接触状態で隣接している。導線８２は、巻線導体が、複数の素線８６が撚られて形成される部位を、相内の１か所以上に持つとともに、撚られた素線８６間の抵抗値が素線８６そのものの抵抗値よりも大きい素線集合体となっている。言い換えると、隣接する各２つの素線８６はその隣接する方向において第１電気抵抗率を有し、素線８６の各々はその長さ方向において第２電気抵抗率を有する場合、第１電気抵抗率は第２電気抵抗率より大きい値になっている。なお、導線８２が複数の素線８６により形成されるとともに、第１電気抵抗率が極めて高い絶縁部材により複数の素線８６を覆う素線集合体となっていても良い。また、導線８２の導体８２ａは、撚り合わされた複数の素線８６により構成されている。 The conductor 82 constitutes an n-phase winding in the stator winding 51. Then, the respective strands 86 of the conductor 82 (that is, the conductor 82a) are adjacent to each other in contact with each other. In the lead wire 82, the winding conductor has a portion formed by twisting a plurality of strands 86 at one or more places in the phase, and the resistance value between the twisted strands 86 is the strand 86 itself. It is a wire aggregate larger than the resistance value of. In other words, if each of the two adjacent strands 86 has a first electrical resistivity in its adjacent direction and each of the strands 86 has a second electrical resistivity in its length direction, then the first electrical resistance The rate is larger than the second electrical resistivity. The conducting wire 82 may be formed of a plurality of strands 86, and may be an aggregate of strands covering the plurality of strands 86 by an insulating member having an extremely high first electrical resistivity. Further, the conductor 82a of the conductor 82 is composed of a plurality of twisted strands 86.
　上記の導体８２ａでは、複数の素線８６が撚り合わされて構成されているため、各素線８６での渦電流の発生が抑えられ、導体８２ａにおける渦電流の低減を図ることができる。また、各素線８６が捻られていることで、１本の素線８６において磁界の印加方向が互いに逆になる部位が生じて逆起電圧が相殺される。そのため、やはり渦電流の低減を図ることができる。特に、素線８６を繊維状の導電材８７により構成することで、細線化することと捻り回数を格段に増やすこととが可能になり、渦電流をより好適に低減することができる。 Since the conductor 82a is configured by twisting a plurality of strands 86, the generation of eddy currents in each strands 86 can be suppressed, and the eddy currents in the conductor 82a can be reduced. Further, since each wire 86 is twisted, a portion where the magnetic field application directions are opposite to each other is generated in one wire 86, and the counter electromotive voltage is canceled out. Therefore, the eddy current can also be reduced. In particular, by forming the wire 86 with the fibrous conductive material 87, it is possible to make the wire thinner and to significantly increase the number of twists, and it is possible to more preferably reduce the eddy current.
　なお、ここでいう素線８６同士の絶縁方法は、前述の高分子絶縁膜に限定されず、接触抵抗を利用し撚られた素線８６間で電流を流れにくくする方法であってもよい。すなわち撚られた素線８６間の抵抗値が、素線８６そのものの抵抗値よりも大きい関係になっていれば、抵抗値の差に起因して発生する電位差により、上記効果を得ることができる。たとえば、素線８６を作成する製造設備と、回転電機１０の固定子５０（電機子）を作成する製造設備とを別の非連続の設備として用いることで、移動時間や作業間隔などから素線８６が酸化し、接触抵抗を増やすことができ、好適である。 The method of insulating the wires 86 from each other here is not limited to the above-mentioned polymer insulating film, and may be a method of making it difficult for current to flow between the twisted wires 86 by using contact resistance. That is, if the resistance value between the twisted strands 86 is larger than the resistance value of the strands 86 itself, the above effect can be obtained by the potential difference generated due to the difference in the resistance values. .. For example, by using the manufacturing equipment for creating the wire 86 and the manufacturing equipment for making the stator 50 (armature) of the rotary electric machine 10 as different discontinuous equipment, the wire is used based on the movement time, work interval, and the like. 86 is suitable because it can be oxidized and the contact resistance can be increased.
　上述のとおり導線８２は、断面が扁平矩形状をなし、径方向に複数並べて配置されるものとなっており、例えば融着層と絶縁層とを備えた自己融着被覆線で被覆された複数の素線８６を撚った状態で集合させ、その融着層同士を融着させることで形状を維持している。なお、融着層を備えない素線や自己融着被覆線の素線を撚った状態で合成樹脂等により所望の形状に固めて成形してもよい。導線８２における絶縁被膜８２ｂの厚さを例えば８０μｍ～１００μｍとし、一般に使用される導線の被膜厚さ（５～４０μｍ）よりも厚肉とした場合、導線８２と固定子コア５２との間に絶縁紙等を介在させることをしなくても、これら両者の間の絶縁性が確保することができる。 As described above, the conductor 82 has a flat rectangular cross section and is arranged side by side in the radial direction. For example, a plurality of conductors 82 covered with a self-bonding coated wire having a fusion layer and an insulating layer. The wire 86 is assembled in a twisted state, and the fused layers are fused to maintain the shape. It should be noted that the strands having no fusion layer or the strands of the self-bonding coated wire may be twisted and solidified into a desired shape with a synthetic resin or the like for molding. When the thickness of the insulating coating 82b in the conductor 82 is set to, for example, 80 μm to 100 μm and is thicker than the film thickness (5 to 40 μm) of the commonly used conductor, insulation is provided between the conductor 82 and the stator core 52. Insulation between the two can be ensured without the intervention of paper or the like.
　また、絶縁被膜８２ｂは、素線８６の絶縁層よりも高い絶縁性能を有し、相間を絶縁することができるように構成されていることが望ましい。例えば、素線８６の高分子絶縁層の厚さを例えば５μｍ程度にした場合、導線８２の絶縁被膜８２ｂの厚さを８０μｍ～１００μｍ程度にして、相間の絶縁を好適に実施できるようにすることが望ましい。 Further, it is desirable that the insulating coating 82b has 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 86 is set to, for example, about 5 μm, the thickness of the insulating coating 82b of the conducting wire 82 is set to about 80 μm to 100 μm so that insulation between the phases can be preferably performed. Is desirable.
　また、導線８２は、複数の素線８６が撚られることなく束ねられている構成であってもよい。つまり、導線８２は、その全長において複数の素線８６が撚られている構成、全長のうち一部で複数の素線８６が撚られている構成、全長において複数の素線８６が撚られることなく束ねられている構成のいずれかであればよい。まとめると、導線部を構成する各導線８２は、複数の素線８６が束ねられているとともに、束ねられた素線間の抵抗値が素線８６そのものの抵抗値よりも大きい素線集合体となっている。 Further, the conductor 82 may have a configuration in which a plurality of strands 86 are bundled without being twisted. That is, the conductor 82 has a configuration in which a plurality of strands 86 are twisted in the total length, a configuration in which a plurality of strands 86 are twisted in a part of the total length, and a plurality of strands 86 are twisted in the total length. It may be any of the configurations that are bundled together. In summary, each conductor 82 constituting the conductor portion is a wire aggregate in which a plurality of conductors 86 are bundled and the resistance value between the bundled wires is larger than the resistance value of the wire 86 itself. It has become.
　各導線８２は、固定子巻線５１の周方向に所定の配置パターンで配置されるように折り曲げ形成されており、これにより、固定子巻線５１として相ごとの相巻線が形成されている。図１２に示すように、固定子巻線５１では、各導線８２のうち軸方向に直線状に延びる直線部８３によりコイルサイド部５３が形成され、軸方向においてコイルサイド部５３よりも両外側に突出するターン部８４によりコイルエンド５４，５５が形成されている。各導線８２は、直線部８３とターン部８４とが交互に繰り返されることにより、波巻状の一連の導線として構成されている。直線部８３は、磁石ユニット４２に対して径方向に対向する位置に配置されており、磁石ユニット４２の軸方向外側となる位置において所定間隔を隔てて配置される同相の直線部８３同士が、ターン部８４により互いに接続されている。なお、直線部８３が「磁石対向部」に相当する。 Each conductor 82 is bent and formed so as to be arranged in a predetermined arrangement pattern in the circumferential direction of the stator winding 51, whereby a phase winding for each phase is formed as the stator winding 51. .. As shown in FIG. 12, in the stator winding 51, the coil side portion 53 is formed by the straight portion 83 of each conducting wire 82 extending linearly in the axial direction, and the coil side portion 53 is formed on both outer sides of the coil side portion 53 in the axial direction. The coil ends 54 and 55 are formed by the protruding turn portions 84. Each conducting wire 82 is configured as a series of wave-shaped conducting wires by alternately repeating a straight line portion 83 and a turn portion 84. The straight line portions 83 are arranged at positions facing the magnet unit 42 in the radial direction, and in-phase straight line portions 83 arranged at positions on the outer side in the axial direction of the magnet unit 42 at predetermined intervals are arranged. They are connected to each other by a turn portion 84. The straight line portion 83 corresponds to the “magnet facing portion”.
　本実施形態では、固定子巻線５１が分布巻きにより円環状に巻回形成されている。この場合、コイルサイド部５３では、相ごとに、磁石ユニット４２の１極対に対応する間隔で周方向に直線部８３が配置され、コイルエンド５４，５５では、相ごとの各直線部８３が、略Ｖ字状に形成されたターン部８４により互いに接続されている。１極対に対応して対となる各直線部８３は、それぞれ電流の向きが互いに逆になるものとなっている。また、一方のコイルエンド５４と他方のコイルエンド５５とでは、ターン部８４により接続される一対の直線部８３の組み合わせがそれぞれ相違しており、そのコイルエンド５４，５５での接続が周方向に繰り返されることにより、固定子巻線５１が略円筒状に形成されている。 In the present embodiment, the stator winding 51 is wound in an annular shape by distributed winding. In this case, in the coil side portion 53, linear portions 83 are arranged in the circumferential direction at intervals corresponding to one pole pair of the magnet unit 42 for each phase, and in the coil ends 54 and 55, each linear portion 83 for each phase is arranged. , They are connected to each other by a turn portion 84 formed in a substantially V shape. The directions of the currents of the linear portions 83 that are paired corresponding to the one-pole pair are opposite to each other. Further, the combination of the pair of linear portions 83 connected by the turn portion 84 is different between the one coil end 54 and the other coil end 55, and the connections at the coil ends 54 and 55 are in the circumferential direction. By repeating the process, the stator winding 51 is formed in a substantially cylindrical shape.
　より具体的には、固定子巻線５１は、各相２対ずつの導線８２を用いて相ごとの巻線を構成しており、固定子巻線５１のうち一方の３相巻線（Ｕ相、Ｖ相、Ｗ相）と他方の３相巻線（Ｘ相、Ｙ相、Ｚ相）とが径方向内外の２層に設けられるものとなっている。この場合、固定子巻線５１の相数をＳ（実施例の場合は６）、導線８２の一相あたりの数をｍとすれば、極対ごとに２×Ｓ×ｍ＝２Ｓｍ個の導線８２が形成されることになる。本実施形態では、相数Ｓが６、数ｍが４であり、８極対（１６極）の回転電機であることから、６×４×８＝１９２の導線８２が固定子コア５２の周方向に配置されている。 More specifically, the stator winding 51 constitutes a winding for each phase by using two pairs of conductors 82 for each phase, and one of the stator windings 51 is a three-phase winding (U). (Phase, V phase, W phase) and the other three-phase winding (X phase, Y phase, Z phase) are provided in two layers inside and outside in the radial direction. In this case, if the number of phases of the stator winding 51 is S (6 in the case of the embodiment) and the number of conductors 82 per phase is m, then 2 × S × m = 2 Sm conductors for each pole pair. 82 will be formed. In the present embodiment, the number of phases S is 6, the number of m is 4, and since it is an 8-pole pair (16-pole) rotary electric machine, the lead wire 82 of 6 × 4 × 8 = 192 is the circumference of the stator core 52. Arranged in the direction.
　図１２に示す固定子巻線５１では、コイルサイド部５３において、径方向に隣接する２層で直線部８３が重ねて配置されるとともに、コイルエンド５４，５５において、径方向に重なる各直線部８３から、互いに周方向逆となる向きでターン部８４が周方向に延びる構成となっている。つまり、径方向に隣り合う各導線８２では、固定子巻線５１の端部を除き、ターン部８４の向きが互いに逆となっている。 In the stator winding 51 shown in FIG. 12, in the coil side portion 53, the straight portions 83 are arranged so as to overlap in two layers adjacent in the radial direction, and in the coil ends 54 and 55, the linear portions overlapping in the radial direction are respectively arranged. From 83, the turn portion 84 extends in the circumferential direction in directions opposite to each other in the circumferential direction. That is, in each of the conducting 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.
　ここで、固定子巻線５１における導線８２の巻回構造を具体的に説明する。本実施形態では、波巻にて形成された複数の導線８２を、径方向に隣接する複数層（例えば２層）に重ねて設ける構成としている。図１５（ａ）、図１５（ｂ）は、ｎ層目における各導線８２の形態を示す図であり、図１５（ａ）には、固定子巻線５１の側方から見た導線８２の形状を示し、図１５（ｂ）には、固定子巻線５１の軸方向一側から見た導線８２の形状を示している。なお、図１５（ａ）、図１５（ｂ）では、導線群８１が配置される位置をそれぞれＤ１，Ｄ２，Ｄ３，…と示している。また、説明の便宜上、３本の導線８２のみを示しており、それを第１導線８２＿Ａ、第２導線８２＿Ｂ、第３導線８２＿Ｃとしている。 Here, the winding structure of the conducting wire 82 in the stator winding 51 will be specifically described. In the present embodiment, a plurality of conductors 82 formed by wave winding are provided so as to be stacked on a plurality of layers (for example, two layers) adjacent to each other in the radial direction. 15 (a) and 15 (b) are views showing the form of each conductor 82 in the nth layer, and FIG. 15 (a) shows the conductor 82 seen from the side of the stator winding 51. The shape is shown, and FIG. 15B shows the shape of the conducting wire 82 seen from one side in the axial direction of the stator winding 51. In addition, in FIG. 15A and FIG. 15B, the positions where the conductor group 81 is arranged are shown as D1, D2, D3, ..., Respectively. Further, for convenience of explanation, only three conductors 82 are shown, which are referred to as the first conductor 82_A, the second conductor 82_B, and the third conductor 82_C.
　各導線８２＿Ａ～８２＿Ｃでは、直線部８３が、いずれもｎ層目の位置、すなわち径方向において同じ位置に配置され、周方向に６位置（３×ｍ対分）ずつ離れた直線部８３同士がターン部８４により互いに接続されている。換言すると、各導線８２＿Ａ～８２＿Ｃでは、いずれも回転子４０の軸心を中心とする同一の円上において、固定子巻線５１の周方向に隣接して並ぶ７個の直線部８３の両端の二つが一つのターン部８４により互いに接続されている。例えば第１導線８２＿Ａでは、一対の直線部８３がＤ１，Ｄ７にそれぞれ配置され、その一対の直線部８３同士が、逆Ｖ字状のターン部８４により接続されている。また、他の導線８２＿Ｂ，８２＿Ｃは、同じｎ層目において周方向の位置を１つずつずらしてそれぞれ配置されている。この場合、各導線８２＿Ａ～８２＿Ｃは、いずれも同じ層に配置されるため、ターン部８４が互いに干渉することが考えられる。そのため本実施形態では、各導線８２＿Ａ～８２＿Ｃのターン部８４に、その一部を径方向にオフセットした干渉回避部を形成することとしている。 In each of the conducting wires 82_A to 82_C, the straight line portions 83 are all arranged at the nth layer position, that is, at the same position in the radial direction, and the straight line portions 83 separated by 6 positions (3 × m pairs) in the circumferential direction are separated from each other. They are connected to each other by a turn portion 84. In other words, in each of the conducting wires 82_A to 82_C, on the same circle centered on the axis of the rotor 40, both ends of the seven straight line portions 83 arranged adjacent to each other in the circumferential direction of the stator winding 51. The two are connected to each other by one turn 84. For example, in the first conductor 82_A, a pair of straight lines 83 are arranged at D1 and D7, respectively, and the pair of straight lines 83 are connected to each other by an inverted V-shaped turn portion 84. Further, the other conductors 82_B and 82_C are arranged in the same nth layer with their circumferential positions shifted by one. In this case, since the conductors 82_A to 82_C are all arranged in the same layer, it is conceivable that the turn portions 84 interfere with each other. Therefore, in the present embodiment, an interference avoidance portion is formed in the turn portion 84 of each of the conducting wires 82_A to 82_C by offsetting a part thereof in the radial direction.
　具体的には、各導線８２＿Ａ～８２＿Ｃのターン部８４は、同一の円（第１の円）上で周方向に延びる部分である１つの傾斜部８４ａと、傾斜部８４ａからその同一の円よりも径方向内側（図１５（ｂ）において上側）にシフトし、別の円（第２の円）に達する頂部８４ｂ、第２の円上で周方向に延びる傾斜部８４ｃ及び第１の円から第２の円に戻る戻り部８４ｄとを有している。頂部８４ｂ、傾斜部８４ｃ及び戻り部８４ｄが干渉回避部に相当する。なお、傾斜部８４ｃは、傾斜部８４ａに対して径方向外側にシフトする構成であってもよい。 Specifically, the turn portion 84 of each of the conducting wires 82_A to 82_C is from one inclined portion 84a which is a portion extending in the circumferential direction on the same circle (first circle) and the same circle from the inclined portion 84a. From the top 84b, which shifts inward in the radial direction (upper side in FIG. 15B) and reaches another circle (second circle), the inclined portion 84c extending in the circumferential direction on the second circle, and the first circle. It has a return portion 84d that returns to the second circle. The top portion 84b, the inclined portion 84c, and the return portion 84d correspond to the interference avoidance portion. The inclined portion 84c may be configured to shift outward in the radial direction with respect to the inclined portion 84a.
　つまり、各導線８２＿Ａ～８２＿Ｃのターン部８４は、周方向の中央位置である頂部８４ｂを挟んでその両側に、一方側の傾斜部８４ａと他方側の傾斜部８４ｃとを有しており、それら各傾斜部８４ａ，８４ｃの径方向の位置（図１５（ａ）では紙面前後方向の位置、図１５（ｂ）では上下方向の位置）が互いに相違するものとなっている。例えば第１導線８２＿Ａのターン部８４は、ｎ層のＤ１位置を始点位置として周方向に沿って延び、周方向の中央位置である頂部８４ｂで径方向（例えば径方向内側）に曲がった後、周方向に再度曲がることで、再び周方向に沿って延び、さらに戻り部８４ｄで再び径方向（例えば径方向外側）に曲がることで、終点位置であるｎ層のＤ７位置に達する構成となっている。 That is, the turn portions 84 of the conducting wires 82_A to 82_C have an inclined portion 84a on one side and an inclined portion 84c on the other side on both sides of the top portion 84b which is a central position in the circumferential direction. The radial positions of the inclined portions 84a and 84c (the position in the front-rear direction of the paper surface in FIG. 15A and the position in the vertical direction in FIG. 15B) are different from each other. For example, the turn portion 84 of the first lead wire 82_A extends along the circumferential direction starting from the D1 position of the n layer, bends in the radial direction (for example, inward in the radial direction) at the top portion 84b which is the central position in the circumferential direction, and then. By bending again in the circumferential direction, it extends along the circumferential direction again, and further bends in the radial direction (for example, outside in the radial direction) again at the return portion 84d to reach the D7 position of the n layer, which is the end point position. There is.
　上記構成によれば、導線８２＿Ａ～８２＿Ｃでは、一方の各傾斜部８４ａが、上から第１導線８２＿Ａ→第２導線８２＿Ｂ→第３導線８２＿Ｃの順に上下に並ぶとともに、頂部８４ｂで各導線８２＿Ａ～８２＿Ｃの上下が入れ替わり、他方の各傾斜部８４ｃが、上から第３導線８２＿Ｃ→第２導線８２＿Ｂ→第１導線８２＿Ａの順に上下に並ぶ構成となっている。そのため、各導線８２＿Ａ～８２＿Ｃが互いに干渉することなく周方向に配置できるようになっている。 According to the above configuration, in the conductors 82_A to 82_C, one of the inclined portions 84a is arranged vertically in the order of the first conductor 82_A → the second conductor 82_B → the third conductor 82_C from the top, and each conductor 82_A to the top 84b. The top and bottom of 82_C are interchanged, and the other inclined portions 84c are arranged vertically in the order of the third conductor 82_C → the second conductor 82_B → the first conductor 82_A from the top. Therefore, the conductors 82_A to 82_C can be arranged in the circumferential direction without interfering with each other.
　ここで、複数の導線８２を径方向に重ねて導線群８１とする構成において、複数層の各直線部８３のうち径方向内側の直線部８３に接続されたターン部８４と、径方向外側の直線部８３に接続されたターン部８４とが、それら各直線部８３同士よりも径方向に離して配置されているとよい。また、ターン部８４の端部、すなわち直線部８３との境界部付近で、複数層の導線８２が径方向の同じ側に曲げられる場合に、その隣り合う層の導線８２同士の干渉により絶縁性が損なわれることが生じないようにするとよい。 Here, in a configuration in which a plurality of lead wires 82 are stacked in the radial direction to form a lead wire group 81, the turn portion 84 connected to the linear portion 83 on the inner side in the radial direction and the outer side in the radial direction among the straight line portions 83 of the plurality of layers It is preferable that the turn portion 84 connected to the straight portion 83 is arranged so as to be radially separated from each of the straight portions 83. Further, when the conductors 82 of a plurality of layers are bent to the same side in the radial direction near the end of the turn portion 84, that is, the boundary portion with the straight portion 83, the conductors 82 of the adjacent layers have an insulating property due to interference between the conductors 82. It is good to prevent the damage from being damaged.
　例えば図１５（ａ）、図１５（ｂ）のＤ７～Ｄ９では、径方向に重なる各導線８２が、ターン部８４の戻り部８４ｄでそれぞれ径方向に曲げられる。この場合、図１６に示すように、ｎ層目の導線８２とｎ＋１層目の導線８２とで、曲がり部の曲率半径を相違させるとよい。具体的には、径方向内側（ｎ層目）の導線８２の曲率半径Ｒ１を、径方向外側（ｎ＋１層目）の導線８２の曲率半径Ｒ２よりも小さくする。 For example, in D7 to D9 of FIGS. 15A and 15B, the conducting wires 82 overlapping in the radial direction are bent in the radial direction at the return portion 84d of the turn portion 84, respectively. In this case, as shown in FIG. 16, it is preferable that the radius of curvature of the bent portion is different between the conductor 82 of the nth layer and the conductor 82 of the n + 1 layer. Specifically, the radius of curvature R1 of the conductive wire 82 on the inner side in the radial direction (nth layer) is made smaller than the radius of curvature R2 of the lead wire 82 on the outer side in the radial direction (n + 1th layer).
　また、ｎ層目の導線８２とｎ＋１層目の導線８２とで、径方向のシフト量を相違させるとよい。具体的には、径方向内側（ｎ層目）の導線８２のシフト量Ｓ１を、径方向外側（ｎ＋１層目）の導線８２のシフト量Ｓ２よりも大きくする。 Further, it is advisable to make the shift amount in the radial direction different between the conductor 82 of the nth layer and the conductor 82 of the n + 1 layer. Specifically, the shift amount S1 of the conductor 82 on the inner side (nth layer) in the radial direction is made larger than the shift amount S2 of the conductor 82 on the outer side (n + 1 layer) in the radial direction.
　上記構成により、径方向に重なる各導線８２が同じ向きに曲げられる場合であっても、各導線８２の相互干渉を好適に回避することができる。これにより、良好な絶縁性が得られることとなる。 With the above configuration, mutual interference between the conductors 82 can be suitably avoided even when the conductors 82 overlapping in the radial direction are bent in the same direction. As a result, good insulation can be obtained.
　次に、回転子４０における磁石ユニット４２の構造について説明する。本実施形態では、磁石ユニット４２が永久磁石からなり、残留磁束密度Ｂｒ＝１．０［Ｔ］、固有保磁力Ｈｃｊ＝４００［ｋＡ／ｍ］以上のものを想定している。要は、本実施形態で用いる永久磁石は、粒状の磁性材料を焼結して成型固化した焼結磁石であり、Ｊ－Ｈ曲線上の固有保磁力Ｈｃｊは４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒは１．０［Ｔ］以上である。５０００～１００００［ＡＴ］が相間励磁により掛かる場合、１極対、すなわちＮ極とＳ極の磁気的長さ、言い換えれば、Ｎ極とＳ極間の磁束が流れる経路のうち、磁石内を通る長さが２５［ｍｍ］の永久磁石を使えば、Ｈｃｊ＝１００００［Ａ］となり、減磁をしないことが伺える。 Next, the structure of the magnet unit 42 in the rotor 40 will be described. In the present embodiment, it is assumed that the magnet unit 42 is made of a permanent magnet, has a residual magnetic flux density Br = 1.0 [T], and has an intrinsic coercive force Hcj = 400 [kA / m] or more. In short, the permanent magnet used in this embodiment is a sintered magnet obtained by sintering and solidifying a granular magnetic material, and the intrinsic coercive force Hcj on the JH curve is 400 [kA / m] or more. And the residual magnetic flux density Br is 1.0 [T] or more. When 5000 to 10000 [AT] is applied by interphase excitation, it passes through the magnet in the magnetic length of one pole pair, that is, the north pole and the south pole, in other words, the path through which the magnetic flux flows between the north pole and the south pole. If a permanent magnet with a length of 25 [mm] is used, Hcj = 10000 [A], which indicates that demagnetization is not performed.
　また換言すれば、磁石ユニット４２は、飽和磁束密度Ｊｓが１．２［Ｔ］以上で、かつ結晶粒径が１０［μｍ］以下であり、配向率をαとした場合にＪｓ×αが１．０［Ｔ］以上であるものとなっている。 In other words, the magnet unit 42 has a saturation magnetic flux density Js of 1.2 [T] or more, a crystal particle size of 10 [μm] or less, and Js × α of 1 when the orientation ratio is α. It is 0.0 [T] or higher.
　以下に磁石ユニット４２について補足する。磁石ユニット４２（磁石）は、２．１５［Ｔ］≧Ｊｓ≧１．２［Ｔ］であることが特徴である。言い換えれば、磁石ユニット４２に用いられる磁石として、NdFe11TiN、Nd2Fe14B、Sm2Fe17N3、L10型結晶を有するFeNi磁石などが挙げられる。なお、通例サマコバと言われるSmCo5や、FePt、Dy2Fe14B、CoPtなどの構成は使うことができない。注意としては、同型の化合物、例えばDy2Fe14BとNd2Fe14Bのように、一般的に、重希土類であるディスプロシウムを利用して、ネオジウムの高いＪｓ特性を少しだけ失いながらも、Dyの持つ高い保磁力を持たせた磁石でも２．１５［Ｔ］≧Ｊｓ≧１．２［Ｔ］を満たす場合があり、この場合も採用可能である。このような場合は、例えば([Nd1-xDyx]2Fe14B)と呼ぶこととする。更に、異なる組成の２種類以上の磁石、例えば、FeNiプラスSm2Fe17N3というように２種類以上の材料からなる磁石でも、達成が可能であるし、例えば、Ｊｓ＝１．６［Ｔ］と、Ｊｓに余裕のあるNd2Fe14Bの磁石に、Ｊｓ＜１［Ｔ］の、例えばDy2Fe14Bを少量混ぜ、保磁力を増加させた混合磁石などでも達成が可能である。 The magnet unit 42 is supplemented below. The magnet unit 42 (magnet) is characterized in that 2.15 [T] ≧ Js ≧ 1.2 [T]. In other words, examples of the magnet used in the magnet unit 42 include NdFe11TiN, Nd2Fe14B, Sm2Fe17N3, and FeNi magnets having L10 type crystals. In addition, SmCo5, which is usually called Samarium-cobalt, and configurations such as FePt, Dy2Fe14B, and CoPt cannot be used. Note that the same type of compounds, such as Dy2Fe14B and Nd2Fe14B, generally utilize the heavy rare earth dysprosium to slightly lose the high Js properties of neodymium, but the high coercive force of Dy. 2.15 [T] ≧ Js ≧ 1.2 [T] may be satisfied even with a magnet provided with the above, and this case can also be adopted. In such a case, it is called ([Nd1-xDyx] 2Fe14B), for example. Furthermore, it can be achieved with two or more types of magnets having different compositions, for example, magnets made of two or more types of materials such as FeNi plus Sm2Fe17N3, and for example, Js = 1.6 [T] and Js. This can be achieved by mixing a small amount of Js <1 [T], for example, Dy2Fe14B, with a magnet of Nd2Fe14B that has a margin to increase the coercive force.
　また、人間の活動範囲外の温度、例えば砂漠の温度を超える６０℃以上で動作されるような回転電機、例えば、夏においておけば車中温度が８０℃近くなる車両用モータ用途などにおいては、特に温度依存係数の小さい、FeNi、Sm2Fe17N3の成分を含むことが望ましい。これは、人間の活動範囲内である北欧の－４０℃近い温度状態から、先述の砂漠温度を超える６０℃以上、又はコイルエナメル被膜の耐熱温度１８０～２４０℃程度までのモータ動作において温度依存係数によって大きくモータ特性を異ならせるため、同一のモータドライバでの最適制御などが困難となるためである。前記L10型結晶を有するFeNi、又はSm2Fe17N3などを用いれば、Nd2Fe14Bと比べ、半分以下の温度依存係数を所持しているその特性から、モータドライバの負担を好適に減らすことができる。 In addition, in rotary electric machines that operate at temperatures outside the range of human activity, for example, 60 ° C or higher, which exceeds the temperature of deserts, for example, in vehicle motor applications where the temperature inside the vehicle is close to 80 ° C in summer. In particular, it is desirable to contain the components of FeNi and Sm2Fe17N3, which have a small temperature dependence coefficient. This is a temperature dependence coefficient in motor operation from a temperature state close to -40 ° C in Scandinavia, which is within the range of human activity, to 60 ° C or higher, which exceeds the desert temperature mentioned above, or a heat resistant temperature of 180 to 240 ° C for coil enamel coatings. This is because the motor characteristics differ greatly depending on the motor, and it becomes difficult to perform optimum control with the same motor driver. If FeNi having the L10 type crystal, Sm2Fe17N3, or the like is used, the burden on the motor driver can be suitably reduced due to its characteristic of having a temperature dependence coefficient of less than half that of Nd2Fe14B.
　加えて、磁石ユニット４２は、前記磁石配合を用いて、配向以前の微粉体状態の粒子径の大きさが１０μｍ以下、単磁区粒子径以上としていることを特徴としている。磁石では、粉体の粒子を数百ｎｍオーダまで微細化することにより保磁力が大きくなるため、近年では、できるだけ微細化された粉体が使用されている。ただし、細かくしすぎると、酸化などにより磁石のＢＨ積が落ちてしまうため、単磁区粒子径以上が好ましい。単磁区粒子径までの粒子径であれば、微細化により保磁力が上昇することが知られている。なお、ここで述べてきた粒子径の大きさは、磁石の製造工程でいうところの配向工程の際の微粉体状態の粒子径の大きさである。 In addition, the magnet unit 42 is characterized in that the size of the particle size in the fine powder state before orientation is 10 μm or less and the particle size in the single magnetic domain or more by using the magnet combination. In magnets, the coercive force is increased by refining the powder particles to the order of several hundred nm. Therefore, in recent years, powders as fine as possible have been used. However, if it is made too fine, the BH product of the magnet will drop due to oxidation or the like, so a single magnetic domain particle size or larger is preferable. It is known that the coercive force increases due to miniaturization when the particle size is up to the single magnetic domain particle size. The size of the particle size described here is the size of the particle size in the fine powder state at the time of the alignment step in the magnet manufacturing process.
　更に、磁石ユニット４２の第１磁石９１と第２磁石９２の各々は、磁性粉末を高温で焼き固めた、いわゆる焼結により形成された焼結磁石である。この焼結は、磁石ユニット４２の飽和磁化Ｊｓが１．２Ｔ以上で、第１磁石９１および第２磁石９２の結晶粒径が１０μｍ以下であり、配向率をαとした場合、Ｊｓ×αが１．０Ｔ（テスラ）以上の条件を満足するよう行われる。また、第１磁石９１と第２磁石９２の各々は、以下の条件を満足するように焼結されている。そして、その製造過程において配向工程にて配向が行われることにより、等方性磁石の着磁工程による磁力方向の定義とは異なり、配向率（orientation ratio）を持つ。本実施形態の磁石ユニット４２の飽和磁化Ｊｓが１．２Ｔ以上で、第１磁石９１と第２磁石９２の配向率αが、Ｊｒ≧Ｊｓ×α≧１．０［Ｔ］となるように高い配向率を設定されている。なお、ここで言う配向率αとは、第１磁石９１又は第２磁石９２の各々において、例えば、磁化容易軸が６つあり、そのうちの５つが同じ方向である方向Ａ１０を向き、残りの一つが方向Ａ１０に対して９０度傾いた方向Ｂ１０を向いている場合、α＝５／６であり、残りの一つが方向Ａ１０に対して４５度傾いた方向Ｂ１０を向いている場合には、残りの一つの方向Ａ１０を向く成分はｃｏｓ４５°＝０．７０７であるため、α＝（５＋０．７０７）／６となる。本実施例では焼結により第１磁石９１と第２磁石９２を形成しているが、上記条件が満足されれば、第１磁石９１と第２磁石９２は他の方法により成形してもよい。例えば、ＭＱ３磁石などを形成する方法を採用することができる。 Further, each of the first magnet 91 and the second magnet 92 of the magnet unit 42 is a sintered magnet formed by so-called sintering, in which magnetic powder is baked and hardened at a high temperature. In this sintering, when the saturation magnetization Js of the magnet unit 42 is 1.2 T or more, the crystal grain size of the first magnet 91 and the second magnet 92 is 10 μm or less, and the orientation ratio is α, Js × α is It is performed so as to satisfy the condition of 1.0 T (tesla) or more. Further, each of the first magnet 91 and the second magnet 92 is sintered so as to satisfy the following conditions. Then, since the orientation is performed in the alignment step in the manufacturing process, the orientation ratio (orientation ratio) is different from the definition of the magnetic force direction by the magnetizing step of the isotropic magnet. The saturation magnetization Js of the magnet unit 42 of the present embodiment is 1.2 T or more, and the orientation ratio α of the first magnet 91 and the second magnet 92 is high so that Jr ≧ Js × α ≧ 1.0 [T]. The orientation rate is set. The orientation rate α referred to here means, for example, six easy-to-magnetize axes in each of the first magnet 91 and the second magnet 92, five of which face the direction A10 in the same direction, and the remaining one. If one is facing the direction B10 that is tilted 90 degrees with respect to the direction A10, α = 5/6, and if the other one is facing the direction B10 that is tilted 45 degrees with respect to the direction A10, the rest. Since the component facing one direction A10 is cos45 ° = 0.707, α = (5 + 0.707) / 6. In this embodiment, the first magnet 91 and the second magnet 92 are formed by sintering, but if the above conditions are satisfied, the first magnet 91 and the second magnet 92 may be molded by another method. .. For example, a method of forming an MQ3 magnet or the like can be adopted.
　本実施形態においては、配向により磁化容易軸をコントロールした永久磁石を利用しているから、その磁石内部の磁気回路長を、従来１．０［Ｔ］以上を出す直線配向磁石の磁気回路長と比べて、長くすることができる。すなわち、１極対あたりの磁気回路長を、少ない磁石量で達成できる他、従来の直線配向磁石を利用した設計と比べ、過酷な高熱条件に曝されても、その可逆減磁範囲を保つことができる。また、本願開示者は、従来技術の磁石を用いても、極異方性磁石と近しい特性を得られる構成を見いだした。 In this embodiment, since a permanent magnet whose magnetization easy axis is controlled by orientation is used, the magnetic circuit length inside the magnet is set to the magnetic circuit length of a linearly oriented magnet that conventionally produces 1.0 [T] or more. Compared, it can be made longer. That is, the magnetic circuit length per pole pair can be achieved with a small amount of magnets, and the reversible demagnetization range is maintained even when exposed to harsh high thermal conditions as compared with the conventional design using linearly oriented magnets. Can be done. Further, the discloser of the present application has found a configuration in which characteristics similar to those of a polar anisotropic magnet can be obtained even by using a magnet of the prior art.
　なお、磁化容易軸は、磁石において磁化されやすい結晶方位のことをいう。磁石における磁化容易軸の向きとは、磁化容易軸の方向が揃っている程度を示す配向率が５０％以上となる方向、又は、その磁石の配向の平均となる方向である。 The easy-to-magnetize axis refers to the crystal orientation that is easily magnetized in a magnet. The orientation of the easy-to-magnetize axis in the magnet is a direction in which the orientation ratio indicating the degree to which the directions of the easy-magnetization axes are aligned is 50% or more, or a direction in which the orientation of the magnet is average.
　図８及び図９に示すように、磁石ユニット４２は、円環状をなしており、磁石ホルダ４１の内側（詳しくは円筒部４３の径方向内側）に設けられている。磁石ユニット４２は、それぞれ極異方性磁石でありかつ極性が互いに異なる第１磁石９１及び第２磁石９２を有している。第１磁石９１及び第２磁石９２は周方向に交互に配置されている。第１磁石９１は、固定子巻線５１に近い部分においてＮ極を形成する磁石であり、第２磁石９２は、固定子巻線５１に近い部分においてＳ極を形成する磁石である。第１磁石９１及び第２磁石９２は、例えばネオジム磁石等の希土類磁石からなる永久磁石である。 As shown in FIGS. 8 and 9, the magnet unit 42 has an annular shape and is provided inside the magnet holder 41 (specifically, inside the cylindrical portion 43 in the radial direction). The magnet unit 42 has a first magnet 91 and a second magnet 92, which are polar anisotropic magnets and have different polarities 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 an N pole in a portion close to the stator winding 51, and the second magnet 92 is a magnet that forms an S pole in a portion close to the stator winding 51. The first magnet 91 and the second magnet 92 are permanent magnets made of rare earth magnets such as neodymium magnets.
　各磁石９１，９２では、図９に示すように、公知のｄ－ｑ座標系において磁極中心であるｄ軸(direct-axis)とＮ極とＳ極の磁極境界である（言い換えれば、磁束密度が０テスラである）ｑ軸(quadrature-axis)との間において磁化方向が円弧状に延びている。各磁石９１，９２それぞれにおいて、ｄ軸側では磁化方向が円環状の磁石ユニット４２の径方向とされ、ｑ軸側では円環状の磁石ユニット４２の磁化方向が周方向とされている。以下、更に詳細に説明する。磁石９１，９２のそれぞれは、図９に示すように、第１部分２５０と、磁石ユニット４２の周方向において第１部分２５０の両側に位置する二つの第２部分２６０とを有する。言い換えれば、第１部分２５０は、第２部分２６０よりｄ軸に近く、第２部分２６０は、第１部分２５０よりｑ軸に近い。そして、第１部分２５０の磁化容易軸３００の方向は、第２部分２６０の磁化容易軸３１０の方向よりもｄ軸に対してより平行となるように磁石ユニット４２が構成されている。言い換えれば、第１部分２５０の磁化容易軸３００がｄ軸となす角度θ１１が、第２部分２６０の磁化容易軸３１０がｑ軸となす角度θ１２よりも小さくなるように磁石ユニット４２が構成されている。 In each of the magnets 91 and 92, as shown in FIG. 9, in the known dq coordinate system, the d-axis (direct-axis) which is the center of the magnetic pole and the magnetic pole boundary between the N pole and the S pole (in other words, the magnetic flux density). The magnetization direction extends in an arc shape with the q axis (quadrature-axis). In each of the magnets 91 and 92, the magnetization direction is the radial direction of the annular magnet unit 42 on the d-axis side, and the magnetization direction of the annular magnet unit 42 is the circumferential direction on the q-axis side. Hereinafter, it will be described in more detail. Each of the magnets 91 and 92 has a first portion 250 and two second portions 260 located on both sides of the first portion 250 in the circumferential direction of the magnet unit 42, as shown in FIG. In other words, the first portion 250 is closer to the d-axis than the second portion 260, and the second portion 260 is closer to the q-axis than the first portion 250. The magnet unit 42 is configured so that the direction of the easy-to-magnetize axis 300 of the first portion 250 is more parallel to the d-axis than the direction of the easy-to-magnetize axis 310 of the second portion 260. In other words, the magnet unit 42 is configured so that the angle θ11 formed by the easily magnetized axis 300 of the first portion 250 with the d-axis is smaller than the angle θ12 formed by the easily magnetized axis 310 of the second portion 260 with the q-axis. There is.
　より詳細には、角度θ１１は、ｄ軸において固定子５０（電機子）から磁石ユニット４２に向かう方向を正とした時に、ｄ軸と磁化容易軸３００とがなす角度である。角度θ１２は、ｑ軸において固定子５０（電機子）から磁石ユニット４２に向かう方向を正とした時に、ｑ軸と磁化容易軸３１０とがなす角度である。なお角度θ１１及び角度θ１２共に、本実施形態では９０°以下である。ここでいう、磁化容易軸３００，３１０のそれぞれは、以下の定義による。磁石９１，９２のそれぞれの部分において、一つの磁化容易軸が方向Ａ１１を向き、もう一つの磁化容易軸が方向Ｂ１１を向いているとした場合、方向Ａ１１と方向Ｂ１１の成す角度θのコサインの絶対値（｜ｃｏｓθ｜）を磁化容易軸３００或いは磁化容易軸３１０とする。 More specifically, the angle θ11 is the angle formed by the d-axis and the easily magnetized axis 300 when the direction from the stator 50 (armature) to the magnet unit 42 is positive on the d-axis. The angle θ12 is an angle formed by the q-axis and the easily magnetized axis 310 when the direction from the stator 50 (armature) to the magnet unit 42 is positive on the q-axis. Both the angle θ11 and the angle θ12 are 90 ° or less in this embodiment. Each of the easily magnetized axes 300 and 310 referred to here is defined by the following. Assuming that one easy-to-magnetize axis points to the direction A11 and the other easy-to-magnetize axis points to the direction B11 in each of the magnets 91 and 92, the cosine of the angle θ formed by the direction A11 and the direction B11. The absolute value (| cosθ |) is set to the easy magnetization axis 300 or the easy magnetization axis 310.
　すなわち、各磁石９１，９２のそれぞれは、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じて円弧状の磁石磁路が形成されている。なお、各磁石９１，９２において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。 That is, the directions of the easy-to-magnetize axes of the magnets 91 and 92 are different between the d-axis side (the portion closer to the d-axis) and the q-axis side (the portion closer to the q-axis), and magnetization is performed on the d-axis side. The direction of the easy axis is close to the direction parallel to the d-axis, and the direction of the easy magnetization axis is close to the direction orthogonal to the q-axis on the q-axis side. Then, an arcuate magnet magnetic path is formed according to the direction of the easily magnetized axis. In each of the magnets 91 and 92, the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side, and the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side.
　また、磁石９１，９２では、各磁石９１，９２の周面のうち固定子５０側（図９の下側）となる固定子側外面と、周方向においてｑ軸側の端面とが、磁束の流入流出面である磁束作用面となっており、それらの磁束作用面（固定子側外面及びｑ軸側の端面）を繋ぐように磁石磁路が形成されている。 Further, in the magnets 91 and 92, of the peripheral surfaces of the magnets 91 and 92, the outer surface on the stator side on the stator 50 side (lower side in FIG. 9) and the end surface on the q-axis side in the circumferential direction are magnetic flux. It is a magnetic flux acting surface that is an inflow and outflow surface, and a magnetic magnetic path is formed so as to connect these magnetic flux acting surfaces (the outer surface on the stator side and the end surface on the q-axis side).
　磁石ユニット４２では、各磁石９１，９２により、隣接するＮ，Ｓ極間を円弧状に磁束が流れるため、例えばラジアル異方性磁石に比べて磁石磁路が長くなっている。このため、図１７に示すように、磁束密度分布が正弦波に近いものとなる。その結果、図１８に比較例として示すラジアル異方性磁石の磁束密度分布とは異なり、磁極の中心側に磁束を集中させることができ、回転電機１０のトルクを高めることができる。また、本実施形態の磁石ユニット４２では、従来のハルバッハ配列の磁石と比べても、磁束密度分布の差異があることが確認できる。なお、図１７及び図１８において、横軸は電気角を示し、縦軸は磁束密度を示す。また、図１７及び図１８において、横軸の９０°はｄ軸（すなわち磁極中心）を示し、横軸の０°，１８０°はｑ軸を示す。 In the magnet unit 42, magnetic flux flows in an arc shape between adjacent N and S poles due to the magnets 91 and 92, so that the magnet path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 17, the magnetic flux density distribution is close to that of a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in FIG. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotary 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 electric angle and the vertical axis represents the magnetic flux density. Further, in FIGS. 17 and 18, 90 ° on the horizontal axis indicates the d-axis (that is, the center of the magnetic pole), and 0 ° and 180 ° on the horizontal axis indicate the q-axis.
　つまり、上記構成の各磁石９１，９２によれば、ｄ軸での磁石磁束が強化され、かつｑ軸付近での磁束変化が抑えられる。これにより、各磁極においてｑ軸からｄ軸にかけての表面磁束変化がなだらかになる磁石９１，９２を好適に実現することができる。 That is, according to the magnets 91 and 92 having the above configuration, the magnet magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed. As a result, magnets 91 and 92 in which the change in surface magnetic flux from the q-axis to the d-axis at each magnetic pole is gentle can be preferably realized.
　磁束密度分布の正弦波整合率は、例えば４０％以上の値とされていればよい。このようにすれば、正弦波整合率が３０％程度であるラジアル配向磁石、パラレル配向磁石を用いる場合に比べ、確実に波形中央部分の磁束量を向上させることができる。また、正弦波整合率を６０％以上とすれば、ハルバッハ配列のような磁束集中配列と比べ、確実に波形中央部分の磁束量を向上させることができる。 The sine wave matching factor of the magnetic flux density distribution may be, for example, a value of 40% or more. By doing so, it is possible to surely improve the amount of magnetic flux in the central portion of the waveform as compared with the case of using a radial alignment magnet or a parallel alignment magnet having a sinusoidal matching factor of about 30%. Further, if the sine wave matching factor is 60% or more, the amount of magnetic flux in the central portion of the waveform can be surely improved as compared with the magnetic flux concentrated arrangement such as the Halbach array.
　図１８に示すラジアル異方性磁石では、ｑ軸付近において磁束密度が急峻に変化する。磁束密度の変化が急峻なほど、固定子巻線５１に発生する渦電流が増加してしまう。また、固定子巻線５１側での磁束変化も急峻となる。これに対し、本実施形態では、磁束密度分布が正弦波に近い磁束波形となる。このため、ｑ軸付近において、磁束密度の変化が、ラジアル異方性磁石の磁束密度の変化よりも小さい。これにより、渦電流の発生を抑制することができる。 In the radial anisotropic magnet shown in FIG. 18, the magnetic flux density changes sharply near the q-axis. The steeper the change in magnetic flux density, the greater the eddy current generated in the stator winding 51. Further, the change in magnetic flux on the stator winding 51 side is also steep. On the other hand, in the present embodiment, the magnetic flux density distribution is a magnetic flux waveform close to a sine wave. Therefore, the change in the magnetic flux density near the q-axis is smaller than the change in the magnetic flux density of the radial anisotropic magnet. As a result, the generation of eddy current can be suppressed.
　磁石ユニット４２では、各磁石９１，９２のｄ軸付近（すなわち磁極中心）において、固定子５０側の磁束作用面２８０に直交する向きで磁束が生じ、その磁束は、固定子５０側の磁束作用面２８０から離れるほど、ｄ軸から離れるような円弧状をなす。また、磁束作用面に直交する磁束であるほど、強い磁束となる。この点において、本実施形態の回転電機１０では、上述のとおり各導線群８１を径方向に薄くしたため、導線群８１の径方向の中心位置が磁石ユニット４２の磁束作用面に近づくことになり、固定子５０において回転子４０から強い磁石磁束を受けることができる。 In the magnet unit 42, a magnetic flux is generated in the vicinity of the d-axis (that is, the center of the magnetic pole) of each of the magnets 91 and 92 in a direction orthogonal to the magnetic flux action surface 280 on the stator 50 side, and the magnetic flux acts on the magnetic flux action on the stator 50 side. The farther away from the surface 280, the more arcuate the shape is from the d-axis. Further, the magnetic flux orthogonal to the magnetic flux acting surface becomes stronger. In this respect, in the rotary electric machine 10 of the present embodiment, since each lead wire group 81 is thinned in the radial direction as described above, the radial center position of the lead wire group 81 approaches the magnetic flux acting surface of the magnet unit 42. The stator 50 can receive a strong magnetic flux from the rotor 40.
　また、固定子５０には、固定子巻線５１の径方向内側、すなわち固定子巻線５１を挟んで回転子４０の逆側に円筒状の固定子コア５２が設けられている。そのため、各磁石９１，９２の磁束作用面から延びる磁束は、固定子コア５２に引きつけられ、固定子コア５２を磁路の一部として用いつつ周回する。この場合、磁石磁束の向き及び経路を適正化することができる。 Further, the stator 50 is provided with a cylindrical stator core 52 on the radial inside of the stator winding 51, that is, on the opposite side of the rotor 40 with the stator winding 51 interposed therebetween. Therefore, the magnetic flux extending from the magnetic flux acting surface of each of the magnets 91 and 92 is attracted to the stator core 52 and orbits 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.
　以下に、回転電機１０の製造方法として、図５に示す軸受ユニット２０、ハウジング３０、回転子４０、固定子５０及びインバータユニット６０についての組み付け手順について説明する。なお、インバータユニット６０は、図６に示すようにユニットベース６１と電気コンポーネント６２とを有しており、それらユニットベース６１及び電気コンポーネント６２の組み付け工程を含む各作業工程を説明する。以下の説明では、固定子５０及びインバータユニット６０よりなる組立品を第１ユニット、軸受ユニット２０、ハウジング３０及び回転子４０よりなる組立品を第２ユニットとしている。 The procedure for assembling the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 shown in FIG. 5 will be described below as a method for manufacturing the rotary electric machine 10. As shown in FIG. 6, the inverter unit 60 has a unit base 61 and an electric component 62, and each work process including an assembling process of the unit base 61 and the electric component 62 will be described. In the following description, the assembly including the stator 50 and the inverter unit 60 is referred to as the first unit, and the assembly including the bearing unit 20, the housing 30 and the rotor 40 is referred to as the second unit.
　本製造工程は、
・ユニットベース６１の径方向内側に電気コンポーネント６２を装着する第１工程と、
・固定子５０の径方向内側にユニットベース６１を装着して第１ユニットを製作する第２工程と、
・ハウジング３０に組み付けられた軸受ユニット２０に、回転子４０の固定部４４を挿入して第２ユニットを製作する第３工程と、
・第２ユニットの径方向内側に第１ユニットを装着する第４工程と、
・ハウジング３０とユニットベース６１とを締結固定する第５工程と、
を有している。これら各工程の実施順序は、第１工程→第２工程→第３工程→第４工程→第５工程である。 This manufacturing process is
-The first step of mounting the electrical component 62 inside the unit base 61 in the radial direction, and
-The second step of mounting the unit base 61 inside the stator 50 in the radial direction to manufacture the first unit, and
A third step of inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled to the housing 30 to manufacture the second unit, and
・ The fourth step of mounting the first unit inside the second unit in the radial direction, and
Fifth step of fastening and fixing the housing 30 and the unit base 61,
have. The execution order of each of these steps is as follows: 1st step → 2nd step → 3rd step → 4th step → 5th step.
　上記の製造方法によれば、軸受ユニット２０、ハウジング３０、回転子４０、固定子５０及びインバータユニット６０を複数の組立品（サブアセンブリ）として組み立てた後に、それら組立品同士を組み付けるようにしたため、ハンドリングのし易さやユニット毎の検査完結などを実現でき、合理的な組み立てラインの構築が可能となる。したがって、多品種生産にも容易に対応が可能となる。 According to the above manufacturing method, the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 are assembled as a plurality of assemblies (subassemblies), and then the assemblies are assembled to each other. Ease of handling and completion of inspection for each unit can be realized, and a rational assembly line can be constructed. Therefore, it is possible to easily cope with high-mix production.
　第１工程では、ユニットベース６１の径方向内側及び電気コンポーネント６２の径方向外部の少なくともいずれかに、熱伝導が良好な良熱伝導体を塗布や接着等により付着させておき、その状態で、ユニットベース６１に対して電気コンポーネント６２を装着するとよい。これにより、半導体モジュール６６の発熱をユニットベース６１に対して効果的に伝達させることが可能となる。 In the first step, a good thermal conductor having good thermal conductivity is attached to at least one of the radial inside of the unit base 61 and the radial outside of the electric component 62 by coating, adhesion, etc., and in that state, The electrical component 62 may be attached to the unit base 61. This makes it possible to effectively transmit the heat generated by the semiconductor module 66 to the unit base 61.
　第３工程では、ハウジング３０と回転子４０との同軸を維持しながら、回転子４０の挿入作業を実施するとよい。具体的には、例えばハウジング３０の内周面を基準として回転子４０の外周面（磁石ホルダ４１の外周面）又は回転子４０の内周面（磁石ユニット４２の内周面）の位置を定める治具を用い、その治具に沿ってハウジング３０及び回転子４０のいずれかをスライドさせながら、ハウジング３０と回転子４０との組み付けを実施する。これにより、軸受ユニット２０に偏荷重を掛けることなく重量部品を組み付けることが可能となり、軸受ユニット２０の信頼性が向上する。 In the third step, it is advisable to insert the rotor 40 while maintaining the coaxiality between the housing 30 and the rotor 40. Specifically, for example, the position of 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) is determined with reference to the inner peripheral surface of the housing 30. Using a magnet, the housing 30 and the rotor 40 are assembled while sliding either the housing 30 or the rotor 40 along the magnet. As a result, heavy parts can be assembled without applying an eccentric load to the bearing unit 20, and the reliability of the bearing unit 20 is improved.
　第４工程では、第１ユニットと第２ユニットとの同軸を維持しながら、それら両ユニットの組み付けを実施するとよい。具体的には、例えば回転子４０の固定部４４の内周面を基準としてユニットベース６１の内周面の位置を定める治具を用い、その治具に沿って第１ユニット及び第２ユニットのいずれかをスライドさせながら、これら各ユニットの組み付けを実施する。これにより、回転子４０と固定子５０との極少隙間間での互いの干渉を防止しながら組み付けることが可能となるため、固定子巻線５１へのダメージや永久磁石の欠け等、組み付け起因の不良品の撲滅が可能となる。 In the fourth step, it is advisable to assemble both units while maintaining the coaxiality between the first unit and the second unit. Specifically, for example, a jig for determining 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 unit and the second unit are formed along the jig. Assemble each of these units while sliding one of them. As a result, it is possible to assemble while preventing mutual interference between the rotor 40 and the stator 50, which is caused by the assembly such as damage to the stator winding 51 and chipping of permanent magnets. It is possible to eradicate defective products.
　上記各工程の順序を、第２工程→第３工程→第４工程→第５工程→第１工程とすることも可能である。この場合、デリケートな電気コンポーネント６２を最後に組み付けることになり、組み付け工程内での電気コンポーネント６２へのストレスを最小限にとどめることができる。 It is also possible that the order of each of the above steps is as follows: 2nd step → 3rd step → 4th step → 5th step → 1st step. In this case, the delicate electric component 62 is assembled last, and the stress on the electric component 62 in the assembling process can be minimized.
　次に、回転電機１０を制御する制御システムの構成について説明する。図１９は、回転電機１０の制御システムの電気回路図であり、図２０は、制御装置１１０による制御処理を示す機能ブロック図である。 Next, the configuration of the control system that controls the rotary electric machine 10 will be described. FIG. 19 is an electric circuit diagram of the control system of the rotary electric machine 10, and FIG. 20 is a functional block diagram showing a control process by the control device 110.
　図１９では、固定子巻線５１として２組の３相巻線５１ａ，５１ｂが示されており、３相巻線５１ａはＵ相巻線、Ｖ相巻線及びＷ相巻線よりなり、３相巻線５１ｂはＸ相巻線、Ｙ相巻線及びＺ相巻線よりなる。３相巻線５１ａ，５１ｂごとに、電力変換器に相当する第１インバータ１０１と第２インバータ１０２とがそれぞれ設けられている。インバータ１０１，１０２は、相巻線の相数と同数の上下アームを有するフルブリッジ回路により構成されており、各アームに設けられたスイッチ（半導体スイッチング素子）のオンオフにより、固定子巻線５１の各相巻線において通電電流が調整される。 In FIG. 19, two sets of three-phase windings 51a and 51b are shown as the stator windings 51, and the three-phase winding 51a is composed of a U-phase winding, a V-phase winding, and a W-phase winding. The phase winding 51b includes an X-phase winding, a Y-phase winding, and a Z-phase winding. A first inverter 101 and a second inverter 102 corresponding to a power converter are provided for each of the three-phase windings 51a and 51b, respectively. The inverters 101 and 102 are composed of a full bridge circuit having the same number of upper and lower arms as the number of phases of the phase windings, and the stator windings 51 can be turned on and off by turning on / off a switch (semiconductor switching element) provided on each arm. The energizing current is adjusted in each phase winding.
　各インバータ１０１，１０２には、直流電源１０３と平滑用のコンデンサ１０４とが並列に接続されている。直流電源１０３は、例えば複数の単電池が直列接続された組電池により構成されている。なお、インバータ１０１，１０２の各スイッチが、図１等に示す半導体モジュール６６に相当し、コンデンサ１０４が、図１等に示すコンデンサモジュール６８に相当する。 A DC power supply 103 and a smoothing capacitor 104 are connected in parallel to each of the inverters 101 and 102. The DC power supply 103 is composed of, for example, an assembled battery in which a plurality of single batteries are connected in series. The switches of the inverters 101 and 102 correspond to the semiconductor module 66 shown in FIG. 1 and the like, and the capacitor 104 corresponds to the capacitor module 68 shown in FIG. 1 and the like.
　制御装置１１０は、ＣＰＵや各種メモリからなるマイコンを備えており、回転電機１０における各種の検出情報や、力行駆動及び発電の要求に基づいて、インバータ１０１，１０２における各スイッチのオンオフにより通電制御を実施する。制御装置１１０が、図６に示す制御装置７７に相当する。回転電機１０の検出情報には、例えば、レゾルバ等の角度検出器により検出される回転子４０の回転角度（電気角情報）や、電圧センサにより検出される電源電圧（インバータ入力電圧）、電流センサにより検出される各相の通電電流が含まれる。制御装置１１０は、インバータ１０１，１０２の各スイッチを操作する操作信号を生成して出力する。なお、発電の要求は、例えば回転電機１０が車両用動力源として用いられる場合、回生駆動の要求である。 The control device 110 includes a microcomputer composed of a CPU and various memories, and performs energization control by turning on / off each switch in the inverters 101 and 102 based on various detection information in the rotary electric machine 10 and requests for power running and power generation. carry out. The control device 110 corresponds to the control device 77 shown in FIG. The detection information of the rotary electric machine 10 includes, for example, the rotation angle (electric angle information) of the rotor 40 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by the voltage sensor, and the current sensor. Includes the energizing current of each phase detected by. The control device 110 generates and outputs an operation signal for operating each of the switches of the inverters 101 and 102. The power generation requirement is, for example, a regenerative drive requirement when the rotary electric machine 10 is used as a power source for a vehicle.
　第１インバータ１０１は、Ｕ相、Ｖ相及びＷ相からなる３相において上アームスイッチＳｐと下アームスイッチＳｎとの直列接続体をそれぞれ備えている。各相の上アームスイッチＳｐの高電位側端子は直流電源１０３の正極端子に接続され、各相の下アームスイッチＳｎの低電位側端子は直流電源１０３の負極端子（グランド）に接続されている。各相の上アームスイッチＳｐと下アームスイッチＳｎとの間の中間接続点には、それぞれＵ相巻線、Ｖ相巻線、Ｗ相巻線の一端が接続されている。これら各相巻線は星形結線（Ｙ結線）されており、各相巻線の他端は中性点にて互いに接続されている。 The first inverter 101 includes a series connection body of the upper arm switch Sp and the lower arm switch Sn in three phases including the U phase, the V phase, and the W phase. The high potential side terminal of the upper arm switch Sp of each phase is connected to the positive electrode terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative electrode terminal (ground) of the DC power supply 103. .. One ends of the U-phase winding, the V-phase winding, and the W-phase winding are connected to the intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase, respectively. Each of these phase windings is star-shaped (Y-connected), and the other end of each phase winding is connected to each other at a neutral point.
　第２インバータ１０２は、第１インバータ１０１と同様の構成を有しており、Ｘ相、Ｙ相及びＺ相からなる３相において上アームスイッチＳｐと下アームスイッチＳｎとの直列接続体をそれぞれ備えている。各相の上アームスイッチＳｐの高電位側端子は直流電源１０３の正極端子に接続され、各相の下アームスイッチＳｎの低電位側端子は直流電源１０３の負極端子（グランド）に接続されている。各相の上アームスイッチＳｐと下アームスイッチＳｎとの間の中間接続点には、それぞれＸ相巻線、Ｙ相巻線、Ｚ相巻線の一端が接続されている。これら各相巻線は星形結線（Ｙ結線）されており、各相巻線の他端は中性点で互いに接続されている。 The second inverter 102 has the same configuration as the first inverter 101, and includes a series connection body of the upper arm switch Sp and the lower arm switch Sn in three phases including the X phase, the Y phase, and the Z phase, respectively. ing. The high potential side terminal of the upper arm switch Sp of each phase is connected to the positive electrode terminal of the DC power supply 103, and the low potential side terminal of the lower arm switch Sn of each phase is connected to the negative electrode terminal (ground) of the DC power supply 103. .. One ends of the X-phase winding, the Y-phase winding, and the Z-phase winding are connected to the intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase, respectively. Each of these phase windings is star-shaped (Y-connected), and the other end of each phase winding is connected to each other at a neutral point.
　図２０には、Ｕ，Ｖ，Ｗ相の各相電流を制御する電流フィードバック制御処理と、Ｘ，Ｙ，Ｚ相の各相電流を制御する電流フィードバック制御処理とが示されている。ここではまず、Ｕ，Ｖ，Ｗ相側の制御処理について説明する。 FIG. 20 shows a current feedback control process that controls each phase current of the U, V, and W phases, and a current feedback control process that controls each phase current of the X, Y, and Z phases. Here, first, the control processing on the U, V, and W phases will be described.
　図２０において、電流指令値設定部１１１は、トルク－ｄｑマップを用い、回転電機１０に対する力行トルク指令値又は発電トルク指令値や、電気角θを時間微分して得られる電気角速度ωに基づいて、ｄ軸の電流指令値とｑ軸の電流指令値とを設定する。なお、電流指令値設定部１１１は、Ｕ，Ｖ，Ｗ相側及びＸ，Ｙ，Ｚ相側において共通に設けられている。なお、発電トルク指令値は、例えば回転電機１０が車両用動力源として用いられる場合、回生トルク指令値である。 In FIG. 20, the current command value setting unit 111 uses a torque −dq map and is based on a power running torque command value or a power generation torque command value for the rotary electric machine 10 and an electric angular velocity ω obtained by time-differentiating the electric angle θ. , The d-axis current command value and the q-axis current command value are set. The current command value setting unit 111 is commonly provided on the U, V, W phase side and the X, Y, Z phase side. The power generation torque command value is, for example, a regenerative torque command value when the rotary electric machine 10 is used as a power source for a vehicle.
　ｄｑ変換部１１２は、相ごとに設けられた電流センサによる電流検出値（３つの相電流）を、界磁方向(direction of an axis of a magnetic field,or field direction)をｄ軸とする直交２次元回転座標系の成分であるｄ軸電流とｑ軸電流とに変換する。 The dq conversion unit 112 sets the current detection values (three phase currents) by the current sensors provided for each phase to the orthogonal 2 with the field direction (direction of an axis of a magnetic field, or field direction) as the d-axis. It is converted into a d-axis current and a q-axis current, which are components of the dimensional rotation coordinate system.
　ｄ軸電流フィードバック制御部１１３は、ｄ軸電流をｄ軸の電流指令値にフィードバック制御するための操作量としてｄ軸の指令電圧を算出する。また、ｑ軸電流フィードバック制御部１１４は、ｑ軸電流をｑ軸の電流指令値にフィードバック制御するための操作量としてｑ軸の指令電圧を算出する。これら各フィードバック制御部１１３，１１４では、ｄ軸電流及びｑ軸電流の電流指令値に対する偏差に基づき、ＰＩフィードバック手法を用いて指令電圧が算出される。 The d-axis current feedback control unit 113 calculates the d-axis command voltage as an operation amount for feedback-controlling the d-axis current to the d-axis current command value. Further, the q-axis current feedback control unit 114 calculates 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 and 114, the command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current with respect to the current command value.
　３相変換部１１５は、ｄ軸及びｑ軸の指令電圧を、Ｕ相、Ｖ相及びＷ相の指令電圧に変換する。なお、上記の各部１１１～１１５が、ｄｑ変換理論による基本波電流のフィードバック制御を実施するフィードバック制御部であり、Ｕ相、Ｖ相及びＷ相の指令電圧がフィードバック制御値である。 The three-phase conversion unit 115 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Each of the above units 111 to 115 is a feedback control unit that performs feedback control of the fundamental wave current according to the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are feedback control values.
　そして、操作信号生成部１１６は、周知の三角波キャリア比較方式を用い、３相の指令電圧に基づいて、第１インバータ１０１の操作信号を生成する。具体的には、操作信号生成部１１６は、３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号（デューティ信号）を生成する。 Then, the operation signal generation unit 116 uses a well-known triangular wave carrier comparison method to generate an operation signal of the first inverter 101 based on the three-phase command voltage. Specifically, the operation signal generation unit 116 switches the upper and lower arms in each phase by PWM control based on the magnitude comparison between the signal obtained by standardizing the command voltage of the three phases with the power supply voltage and the carrier signal such as the triangular wave signal. Generates an operation signal (duty signal).
　また、Ｘ，Ｙ，Ｚ相側においても同様の構成を有しており、ｄｑ変換部１２２は、相ごとに設けられた電流センサによる電流検出値（３つの相電流）を、界磁方向をｄ軸とする直交２次元回転座標系の成分であるｄ軸電流とｑ軸電流とに変換する。 Further, the X, Y, and Z phases also have the same configuration, and the dq conversion unit 122 sets the current detection value (three phase currents) by the current sensor provided for each phase in the field direction. It is converted into a d-axis current and a q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system having the d-axis.
　ｄ軸電流フィードバック制御部１２３はｄ軸の指令電圧を算出し、ｑ軸電流フィードバック制御部１２４はｑ軸の指令電圧を算出する。３相変換部１２５は、ｄ軸及びｑ軸の指令電圧を、Ｘ相、Ｙ相及びＺ相の指令電圧に変換する。そして、操作信号生成部１２６は、３相の指令電圧に基づいて、第２インバータ１０２の操作信号を生成する。具体的には、操作信号生成部１２６は、３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号（デューティ信号）を生成する。 The d-axis current feedback control unit 123 calculates the d-axis command voltage, and the q-axis current feedback control unit 124 calculates the q-axis command voltage. The three-phase conversion unit 125 converts the d-axis and q-axis command voltages into X-phase, Y-phase, and Z-phase command voltages. Then, the operation signal generation unit 126 generates an operation signal of the second inverter 102 based on the three-phase command voltage. Specifically, the operation signal generation unit 126 switches the upper and lower arms in each phase by PWM control based on the magnitude comparison between the signal obtained by standardizing the command voltage of the three phases with the power supply voltage and the carrier signal such as the triangular wave signal. Generates an operation signal (duty signal).
　ドライバ１１７は、操作信号生成部１１６，１２６にて生成されたスイッチ操作信号に基づいて、各インバータ１０１，１０２における各３相のスイッチＳｐ，Ｓｎをオンオフさせる。 The driver 117 turns on / off the switches Sp and Sn of each of the three phases in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 116 and 126.
　続いて、トルクフィードバック制御処理について説明する。この処理は、例えば高回転領域及び高出力領域等、各インバータ１０１，１０２の出力電圧が大きくなる運転条件において、主に回転電機１０の高出力化や損失低減の目的で用いられる。制御装置１１０は、回転電機１０の運転条件に基づいて、トルクフィードバック制御処理及び電流フィードバック制御処理のいずれか一方の処理を選択して実行する。 Next, the torque feedback control process will be described. This process is mainly used for the purpose of increasing the output of the rotary electric machine 10 and reducing the loss under operating conditions in which the output voltage of each of the inverters 101 and 102 becomes large, such as in a high rotation region and a high output region. The control device 110 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotary electric machine 10.
　図２１には、Ｕ，Ｖ，Ｗ相に対応するトルクフィードバック制御処理と、Ｘ，Ｙ，Ｚ相に対応するトルクフィードバック制御処理とが示されている。なお、図２１において、図２０と同じ構成については、同じ符号を付して説明を省略する。ここではまず、Ｕ，Ｖ，Ｗ相側の制御処理について説明する。 FIG. 21 shows a torque feedback control process corresponding to the U, V, and W phases and a torque feedback control process corresponding to the X, Y, and Z phases. In FIG. 21, the same configuration as that in FIG. 20 is designated by the same reference numerals and the description thereof will be omitted. Here, first, the control processing on the U, V, and W phases will be described.
　電圧振幅算出部１２７は、回転電機１０に対する力行トルク指令値又は発電トルク指令値と、電気角θを時間微分して得られる電気角速度ωとに基づいて、電圧ベクトルの大きさの指令値である電圧振幅指令を算出する。 The voltage amplitude calculation unit 127 is a command value of the magnitude of the voltage vector based on the power running torque command value or the power generation torque command value for the rotary electric machine 10 and the electric angular velocity ω obtained by time-differentiating the electric angle θ. Calculate the voltage amplitude command.
　トルク推定部１２８ａは、ｄｑ変換部１１２により変換されたｄ軸電流とｑ軸電流とに基づいて、Ｕ，Ｖ，Ｗ相に対応するトルク推定値を算出する。なお、トルク推定部１２８ａは、ｄ軸電流、ｑ軸電流及び電圧振幅指令が関係付けられたマップ情報に基づいて、電圧振幅指令を算出すればよい。 The torque estimation unit 128a calculates the torque estimation value corresponding to the U, V, and W phases based on the d-axis current and the q-axis current converted by the dq conversion unit 112. The torque estimation unit 128a may calculate the voltage amplitude command based on the map information associated with the d-axis current, the q-axis current, and the voltage amplitude command.
　トルクフィードバック制御部１２９ａは、力行トルク指令値又は発電トルク指令値にトルク推定値をフィードバック制御するための操作量として、電圧ベクトルの位相の指令値である電圧位相指令を算出する。トルクフィードバック制御部１２９ａでは、力行トルク指令値又は発電トルク指令値に対するトルク推定値の偏差に基づき、ＰＩフィードバック手法を用いて電圧位相指令が算出される。 The torque feedback control unit 129a calculates a voltage phase command, which is a command value of the phase of the voltage vector, as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the generated torque command value. The torque feedback control unit 129a calculates the voltage phase command using the PI feedback method based on the deviation of the torque estimated value with respect to the power running torque command value or the generated torque command value.
　操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令及び電気角θに基づいて、第１インバータ１０１の操作信号を生成する。具体的には、操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令及び電気角θに基づいて３相の指令電圧を算出し、算出した３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号を生成する。 The operation signal generation unit 130a generates an operation signal of the first inverter 101 based on the voltage amplitude command, the voltage phase command, and the electric angle θ. Specifically, the operation signal generation unit 130a calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electric angle θ, and the calculated three-phase command voltage is standardized by the power supply voltage. And, by PWM control based on the magnitude comparison with the carrier signal such as the triangular wave signal, the switch operation signal of the upper and lower arms in each phase is generated.
　ちなみに、操作信号生成部１３０ａは、電圧振幅指令、電圧位相指令、電気角θ及びスイッチ操作信号が関係付けられたマップ情報であるパルスパターン情報、電圧振幅指令、電圧位相指令並びに電気角θに基づいて、スイッチ操作信号を生成してもよい。 Incidentally, the operation signal generation unit 130a is based on the pulse pattern information, the voltage amplitude command, the voltage phase command, and the electric angle θ, which are map information related to the voltage amplitude command, the voltage phase command, the electric angle θ, and the switch operation signal. The switch operation signal may be generated.
　また、Ｘ，Ｙ，Ｚ相側においても同様の構成を有しており、トルク推定部１２８ｂは、ｄｑ変換部１２２により変換されたｄ軸電流とｑ軸電流とに基づいて、Ｘ，Ｙ，Ｚ相に対応するトルク推定値を算出する。 Further, the X, Y, Z phase side also has the same configuration, and the torque estimation unit 128b has the X, Y, X, Y, based on the d-axis current and the q-axis current converted by the dq conversion unit 122. The torque estimate corresponding to the Z phase is calculated.
　トルクフィードバック制御部１２９ｂは、力行トルク指令値又は発電トルク指令値にトルク推定値をフィードバック制御するための操作量として、電圧位相指令を算出する。トルクフィードバック制御部１２９ｂでは、力行トルク指令値又は発電トルク指令値に対するトルク推定値の偏差に基づき、ＰＩフィードバック手法を用いて電圧位相指令が算出される。 The torque feedback control unit 129b calculates a voltage phase command as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the power generation torque command value. The torque feedback control unit 129b calculates the voltage phase command using the PI feedback method based on the deviation of the torque estimated value with respect to the power running torque command value or the generated torque command value.
　操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令及び電気角θに基づいて、第２インバータ１０２の操作信号を生成する。具体的には、操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令及び電気角θに基づいて３相の指令電圧を算出し、算出した３相の指令電圧を電源電圧で規格化した信号と、三角波信号等のキャリア信号との大小比較に基づくＰＷＭ制御により、各相における上下アームのスイッチ操作信号を生成する。ドライバ１１７は、操作信号生成部１３０ａ，１３０ｂにて生成されたスイッチ操作信号に基づいて、各インバータ１０１，１０２における各３相のスイッチＳｐ，Ｓｎをオンオフさせる。 The operation signal generation unit 130b generates an operation signal of the second inverter 102 based on the voltage amplitude command, the voltage phase command, and the electric angle θ. Specifically, the operation signal generation unit 130b calculates a three-phase command voltage based on the voltage amplitude command, the voltage phase command, and the electric angle θ, and the calculated three-phase command voltage is standardized by the power supply voltage. And, by PWM control based on the magnitude comparison with the carrier signal such as the triangular wave signal, the switch operation signal of the upper and lower arms in each phase is generated. The driver 117 turns on / off the switches Sp and Sn of each of the three phases in the inverters 101 and 102 based on the switch operation signals generated by the operation signal generation units 130a and 130b.
　ちなみに、操作信号生成部１３０ｂは、電圧振幅指令、電圧位相指令、電気角θ及びスイッチ操作信号が関係付けられたマップ情報であるパルスパターン情報、電圧振幅指令、電圧位相指令並びに電気角θに基づいて、スイッチ操作信号を生成してもよい。 Incidentally, the operation signal generation unit 130b is based on the pulse pattern information, the voltage amplitude command, the voltage phase command, and the electric angle θ, which are map information related to the voltage amplitude command, the voltage phase command, the electric angle θ, and the switch operation signal. The switch operation signal may be generated.
　ところで、回転電機１０においては、軸電流の発生に伴い軸受２１，２２の電食が生じることが懸念されている。例えば固定子巻線５１の通電がスイッチングにより切り替えられる際に、スイッチングタイミングの微小なずれ（スイッチングの不均衡）により磁束の歪みが生じ、それに起因して、回転軸１１を支持する軸受２１，２２において電食が生じることが懸念される。磁束の歪みは固定子５０のインダクタンスに応じて生じ、その磁束の歪みにより生じる軸方向の起電圧によって、軸受２１，２２内での絶縁破壊が起こり電食が進行する。 By the way, in the rotary electric machine 10, there is a concern that electrolytic corrosion of the bearings 21 and 22 may occur due to the generation of the shaft current. For example, when the energization of the stator winding 51 is switched by switching, magnetic flux distortion occurs due to a slight deviation in switching timing (switching imbalance), which causes bearings 21 and 22 to support the rotating shaft 11. There is a concern that electrolytic corrosion will occur in the bearing. The distortion of the magnetic flux occurs according to the inductance of the stator 50, and the electromotive voltage in the axial direction generated by the distortion of the magnetic flux causes dielectric breakdown in the bearings 21 and 22, and electrolytic corrosion proceeds.
　この点本実施形態では、電食対策として、以下に示す３つの対策を講じている。第１の電食対策は、固定子５０のコアレス化に伴いインダクタンスを低減したこと、及び磁石ユニット４２の磁石磁束をなだらかにしたことによる電食抑制対策である。第２の電食対策は、回転軸を軸受２１，２２による片持ち構造としたことによる電食抑制対策である。第３の電食対策は、円環状の固定子巻線５１を固定子コア５２と共にモールド材によりモールドしたことによる電食抑制対策である。以下には、これら各対策の詳細を個々に説明する。 In this respect, in this embodiment, the following three measures are taken as measures against electrolytic corrosion. The first electrolytic corrosion countermeasure is an electrolytic corrosion suppression countermeasure by reducing the inductance due to the coreless stator 50 and by smoothing the magnetic flux of the magnet of the magnet unit 42. The second electrolytic corrosion countermeasure is an electrolytic corrosion suppression measure by adopting a cantilever structure with bearings 21 and 22 for the rotating shaft. The third electrolytic corrosion countermeasure is an electrolytic corrosion suppression countermeasure by molding the annular stator winding 51 together with the stator core 52 with a molding material. The details of each of these measures will be described below individually.
　まず第１の電食対策では、固定子５０において、周方向における各導線群８１の間をティースレスとし、各導線群８１の間に、ティース（鉄心）の代わりに非磁性材料よりなる封止部材５７を設ける構成としている（図１０参照）。これにより、固定子５０のインダクタンス低減が可能となっている。固定子５０におけるインダクタンス低減を図ることで、仮に固定子巻線５１の通電時にスイッチングタイミングのずれが生じても、そのスイッチングタイミングのずれに起因する磁束歪みの発生を抑制し、ひいては軸受２１，２２の電食抑制が可能になっている。なお、ｄ軸のインダクタンスがｑ軸のインダクタンス以下になっているとよい。 First, as a first measure against electrolytic corrosion, in the stator 50, the spaces between the conductor groups 81 in the circumferential direction are made toothless, and the seals between the conductor groups 81 are made of a non-magnetic material instead of the teeth (iron core). The member 57 is provided (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 the switching timing shift occurs when the stator winding 51 is energized, the occurrence of magnetic flux distortion due to the shift timing shift can be suppressed, and eventually the bearings 21 and 22. It is possible to suppress the electrolytic corrosion of. It is preferable that the inductance of the d-axis is equal to or less than the inductance of the q-axis.
　また、磁石９１，９２において、ｄ軸側においてｑ軸側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた構成とした（図９参照）。これにより、ｄ軸での磁石磁束が強化され、各磁極においてｑ軸からｄ軸にかけての表面磁束変化（磁束の増減）がなだらかになる。そのため、スイッチング不均衡に起因する急激な電圧変化が抑制され、ひいては電食抑制に寄与できる構成となっている。 Further, the magnets 91 and 92 are oriented so that the direction of the easy-magnetizing axis is parallel to the d-axis on the d-axis side as compared with the q-axis side (see FIG. 9). As a result, the magnetic flux of the magnet on the d-axis is strengthened, and the change in surface magnetic flux (increase / decrease in magnetic flux) from the q-axis to the d-axis at each magnetic pole becomes gentle. Therefore, the sudden voltage change caused by the switching imbalance is suppressed, and the configuration is such that it can contribute to the suppression of electrolytic corrosion.
　第２の電食対策では、回転電機１０において、各軸受２１，２２を、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置している（図２参照）。これにより、複数の軸受が軸方向において回転子を挟んで両側にそれぞれ設けられる構成と比べて、電食の影響を軽減できる。つまり、回転子を複数の軸受により両持ち支持する構成では、高周波磁束の発生に伴い回転子、固定子及び各軸受（すなわち、回転子を挟んで軸方向両側の各軸受）を通る閉回路が形成され、軸電流により軸受の電食が懸念される。これに対し、回転子４０を複数の軸受２１，２２により片持ち支持する構成では上記閉回路が形成されず、軸受の電食が抑制される。 As a second measure against electrolytic corrosion, in the rotary electric machine 10, the bearings 21 and 22 are arranged unevenly on either side in the axial direction with respect to the center in the axial direction of the rotor 40 (see FIG. 2). As a result, the influence of electrolytic corrosion can be reduced as compared with a configuration in which a plurality of bearings are provided on both sides of the rotor in the axial direction. That is, in a configuration in which the rotor is supported by a plurality of bearings, a closed circuit that passes through the rotor, the stator, and each bearing (that is, each bearing on both sides in the axial direction with the rotor in between) is generated as a high frequency magnetic flux is generated. It is formed, and there is a 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 a plurality of bearings 21 and 22, the closed circuit is not formed and the electrolytic corrosion of the bearings is suppressed.
　また、回転電機１０は、軸受２１，２２の片側配置のための構成に絡み、以下の構成を有する。磁石ホルダ４１において、回転子４０の径方向に張り出す中間部４５に、軸方向に延びて固定子５０に対する接触を回避する接触回避部が設けられている（図２参照）。この場合、磁石ホルダ４１を経由して軸電流の閉回路が形成される場合にあっては、閉回路長を長くしてその回路抵抗を大きくすることが可能となる。これにより、軸受２１，２２の電食の抑制を図ることができる。 Further, the rotary electric machine 10 has the following configurations in connection with the configuration for arranging the bearings 21 and 22 on one side. In the magnet holder 41, a contact avoiding portion that extends in the axial direction and avoids contact with the stator 50 is provided at an intermediate portion 45 that projects in the radial direction of the rotor 40 (see FIG. 2). In this case, when a closed circuit of the shaft current is formed via the magnet holder 41, the closed circuit length can be lengthened to increase the circuit resistance. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be suppressed.
　回転子４０を挟んで軸方向の一方側においてハウジング３０に対して軸受ユニット２０の保持部材２３が固定されるとともに、他方側においてハウジング３０及びユニットベース６１（固定子ホルダ）が互いに結合されている（図２参照）。本構成によれば、回転軸１１の軸方向においてその軸方向の片側に各軸受２１，２２を偏って配置する構成を好適に実現することができる。また本構成では、ユニットベース６１がハウジング３０を介して回転軸１１に繋がる構成となるため、ユニットベース６１を、回転軸１１から電気的に離れた位置に配置することができる。なお、ユニットベース６１とハウジング３０との間に樹脂等の絶縁部材を介在させれば、ユニットベース６１と回転軸１１とが電気的に一層離れた構成となる。これにより、軸受２１，２２の電食を適正に抑制することができる。 The holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 (stator holder) are coupled to each other on the other side. (See FIG. 2). According to this configuration, it is possible to preferably realize a configuration in which the bearings 21 and 22 are unevenly arranged on one side of the rotating shaft 11 in the axial direction. Further, in this configuration, since the unit base 61 is connected to the rotating shaft 11 via the housing 30, the unit base 61 can be arranged at a position electrically separated from the rotating shaft 11. If an insulating member such as resin is interposed between the unit base 61 and the housing 30, the unit base 61 and the rotating shaft 11 are electrically separated from each other. Thereby, the electrolytic corrosion of the bearings 21 and 22 can be appropriately suppressed.
　本実施形態の回転電機１０では、各軸受２１，２２の片側配置等により、軸受２１，２２に作用する軸電圧が低減されている。また、回転子４０と固定子５０との間の電位差が低減されている。そのため、軸受２１，２２において導電性グリースを用いなくても、軸受２１，２２に作用する電位差の低減が可能になっている。導電性グリースは、一般的にカーボンなどの細かい粒子を含むため音鳴りが生じることが考えられる。この点、本実施形態では、軸受２１，２２において非導電性グリースを用いる構成としている。そのため、軸受２１，２２において音鳴りが生じる不都合を抑制できる。例えば電気自動車などの電動車両への適用時には回転電機１０の音鳴り対策が必要になると考えられるが、その音鳴り対策を好適に実施することが可能となる。 In the rotary electric machine 10 of the present embodiment, the shaft voltage acting on the bearings 21 and 22 is reduced by arranging the bearings 21 and 22 on one side and the like. Further, the potential difference between the rotor 40 and the stator 50 is reduced. Therefore, it is possible to reduce the potential difference acting on the bearings 21 and 22 without using conductive grease in the bearings 21 and 22. Since the conductive grease generally contains fine particles such as carbon, it is considered that noise is generated. In this respect, in the present embodiment, the bearings 21 and 22 are configured to use non-conductive grease. Therefore, it is possible to suppress the inconvenience of noise in the bearings 21 and 22. For example, when it is applied to an electric vehicle such as an electric vehicle, it is considered that a countermeasure against the noise of the rotary electric machine 10 is required, and it is possible to preferably implement the countermeasure against the noise.
　第３の電食対策では、固定子巻線５１を固定子コア５２と共にモールド材によりモールドすることで、固定子５０での固定子巻線５１の位置ずれを抑制する構成としている（図１１参照）。特に本実施形態の回転電機１０では、固定子巻線５１における周方向の各導線群８１の間に導線間部材（ティース）を有していないため、固定子巻線５１における位置ずれ生じる懸念が考えられるが、固定子巻線５１を固定子コア５２と共にモールドすることにより、固定子巻線５１の導線位置にずれが抑制される。したがって、固定子巻線５１の位置ずれによる磁束の歪みや、それに起因する軸受２１，２２の電食の発生を抑制することができる。 In the third electrolytic corrosion countermeasure, the stator winding 51 is molded together with the stator core 52 with a molding material to suppress the displacement of the stator winding 51 in the stator 50 (see FIG. 11). ). In particular, since the rotary electric machine 10 of the present embodiment does not have a wire-to-lead member (teeth) between the wire groups 81 in the circumferential direction of the stator winding 51, there is a concern that the stator winding 51 may be displaced. Although it is conceivable, by molding the stator winding 51 together with the stator core 52, deviation of the lead wire position of the stator winding 51 is suppressed. Therefore, it is possible to suppress the distortion of the magnetic flux due to the misalignment of the stator winding 51 and the occurrence of electrolytic corrosion of the bearings 21 and 22 due to the distortion.
　なお、固定子コア５２を固定するハウジング部材としてのユニットベース６１を、炭素繊維強化プラスチック（ＣＦＲＰ）により構成したため、例えばアルミ等により構成する場合に比べて、ユニットベース６１への放電が抑制され、ひいては好適な電食対策が可能となっている。 Since the unit base 61 as a housing member for fixing the stator core 52 is made of carbon fiber reinforced plastic (CFRP), the discharge to the unit base 61 is suppressed as compared with the case where it is made of, for example, aluminum. As a result, suitable measures against electrolytic corrosion are possible.
　その他、軸受２１，２２の電食対策として、外輪２５及び内輪２６の少なくともいずれかをセラミックス材により構成する、又は、外輪２５の外側に絶縁スリーブを設ける等の構成を用いることも可能である。 In addition, as a countermeasure against electrolytic corrosion of the bearings 21 and 22, it is also possible to use a configuration in which at least one of the outer ring 25 and the inner ring 26 is made of a ceramic material, or an insulating sleeve is provided on the outside of the outer ring 25.
　以下に、他の実施形態を第１実施形態との相違点を中心に説明する。 The other embodiments will be described below, focusing on the differences from the first embodiment.
　（第２実施形態）
　本実施形態では、回転子４０における磁石ユニット４２の極異方構造を変更しており、以下に詳しく説明する。 (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.
　図２２及び図２３に示すように、磁石ユニット４２は、ハルバッハ配列と称される磁石配列を用いて構成されている。すなわち、磁石ユニット４２は、磁化方向（磁化ベクトルの向き）を径方向とする第１磁石１３１と、磁化方向（磁化ベクトルの向き）を周方向とする第２磁石１３２とを有しており、周方向に所定間隔で第１磁石１３１が配置されるとともに、周方向において隣り合う第１磁石１３１の間となる位置に第２磁石１３２が配置されている。第１磁石１３１及び第２磁石１３２は、例えばネオジム磁石等の希土類磁石からなる永久磁石である。 As shown in FIGS. 22 and 23, the magnet unit 42 is configured by using a magnet array called a Halbach array. That is, the magnet unit 42 has a first magnet 131 whose radial direction is the magnetization direction (direction of the magnetization vector) and a second magnet 132 whose circumferential direction is the magnetization direction (direction of the magnetization vector). The first magnet 131 is arranged at predetermined intervals in the circumferential direction, and the second magnet 132 is arranged at a position between the adjacent first magnet 131 in the circumferential direction. The first magnet 131 and the second magnet 132 are permanent magnets made of rare earth magnets such as neodymium magnets.
　第１磁石１３１は、固定子５０に対向する側（径方向内側）の極が交互にＮ極、Ｓ極となるように周方向に互いに離間して配置されている。また、第２磁石１３２は、各第１磁石１３１の隣において周方向に極性が交互となるように配置されている。これら各磁石１３１，１３２を囲うように設けられる円筒部４３は、軟磁性材料よりなる軟磁性体コアであるとよく、バックコアとして機能する。なお、この第２実施形態の磁石ユニット４２も、ｄ－ｑ座標系において、ｄ軸やｑ軸に対する磁化容易軸の関係は上記第１実施形態と同じである。 The first magnet 131 is arranged so as to be spaced apart from each other in the circumferential direction so that the poles on the side facing the stator 50 (inside in the radial direction) are alternately N poles and S poles. Further, the second magnet 132 is arranged next to each first magnet 131 so that the polarities alternate in the circumferential direction. The cylindrical portion 43 provided so as to surround each of the magnets 131 and 132 is preferably a soft magnetic core made of a soft magnetic material, and functions as a back core. The magnet unit 42 of the second embodiment also has the same relationship between the d-axis and the easy-magnetization axis with respect to the q-axis in the dq coordinate system as in the first embodiment.
　また、第１磁石１３１の径方向外側、すなわち磁石ホルダ４１の円筒部４３の側には、軟磁性材料よりなる磁性体１３３が配置されている。例えば磁性体１３３は、電磁鋼板や軟鉄、圧粉鉄心材料により構成されているとよい。この場合、磁性体１３３の周方向の長さは第１磁石１３１の周方向の長さ（特に第１磁石１３１の外周部の周方向の長さ）と同じである。また、第１磁石１３１と磁性体１３３とを一体化した状態でのその一体物の径方向の厚さは、第２磁石１３２の径方向の厚さと同じである。換言すれば、第１磁石１３１は第２磁石１３２よりも磁性体１３３の分だけ径方向の厚さが薄くなっている。各磁石１３１，１３２と磁性体１３３とは、例えば接着剤により相互に固着されている。磁石ユニット４２において第１磁石１３１の径方向外側は、固定子５０とは反対側であり、磁性体１３３は、径方向における第１磁石１３１の両側のうち、固定子５０とは反対側（反固定子側）に設けられている。 Further, a magnetic material 133 made of a soft magnetic material is arranged on the radial side of the first magnet 131, that is, on the side of the cylindrical portion 43 of the magnet holder 41. For example, the magnetic material 133 may be made of an electromagnetic steel plate, soft iron, or a dust core material. In this case, the circumferential length of the magnetic body 133 is the same as the circumferential length of the first magnet 131 (particularly, the circumferential length of the outer peripheral portion of the first magnet 131). Further, the radial thickness of the integrated object in the state where the first magnet 131 and the magnetic body 133 are integrated is the same as the radial thickness of the second magnet 132. In other words, the thickness of the first magnet 131 in the radial direction is thinner than that of the second magnet 132 by the amount of the magnetic body 133. The magnets 131 and 132 and the magnetic material 133 are fixed to each other by, for example, an adhesive. In the magnet unit 42, the radial outside of the first magnet 131 is on the opposite side of the stator 50, and the magnetic body 133 is on the opposite side of the stator 50 from both sides of the first magnet 131 in the radial direction (opposite). It is provided on the stator side).
　磁性体１３３の外周部には、径方向外側、すなわち磁石ホルダ４１の円筒部４３の側に突出する凸部としてのキー１３４が形成されている。また、円筒部４３の内周面には、磁性体１３３のキー１３４を収容する凹部としてのキー溝１３５が形成されている。キー１３４の突出形状とキー溝１３５の溝形状とは同じであり、各磁性体１３３に形成されたキー１３４に対応して、キー１３４と同数のキー溝１３５が形成されている。キー１３４及びキー溝１３５の係合により、第１磁石１３１及び第２磁石１３２と磁石ホルダ４１との周方向（回転方向）の位置ずれが抑制されている。なお、キー１３４及びキー溝１３５（凸部及び凹部）を、磁石ホルダ４１の円筒部４３及び磁性体１３３のいずれに設けるかは任意でよく、上記とは逆に、磁性体１３３の外周部にキー溝１３５を設けるとともに、磁石ホルダ４１の円筒部４３の内周部にキー１３４を設けることも可能である。 A key 134 is formed on the outer peripheral portion of the magnetic body 133 as a convex portion protruding outward in the radial direction, that is, toward the cylindrical portion 43 of the magnet holder 41. Further, a key groove 135 is formed on the inner peripheral surface of the cylindrical portion 43 as a recess for accommodating the key 134 of the magnetic body 133. The protruding shape of the key 134 and the groove shape of the key groove 135 are the same, and the same number of key grooves 135 as the key 134 are formed corresponding to the key 134 formed on each magnetic material 133. By engaging the key 134 and the key groove 135, the displacement of the first magnet 131 and the second magnet 132 and the magnet holder 41 in the circumferential direction (rotational direction) is suppressed. It is optional whether the key 134 and the key groove 135 (convex portion and concave portion) are provided in the cylindrical portion 43 or the magnetic body 133 of the magnet holder 41, and contrary to the above, on the outer peripheral portion of the magnetic body 133. In addition to providing the key groove 135, it is also possible to provide the key 134 on the inner peripheral portion of the cylindrical portion 43 of the magnet holder 41.
　ここで、磁石ユニット４２では、第１磁石１３１と第２磁石１３２とを交互に配列することにより、第１磁石１３１での磁束密度を大きくすることが可能となっている。そのため、磁石ユニット４２において、磁束の片面集中を生じさせ、固定子５０寄りの側での磁束強化を図ることができる。 Here, in the magnet unit 42, the magnetic flux density in the first magnet 131 can be increased by alternately arranging the first magnet 131 and the second magnet 132. 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.
　また、第１磁石１３１の径方向外側、すなわち反固定子側に磁性体１３３を配置したことにより、第１磁石１３１の径方向外側での部分的な磁気飽和を抑制でき、ひいては磁気飽和に起因して生じる第１磁石１３１の減磁を抑制できる。これにより、結果的に磁石ユニット４２の磁力を増加させることが可能となっている。本実施形態の磁石ユニット４２は、言うなれば、第１磁石１３１において減磁が生じ易い部分を磁性体１３３に置き換えた構成となっている。 Further, by arranging the magnetic material 133 on the radial outer side of the first magnet 131, that is, on the anti-fixer side, it is possible to suppress partial magnetic saturation on the radial outer side of the first magnet 131, which is caused by magnetic saturation. The demagnetization of the first magnet 131 caused by the above 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 has, so to speak, a configuration in which a portion of the first magnet 131 in which demagnetization is likely to occur is replaced with a magnetic body 133.
　図２４（ａ）、図２４（ｂ）は、磁石ユニット４２における磁束の流れを具体的に示す図であり、図２４（ａ）は、磁石ユニット４２において磁性体１３３を有していない従来構成を用いた場合を示し、図２４（ｂ）は、磁石ユニット４２において磁性体１３３を有している本実施形態の構成を用いた場合を示している。なお、図２４（ａ）、図２４（ｂ）では、磁石ホルダ４１の円筒部４３及び磁石ユニット４２を直線状に展開して示しており、図の下側が固定子側、上側が反固定子側となっている。 24 (a) and 24 (b) are views specifically showing the flow of magnetic flux in the magnet unit 42, and FIG. 24 (a) shows a conventional configuration in which the magnet unit 42 does not have a magnetic body 133. 24 (b) shows the case where the configuration of the present embodiment having the magnetic material 133 in the magnet unit 42 is used. In FIGS. 24 (a) and 24 (b), the cylindrical portion 43 of the magnet holder 41 and the magnet unit 42 are shown in a straight line, with the lower side of the drawing being the stator side and the upper side being the anti-stator side. It is on the side.
　図２４（ａ）の構成では、第１磁石１３１の磁束作用面と第２磁石１３２の側面とが、それぞれ円筒部４３の内周面に接触している。また、第２磁石１３２の磁束作用面が第１磁石１３１の側面に接触している。この場合、円筒部４３には、第２磁石１３２の外側経路を通って第１磁石１３１との接触面に入る磁束Ｆ１と、円筒部４３と略平行で、かつ第２磁石１３２の磁束Ｆ２を引きつける磁束との合成磁束が生じる。そのため、円筒部４３において第１磁石１３１と第２磁石１３２との接触面付近において、部分的に磁気飽和が生じることが懸念される。 In the configuration of FIG. 24A, the magnetic flux acting surface of the first magnet 131 and the side surface of the second magnet 132 are in contact with the inner peripheral surface of the cylindrical portion 43, respectively. Further, the magnetic flux acting surface of the second magnet 132 is in contact with the side surface of the first magnet 131. In this case, the cylindrical portion 43 receives a magnetic flux F1 that enters the contact surface with the first magnet 131 through the outer path of the second magnet 132 and a magnetic flux F2 that is substantially parallel to the cylindrical portion 43 and enters the contact surface of the second magnet 132. A combined magnetic flux with the attractive magnetic flux is generated. Therefore, there is a concern that magnetic saturation may partially occur in the vicinity of the contact surface between the first magnet 131 and the second magnet 132 in the cylindrical portion 43.
　これに対し、図２４（ｂ）の構成では、第１磁石１３１の固定子５０とは反対側において第１磁石１３１の磁束作用面と円筒部４３の内周面との間に磁性体１３３が設けられているため、その磁性体１３３で磁束の通過が許容される。したがって、円筒部４３での磁気飽和を抑制でき、減磁に対する耐力が向上する。 On the other hand, in the configuration of FIG. 24B, the magnetic material 133 is formed between the magnetic flux acting surface of the first magnet 131 and the inner peripheral surface of the cylindrical portion 43 on the side opposite to the stator 50 of the first magnet 131. Since it is provided, the magnetic body 133 allows the passage of magnetic flux. Therefore, magnetic saturation in the cylindrical portion 43 can be suppressed, and the proof stress against demagnetization is improved.
　また、図２４（ｂ）の構成では、図２４（ａ）とは異なり、磁気飽和を促すＦ２を消すことができる。これにより、磁気回路全体のパーミアンスを効果的に向上させることができる。このように構成することで、その磁気回路特性を、過酷な高熱条件下でも保つことができる。 Further, in the configuration of FIG. 24 (b), unlike FIG. 24 (a), F2 that promotes magnetic saturation can be erased. As a result, the permeance of the entire magnetic circuit can be effectively improved. With such a configuration, the magnetic circuit characteristics can be maintained even under severe high heat conditions.
　また、従来のＳＰＭロータにおけるラジアル磁石と比べて、磁石内部を通る磁石磁路が長くなる。そのため、磁石パーミアンスが上昇し、磁力を上げ、トルクを増強することができる。さらに、磁束がｄ軸の中央に集まることにより、正弦波整合率を高くすることができる。特に、ＰＷＭ制御により、電流波形を正弦波や台形波とする、又は１２０度通電のスイッチングＩＣを利用すると、より効果的にトルクを増強することができる。 In addition, the magnetic path through the inside of the magnet is longer than that of the radial magnet in the conventional SPM rotor. Therefore, the magnet permeance can be increased, the magnetic force can be increased, and the torque can be increased. Further, the magnetic flux is concentrated in the center of the d-axis, so that the sine wave matching rate can be increased. In particular, if the current waveform is made into a sine wave or a trapezoidal wave by PWM control, or if a switching IC energized at 120 degrees is used, the torque can be increased more effectively.
　なお、固定子コア５２が電磁鋼板により構成される場合において、固定子コア５２の径方向厚さは、磁石ユニット４２の径方向厚さの１／２、又は１／２よりも大きいとよい。例えば、固定子コア５２の径方向厚さは、磁石ユニット４２において磁極中心に設けられる第１磁石１３１の径方向厚さの１／２以上であるとよい。また、固定子コア５２の径方向厚さは、磁石ユニット４２の径方向厚さより小さいとよい。この場合、磁石磁束は約１［Ｔ］であり、固定子コア５２の飽和磁束密度は２［Ｔ］であるため、固定子コア５２の径方向厚さを、磁石ユニット４２の径方向厚さの１／２以上にすることで、固定子コア５２の内周側への磁束漏洩を防ぐことができる。 When the stator core 52 is made of an electromagnetic steel plate, the radial thickness of the stator core 52 is preferably half or more than 1/2 of the radial thickness of the magnet unit 42. For example, the radial thickness of the stator core 52 is preferably ½ or more of the radial thickness of the first magnet 131 provided at the center of the magnetic pole in the magnet unit 42. Further, the radial thickness of the stator core 52 is preferably smaller than the radial thickness of the magnet unit 42. In this case, the magnetic flux of the magnet is about 1 [T], and the saturation magnetic flux density of the stator core 52 is 2 [T]. Therefore, the radial thickness of the stator core 52 is the radial thickness of the magnet unit 42. By setting the value to 1/2 or more of the above, it is possible to prevent magnetic flux leakage to the inner peripheral side of the stator core 52.
　ハルバッハ構造や極異方構造の磁石では、磁路が擬似円弧状になっているため、周方向の磁束を扱う磁石厚みに比例して、その磁束を上昇させることができる。こういった構成においては、固定子コア５２に流れる磁束は、周方向の磁束を超えることはないと考えられる。すなわち、磁石の磁束１［Ｔ］に対して飽和磁束密度２［Ｔ］の鉄系金属を利用した場合、固定子コア５２の厚みを磁石厚みの半分以上とすれば、磁気飽和せず好適に小型かつ軽量の回転電機を提供することができる。ここで、磁石磁束に対して固定子５０からの反磁界が作用するため、磁石磁束は一般的に０．９［Ｔ］以下となる。そのため、固定子コアは磁石の半分の厚みを持てば、その透磁率を好適に高く保つことができる。 In a magnet with a Halbach structure or a very heterogeneous structure, the magnetic path has a pseudo-arc shape, so the magnetic flux can be increased in proportion to the thickness of the magnet that handles the magnetic flux in the circumferential direction. In such a configuration, it is considered that the magnetic flux flowing through the stator core 52 does not exceed the magnetic flux in the circumferential direction. That is, when an iron-based metal having a saturation magnetic flux density of 2 [T] is used with respect to the magnetic flux of the magnet 1 [T], if the thickness of the stator core 52 is set to half or more of the magnet thickness, magnetic saturation is not preferably performed. It is possible to provide a small and lightweight rotary electric machine. Here, since the demagnetic field from the stator 50 acts on the magnet magnetic flux, the magnet magnetic flux is generally 0.9 [T] or less. Therefore, if the stator core has half the thickness of the magnet, its magnetic permeability can be kept suitably high.
　以下に、上述した構成の一部を変更した変形例について説明する。 Below, a modified example in which a part of the above configuration is changed will be described.
　（変形例１）
　上記実施形態では、固定子コア５２の外周面を凹凸のない曲面状とし、その外周面に所定間隔で複数の導線群８１を並べて配置する構成としたが、これを変更してもよい。例えば、図２５に示すように、固定子コア５２は、固定子巻線５１の径方向両側のうち回転子４０とは反対側（図の下側）に設けられた円環状のヨーク１４１と、そのヨーク１４１から、周方向に隣り合う直線部８３の間に向かって突出するように延びる突起部１４２とを有している。突起部１４２は、ヨーク１４１の径方向外側、すなわち回転子４０側に所定間隔で設けられている。固定子巻線５１の各導線群８１は、突起部１４２と周方向において係合しており、突起部１４２を導線群８１の位置決め部として用いつつ周方向に並べて配置されている。なお、突起部１４２が「導線間部材」に相当する。 (Modification example 1)
In the above embodiment, the outer peripheral surface of the stator core 52 has a curved surface without unevenness, and a plurality of conductor groups 81 are arranged side by side at predetermined intervals on the outer peripheral surface, but this may be changed. For example, as shown in FIG. 25, the stator core 52 includes an annular yoke 141 provided on both sides of the stator winding 51 in the radial direction opposite to the rotor 40 (lower side in the drawing). It has a protrusion 142 extending from the yoke 141 so as to project between the straight portions 83 adjacent to each other in the circumferential direction. The protrusions 142 are provided at predetermined intervals on the radial outer side of the yoke 141, that is, on the rotor 40 side. Each conductor group 81 of the stator winding 51 is engaged with the protrusion 142 in the circumferential direction, and is arranged side by side in the circumferential direction while using the protrusion 142 as a positioning portion of the conductor group 81. The protrusion 142 corresponds to the "member between conductors".
　突起部１４２は、ヨーク１４１からの径方向の厚さ寸法、言い換えれば、図２５に示すように、ヨーク１４１の径方向において、直線部８３のヨーク１４１に隣接する内側面３２０から突起部１４２の頂点までの距離Ｗが、径方向内外の複数層の直線部８３のうち、ヨーク１４１に径方向に隣接する直線部８３の径方向の厚さ寸法の１／２（図のＨ１）よりも小さい構成となっている。言い換えれば、固定子巻線５１（固定子コア５２）の径方向における導線群８１（伝導部材）の寸法（厚み）Ｔ１（導線８２の厚みの２倍、言い換えれば、導線群８１の固定子コア５２に接する面３２０と、導線群８１の回転子４０に向いた面３３０との最短距離）の４分の３の範囲は非磁性部材（封止部材５７）が占有していればよい。こうした突起部１４２の厚さ制限により、周方向に隣り合う導線群８１（すなわち直線部８３）の間において突起部１４２がティースとして機能せず、ティースによる磁路形成がなされないようになっている。突起部１４２は、周方向に並ぶ各導線群８１の間ごとに全て設けられていなくてもよく、周方向に隣り合う少なくとも１組の導線群８１の間に設けられていればよい。例えば、突起部１４２は、周方向において各導線群８１の間の所定数ごとに等間隔で設けられているとよい。突起部１４２の形状は、矩形状、円弧状など任意の形状でよい。 The protrusion 142 has a thickness dimension in the radial direction from the yoke 141, in other words, as shown in FIG. 25, from the inner side surface 320 adjacent to the yoke 141 of the straight portion 83 in the radial direction of the yoke 141 to the protrusion 142. The distance W to the apex is smaller than 1/2 (H1 in the figure) of the radial thickness dimension of the linear portion 83 radially adjacent to the yoke 141 among the linear portions 83 of the plurality of layers inside and outside the radial direction. It is composed. In other words, the dimensions (thickness) of the conductor group 81 (conducting member) in the radial direction of the stator winding 51 (stator core 52) T1 (twice the thickness of the conductor 82, in other words, the stator core of the conductor group 81). The non-magnetic member (sealing member 57) may occupy a range of three-quarters of the range (the shortest distance between the surface 320 in contact with the 52 and the surface 330 facing the rotor 40 of the conductor group 81). Due to the thickness limitation of the protrusion 142, the protrusion 142 does not function as a tooth between the conductor groups 81 (that is, the straight portion 83) adjacent to each other in the circumferential direction, and the magnetic path is not formed by the tooth. .. The protrusions 142 may not be all provided between the conductor groups 81 arranged in the circumferential direction, but may be provided between at least one set of conductor groups 81 adjacent to each other in the circumferential direction. For example, the protrusions 142 may be provided at equal intervals in a predetermined number between the conductor groups 81 in the circumferential direction. The shape of the protrusion 142 may be any shape such as a rectangular shape or an arc shape.
　また、固定子コア５２の外周面では、直線部８３が一層で設けられていてもよい。したがって、広義には、突起部１４２におけるヨーク１４１からの径方向の厚さ寸法は、直線部８３における径方向の厚さ寸法の１／２よりも小さいものであればよい。 Further, the straight portion 83 may be provided as a single layer on the outer peripheral surface of the stator core 52. Therefore, in a broad sense, the radial thickness dimension of the protrusion 142 from the yoke 141 may be smaller than 1/2 of the radial thickness dimension of the straight portion 83.
　なお、回転軸１１の軸心を中心とし、かつヨーク１４１に径方向に隣接する直線部８３の径方向の中心位置を通る仮想円を想定すると、突起部１４２は、その仮想円の範囲内においてヨーク１４１から突出する形状、換言すれば仮想円よりも径方向外側（すなわち回転子４０側）に突出しない形状をなしているとよい。 Assuming a virtual circle centered on the axis of the rotating shaft 11 and passing through the radial center position of the straight line portion 83 radially adjacent to the yoke 141, the protrusion 142 is within the range of the virtual circle. It is preferable that the shape protrudes from the yoke 141, in other words, the shape does not protrude outward in the radial direction (that is, the rotor 40 side) from the virtual circle.
　上記構成によれば、突起部１４２は、径方向の厚さ寸法が制限されており、周方向に隣り合う直線部８３の間においてティースとして機能するものでないため、各直線部８３の間にティースが設けられている場合に比べて、隣り合う各直線部８３を近づけることができる。これにより、導体８２ａの断面積を大きくすることができ、固定子巻線５１の通電に伴い生じる発熱を低減することができる。かかる構成では、ティースがないことで磁気飽和の解消が可能となり、固定子巻線５１への通電電流を増大させることが可能となる。この場合において、その通電電流の増大に伴い発熱量が増えることに好適に対処することができる。また、固定子巻線５１では、ターン部８４が、径方向にシフトされ、他のターン部８４との干渉を回避する干渉回避部を有することから、異なるターン部８４同士を径方向に離して配置することができる。これにより、ターン部８４においても放熱性の向上を図ることができる。以上により、固定子５０での放熱性能を適正化することが可能になっている。 According to the above configuration, the protrusion 142 has a limited thickness dimension in the radial direction and does not function as a teeth between the straight portions 83 adjacent to each other in the circumferential direction. Therefore, the teeth are formed between the straight portions 83. It is possible to bring the adjacent straight portions 83 closer to each other as compared with the case where is provided. As a result, the cross-sectional area of the conductor 82a can be increased, and the heat generated by the energization of the stator winding 51 can be reduced. In such a configuration, the absence of teeth makes it possible to eliminate magnetic saturation and increase the energizing current to the stator winding 51. In this case, it is possible to preferably cope with the increase in the amount of heat generated as the energizing current increases. Further, in the stator winding 51, since the turn portion 84 is shifted in the radial direction and has an interference avoidance portion for avoiding interference with other turn portions 84, the different turn portions 84 are separated from each other in the radial direction. Can be placed. As a result, heat dissipation can be improved even in the turn portion 84. As described above, it is possible to optimize the heat dissipation performance of the stator 50.
　また、固定子コア５２のヨーク１４１と、回転子４０の磁石ユニット４２（すなわち各磁石９１，９２）とが所定距離以上離れていれば、突起部１４２の径方向の厚さ寸法は、図２５のＨ１に縛られるものではない。具体的には、ヨーク１４１と磁石ユニット４２とが２ｍｍ以上離れていれば、突起部１４２の径方向の厚さ寸法は、図２５のＨ１以上であってもよい。例えば、直線部８３の径方向厚み寸法が２ｍｍを越えており、かつ導線群８１が径方向内外の２層の導線８２により構成されている場合に、ヨーク１４１に隣接していない直線部８３、すなわちヨーク１４１から数えて２層目の導線８２の半分位置までの範囲で、突起部１４２が設けられていてもよい。この場合、突起部１４２の径方向厚さ寸法が「Ｈ１×３／２」までになっていれば、導線群８１における導体断面積を大きくすることで、前記効果を少なからず得ることはできる。 Further, if the yoke 141 of the stator core 52 and the magnet unit 42 of the rotor 40 (that is, the magnets 91 and 92) are separated by a predetermined distance or more, the thickness dimension of the protrusion 142 in the radial direction is shown in FIG. 25. It is not tied to H1. Specifically, if the yoke 141 and the magnet unit 42 are separated by 2 mm or more, the radial thickness dimension of the protrusion 142 may be H1 or more in FIG. 25. For example, when the radial thickness dimension of the straight portion 83 exceeds 2 mm and the conductor group 81 is composed of two layers of conductors 82 inside and outside the radial direction, the straight portion 83 not adjacent to the yoke 141, That is, the protrusion 142 may be provided in the range from the yoke 141 to the half position of the second layer conductor 82. In this case, if the radial thickness dimension of the protrusion 142 is up to "H1 x 3/2", the effect can be obtained not a little by increasing the cross-sectional area of the conductor in the conductor group 81.
　また、固定子コア５２は、図２６に示す構成であってもよい。なお、図２６では、封止部材５７を省略しているが、封止部材５７が設けられていてもよい。図２６では、便宜上、磁石ユニット４２及び固定子コア５２を直線状に展開して示している。 Further, the stator core 52 may have the configuration shown in FIG. 26. Although the sealing member 57 is omitted in FIG. 26, the sealing member 57 may be provided. In FIG. 26, for convenience, the magnet unit 42 and the stator core 52 are shown in a linearly developed manner.
　図２６の構成では、固定子５０は、周方向に隣接する導線８２（すなわち直線部８３）の間に、導線間部材としての突起部１４２を有している。固定子５０は、固定子巻線５１が通電されると、磁石ユニット４２の磁極の一つ（Ｎ極、またはＳ極）とともに磁気的に機能し、固定子５０の周方向に延びる一部分３５０を有する。この部分３５０の固定子５０の周方向への長さをＷｎとすると、この長さ範囲Ｗｎに存在する突起部１４２の合計の幅（すなわち、固定子５０の周方向への合計の寸法）をＷｔとし、突起部１４２の飽和磁束密度をＢｓ、磁石ユニット４２の１極分の周方向の幅寸法をＷｍ、磁石ユニット４２の残留磁束密度をＢｒとする場合、突起部１４２は、
Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒ　　　…（１）
となる磁性材料により構成されている。 In the configuration of FIG. 26, the stator 50 has a protrusion 142 as a member between the conductors between the conductors 82 (that is, the straight line portion 83) adjacent to each other in the circumferential direction. When the stator winding 51 is energized, the stator 50 magnetically functions together with one of the magnetic poles (N pole or S pole) of the magnet unit 42, and a part 350 extending in the circumferential direction of the stator 50 is formed. Have. Assuming that the circumferential length of the stator 50 of this portion 350 is Wn, the total width of the protrusions 142 existing in this length range Wn (that is, the total dimension of the stator 50 in the circumferential direction) is set. When Wt, the saturation magnetic flux density of the protrusion 142 is Bs, the width dimension of one pole of the magnet unit 42 in the circumferential direction is Wm, and the residual magnetic flux density of the magnet unit 42 is Br, the protrusion 142 is
Wt × Bs ≦ Wm × Br… (1)
It is composed of a magnetic material that serves as.
　なお、範囲Ｗｎは、周方向に隣接する複数の導線群８１であって、励磁時期が重複する複数の導線群８１を含むように設定される。その際、範囲Ｗｎを設定する際の基準（境界）として、導線群８１の間隙５６の中心を設定することが好ましい。例えば、図２６に例示する構成の場合、周方向においてＮ極の磁極中心からの距離が最も短いものから順番に、４番目までの導線群８１が、当該複数の導線群８１に相当する。そして、当該４つの導線群８１を含むように範囲Ｗｎが設定される。その際、範囲Ｗｎの端（起点と終点）が間隙５６の中心とされている。 The range Wn is set to include a plurality of conductor groups 81 adjacent to each other in the circumferential direction and include a plurality of conductor groups 81 having overlapping excitation timings. At that time, it is preferable to set the center of the gap 56 of the conductor group 81 as a reference (boundary) when setting the range Wn. For example, in the case of the configuration illustrated in FIG. 26, the fourth conductor group 81 corresponds to the plurality of conductor groups 81 in order from the one having the shortest distance from the magnetic pole center of the N pole in the circumferential direction. Then, the range Wn is set so as to include the four conductor groups 81. At that time, the ends (starting point and ending point) of the range Wn are set as the center of the gap 56.
　図２６において、範囲Ｗｎの両端には、それぞれ突起部１４２が半分ずつ含まれていることから、範囲Ｗｎには、合計４つ分の突起部１４２が含まれている。したがって、突起部１４２の幅（すなわち、固定子５０の周方向における突起部１４２の寸法、言い換えれば、隣接する導線群８１の間隔）をＡとすると、範囲Ｗｎに含まれる突起部１４２の合計の幅は、Ｗｔ＝１／２Ａ＋Ａ＋Ａ＋Ａ＋１／２Ａ＝４Ａとなる。 In FIG. 26, since half of the protrusions 142 are included at both ends of the range Wn, the range Wn includes a total of four protrusions 142. Therefore, assuming that the width of the protrusion 142 (that is, the dimension of the protrusion 142 in the circumferential direction of the stator 50, that is, the distance between the adjacent conductor groups 81) is A, the total of the protrusions 142 included in the range Wn. The width is Wt = 1 / 2A + A + A + A + 1 / 2A = 4A.
　詳しくは、本実施形態では、固定子巻線５１の３相巻線が分布巻であり、その固定子巻線５１では、磁石ユニット４２の１極に対して、突起部１４２の数、すなわち各導線群８１の間となる間隙５６の数が「相数×Ｑ」個となっている。ここでＱとは、１相の導線８２のうち固定子コア５２と接する数である。なお、導線８２が回転子４０の径方向に積層された導線群８１である場合には、１相の導線群８１の内周側の導線８２の数であるともいえる。この場合、固定子巻線５１の３相巻線が各相所定順序で通電されると、１極内において２相分の突起部１４２が励磁される。したがって、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される突起部１４２の周方向の合計幅寸法Ｗｔは、突起部１４２（つまり、間隙５６）の周方向の幅寸法をＡとすると、「励磁される相数×Ｑ×Ａ＝２×２×Ａ」となる。 Specifically, in the present embodiment, the three-phase winding of the stator winding 51 is a distributed winding, and in the stator winding 51, the number of protrusions 142 with respect to one pole of the magnet unit 42, that is, each The number of gaps 56 between the conductor groups 81 is "number of phases x Q". Here, Q is the number of the one-phase conducting wires 82 that are in contact with the stator core 52. When the conductors 82 are the conductors 81 stacked in the radial direction of the rotor 40, it can be said that the number of the conductors 82 is the number of the conductors 82 on the inner peripheral side of the one-phase conductor group 81. In this case, when the three-phase windings of the stator winding 51 are energized in a predetermined order for each phase, the protrusions 142 for two phases are excited in one pole. Therefore, the total width dimension Wt in the circumferential direction of the protrusion 142 excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is the width of the protrusion 142 (that is, the gap 56) in the circumferential direction. Assuming that the dimension is A, "the number of excited phases x Q x A = 2 x 2 x A".
　そして、こうして合計幅寸法Ｗｔが規定された上で、固定子コア５２において、突起部１４２が、上記（１）の関係を満たす磁性材料として構成されている。なお、合計幅寸法Ｗｔは、１極内において比透磁率が１よりも大きくなりえる部分の周方向寸法でもある。また、余裕を考えて、合計幅寸法Ｗｔを、１磁極における突起部１４２の周方向の幅寸法としてもよい。具体的には、磁石ユニット４２の１極に対する突起部１４２の数が「相数×Ｑ」であることから、１磁極における突起部１４２の周方向の幅寸法（合計幅寸法Ｗｔ）を、「相数×Ｑ×Ａ＝３×２×Ａ＝６Ａ」としてもよい。 Then, after the total width dimension Wt is defined in this way, in the stator core 52, the protrusion 142 is configured as a magnetic material satisfying the relationship (1) above. The total width dimension Wt is also the circumferential dimension of the portion where the relative magnetic permeability can be larger than 1 in one pole. Further, in consideration of a margin, the total width dimension Wt may be set as the width dimension in the circumferential direction of the protrusion 142 at one magnetic pole. Specifically, since the number of protrusions 142 with respect to one pole of the magnet unit 42 is "number of phases x Q", the width dimension (total width dimension Wt) of the protrusions 142 in one magnetic pole in the circumferential direction is set to ". The number of phases × Q × A = 3 × 2 × A = 6A ”may be used.
　なお、ここでいう分布巻とは、磁極の１極対周期（Ｎ極とＳ極）で、固定子巻線５１の一極対があるものである。ここでいう固定子巻線５１の一極対は、電流が互いに逆方向に流れ、ターン部８４で電気的に接続された２つの直線部８３とターン部８４からなる。上記条件みたすものであれば、短節巻（Short Pitch Winding）であっても、全節巻（Full Pitch Winding）の分布巻の均等物とみなす。 The distributed winding referred to here is a one-pole pair period (N-pole and S-pole) of the magnetic poles, and has a one-pole pair of the stator winding 51. The one-pole pair of the stator winding 51 referred to 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. If the above conditions are met, even if it is a short Pitch Winding, it is regarded as an equivalent of the distribution volume of the Full Pitch Winding.
　次に、集中巻の場合の例を示す。ここでいう集中巻とは、磁極の１極対の幅と、固定子巻線５１の一極対の幅とが異なるものである。集中巻の一例としては、１つの磁極対に対して導線群８１が３つ、２つの磁極対に対して導線群８１が３つ、４つの磁極対に対して導線群８１が９つ、５つの磁極対に対して導線群８１が９つのような関係であるものが挙げられる。 Next, an example in the case of concentrated winding is shown. The centralized winding here means that the width of the one-pole pair of magnetic poles and the width of the one-pole pair of the stator winding 51 are different. As an example of concentrated winding, there are three conductor groups 81 for one magnetic pole pair, three conductor groups 81 for two magnetic pole pairs, nine conductor groups 81 for four magnetic pole pairs, and five. Examples thereof include a case in which the conductor group 81 has a relationship of nine with respect to one magnetic pole pair.
　ここで、固定子巻線５１を集中巻とする場合には、固定子巻線５１の３相巻線が所定順序で通電されると、２相分の固定子巻線５１が励磁される。その結果、２相分の突起部１４２が励磁される。したがって、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される突起部１４２の周方向の幅寸法Ｗｔは、「Ａ×２」となる。そして、こうして幅寸法Ｗｔが規定された上で、突起部１４２が、上記（１）の関係を満たす磁性材料として構成されている。なお、上記で示した集中巻の場合は、同一相の導線群８１に囲まれた領域において、固定子５０の周方向にある突起部１４２の幅の総和をＡとする。また、集中巻におけるＷｍは「磁石ユニット４２のエアギャップに対向する面の全周」×「相数」÷「導線群８１の分散数」に相当する。 Here, when the stator winding 51 is a centralized winding, when the three-phase windings of the stator winding 51 are energized in a predetermined order, the stator windings 51 for two phases are excited. As a result, the protrusions 142 for the two phases are excited. Therefore, the width dimension Wt in the circumferential direction of the protrusion 142 excited by the energization of the stator winding 51 in the range of one pole of the magnet unit 42 is “A × 2”. Then, after the width dimension Wt is defined in this way, the protrusion 142 is configured as a magnetic material satisfying the relationship (1) above. In the case of the concentrated winding shown above, the total width of the protrusions 142 in the circumferential direction of the stator 50 in the region surrounded by the conductors 81 of the same phase is defined as A. Further, Wm in the concentrated winding corresponds to "the entire circumference of the surface of the magnet unit 42 facing the air gap" x "the number of phases" ÷ "the number of dispersions of the conductor group 81".
　ちなみに、ネオジム磁石やサマリウムコバルト磁石、フェライト磁石といったＢＨ積が２０［ＭＧＯｅ（ｋＪ／ｍ^3）］以上の磁石ではＢｄ＝１．０強［Ｔ］、鉄ではＢｒ＝２．０強［Ｔ］である。そのため、高出力モータとしては、固定子コア５２において、突起部１４２が、Ｗｔ＜１／２×Ｗｍの関係を満たす磁性材料であればよい。 By the way, for magnets with a BH product of 20 [MGOe (kJ / m ^ 3)] or more, such as neodymium magnets, samarium-cobalt magnets, and ferrite magnets, Bd = 1.0-strong [T], and for iron, Br = 2.0-strong [T]. ]. Therefore, as the high output motor, in the stator core 52, the protrusion 142 may be a magnetic material satisfying the relationship of Wt <1/2 × Wm.
　また、後述するように導線８２が外層被膜１８２を備える場合には、導線８２同士の外層被膜１８２が接触するように、導線８２を固定子コア５２の周方向に配置しても良い。この場合は、Ｗｔは、０又は接触する両導線８２の外層被膜１８２の厚さ、と看做すことができる。 Further, when the conductor 82 includes the outer layer coating 182 as described later, the conductor 82 may be arranged in the circumferential direction of the stator core 52 so that the outer layer coatings 182 of the conductors 82 come into contact with each other. In this case, Wt can be regarded as 0 or the thickness of the outer layer coating 182 of both conducting wires 82 in contact with each other.
　図２５や図２６の構成では、回転子４０側の磁石磁束に対して不相応に小さい導線間部材（突起部１４２）を有する構成となっている。なお、回転子４０は、インダクタンスが低くかつ平坦な表面磁石型ロータであり、磁気抵抗的に突極性を有していないものとなっている。かかる構成では、固定子５０のインダクタンス低減が可能となっており、固定子巻線５１のスイッチングタイミングのずれに起因する磁束歪みの発生が抑制され、ひいては軸受２１，２２の電食が抑制される。 The configurations shown in FIGS. 25 and 26 have a conductor-to-conductor member (projection 142) that is disproportionately small with respect to the magnetic flux of the magnet on the rotor 40 side. The rotor 40 is a surface magnet type rotor having a low inductance and a flat surface, and has no reluctance in terms of magnetic resistance. In 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 the electrolytic corrosion of the bearings 21 and 22 is suppressed. ..
　（変形例２）
　上記式（１）の関係を満たす導線間部材を用いる固定子５０として、以下の構成を採用することも可能である。図２７では、固定子コア５２の外周面側（図の上面側）に、導線間部材として歯状部１４３が設けられている。歯状部１４３は、ヨーク１４１から突出するようにして周方向に所定間隔で設けられており、径方向に導線群８１と同じ厚み寸法を有している。歯状部１４３の側面は導線群８１の各導線８２に接している。ただし、歯状部１４３と各導線８２との間に隙間があってもよい。 (Modification 2)
The following configuration can also be adopted as the stator 50 using the conductor-to-conductor member satisfying the relationship of the above formula (1). In FIG. 27, a tooth-shaped portion 143 is provided as a member between conductors on the outer peripheral surface side (upper surface side in the drawing) of the stator core 52. The dentate portions 143 are provided at predetermined intervals in the circumferential direction so as to protrude from the yoke 141, and have the same thickness dimension as the conductor group 81 in the radial direction. The side surface of the dentate portion 143 is in contact with each of the conductors 82 of the conductor group 81. However, there may be a gap between the tooth-shaped portion 143 and each of the conducting wires 82.
　歯状部１４３は、周方向における幅寸法に制限が付与されており、磁石量に対して不相応に細い極歯（ステータティース）を備えるものとなっている。かかる構成により、歯状部１４３は、１．８Ｔ以上で磁石磁束により確実に飽和し、パーミアンスの低下によりインダクタンスを下げることができる。 The dentate portion 143 is provided with a limitation on the width dimension in the circumferential direction, and is provided with polar teeth (statoth teeth) that are disproportionately thin with respect to the amount of magnets. With such a configuration, the dentate portion 143 is surely saturated by the magnetic flux of the magnet at 1.8 T or more, and the inductance can be lowered by lowering the permeance.
　ここで、磁石ユニット４２において、固定子側における磁束作用面の１極あたりの表面積をＳｍ、磁石ユニット４２の残留磁束密度をＢｒとすると、磁石ユニット側の磁束は、例えば「Ｓｍ×Ｂｒ」となる。また、各歯状部１４３における回転子側の表面積をＳｔ、導線８２の一相あたりの数をｍとし、固定子巻線５１の通電により１極内において２相分の歯状部１４３が励磁されるとすると、固定子側の磁束は、例えば「Ｓｔ×ｍ×２×Ｂｓ」となる。この場合、
Ｓｔ×ｍ×２×Ｂｓ＜Ｓｍ×Ｂｒ　　　…（２）
の関係が成立するように歯状部１４３の寸法を制限することで、インダクタンスの低減が図られている。 Here, in the magnet unit 42, assuming that the surface area per pole of the magnetic flux acting surface on the stator side is Sm and the residual magnetic flux density of the magnet unit 42 is Br, the magnetic flux on the magnet unit side is, for example, "Sm x Br". Become. Further, the surface area on the rotor side of each dentate portion 143 is St, the number per phase of the conducting wire 82 is m, and the dentate portion 143 for two phases is excited in one pole by energization of the stator winding 51. If so, the magnetic flux on the stator side is, for example, "St × m × 2 × Bs". in this case,
St × m × 2 × Bs <Sm × Br… (2)
By limiting the dimensions of the dentate portion 143 so that the relationship of the above is established, the inductance is reduced.
　なお、磁石ユニット４２と歯状部１４３とで軸方向の寸法が同一である場合、磁石ユニット４２の１極分の周方向の幅寸法をＷｍ、歯状部１４３の周方向の幅寸法をＷｓｔとすると、上記式（２）は、式（３）のように置き換えられる。
Ｗｓｔ×ｍ×２×Ｂｓ＜Ｗｍ×Ｂｒ　　　…（３）
　より具体的には、例えばＢｓ＝２Ｔ、Ｂｒ＝１Ｔであり、ｍ＝２であると想定すると、上記式（３）は、「Ｗｓｔ＜Ｗｍ／８」の関係となる。この場合、歯状部１４３の幅寸法Ｗｓｔを、磁石ユニット４２の１極分の幅寸法Ｗｍの１／８よりも小さくすることで、インダクタンスの低減が図られている。なお、数ｍが１であれば、歯状部１４３の幅寸法Ｗｓｔを、磁石ユニット４２の１極分の幅寸法Ｗｍの１／４よりも小さくするとよい。 When the magnet unit 42 and the tooth-shaped portion 143 have the same axial dimension, the width dimension of one pole of the magnet unit 42 in the circumferential direction is Wm, and the width dimension of the tooth-shaped portion 143 in the circumferential direction is Wst. Then, the above equation (2) is replaced with the equation (3).
Wst x m x 2 x Bs <Wm x Br ... (3)
More specifically, assuming that, for example, Bs = 2T, Br = 1T, and m = 2, the above equation (3) has a relationship of “Wst <Wm / 8”. In this case, the inductance is reduced by making the width dimension Wst of the tooth-shaped portion 143 smaller than 1/8 of the width dimension Wm of one pole of the magnet unit 42. If the number m is 1, the width dimension Wst of the tooth-shaped portion 143 may be smaller than 1/4 of the width dimension Wm of one pole of the magnet unit 42.
　なお、上記式（３）において、「Ｗｓｔ×ｍ×２」は、磁石ユニット４２の１極分の範囲において固定子巻線５１の通電により励磁される歯状部１４３の周方向の幅寸法に相当する。 In the above formula (3), "Wst x m x 2" has a width dimension in the circumferential direction of the tooth-shaped portion 143 excited by energization of the stator winding 51 in the range of one pole of the magnet unit 42. Equivalent to.
　図２７の構成では、上述した図２５，図２６の構成と同様に、回転子４０側の磁石磁束に対して不相応に小さい導線間部材（歯状部１４３）を有する構成となっている。かかる構成では、固定子５０のインダクタンス低減が可能となっており、固定子巻線５１のスイッチングタイミングのずれに起因する磁束歪みの発生が抑制され、ひいては軸受２１，２２の電食が抑制される。 In the configuration of FIG. 27, similar to the configurations of FIGS. 25 and 26 described above, the interconductor member (dental portion 143) which is disproportionately small with respect to the magnetic flux of the magnet on the rotor 40 side is provided. In 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 the electrolytic corrosion of the bearings 21 and 22 is suppressed. ..
　（変形例３）
　上記実施形態では、固定子巻線５１を覆う封止部材５７を、固定子コア５２の径方向外側において各導線群８１を全て含む範囲、すなわち径方向の厚さ寸法が各導線群８１の径方向の厚さ寸法よりも大きくなる範囲で設ける構成としたが、これを変更してもよい。例えば、図２８に示すように、封止部材５７を、導線８２の一部がはみ出すように設ける構成とする。より具体的には、封止部材５７を、導線群８１において最も径方向外側となる導線８２の一部を径方向外側、すなわち固定子５０側に露出させた状態で設ける構成とする。この場合、封止部材５７の径方向の厚さ寸法は、各導線群８１の径方向の厚さ寸法と同じ、又はその厚さ寸法よりも小さいとよい。 (Modification example 3)
In the above embodiment, the sealing member 57 covering the stator winding 51 is provided in a range including all the conductor groups 81 on the radial outside of the stator core 52, that is, the thickness dimension in the radial direction is the diameter of each conductor group 81. The configuration is provided in a range larger than the thickness dimension in the direction, but 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 a state where a part of the conductor 82 which is the outermost in the radial direction in the conductor group 81 is exposed on the radial outer side, that is, on the stator 50 side. In this case, the radial thickness dimension of the sealing member 57 may be the same as or smaller than the radial thickness dimension of each conductor group 81.
　（変形例４）
　図２９に示すように、固定子５０において、各導線群８１が封止部材５７により封止されていない構成としてもよい。つまり、固定子巻線５１を覆う封止部材５７を用いない構成とする。この場合、周方向に並ぶ各導線群８１の間に導線間部材が設けられず空隙となっている。要するに、周方向に並ぶ各導線群８１の間に導線間部材が設けられていない構成となっている。なお、空気を非磁性体、又は非磁性体の均等物としてＢｓ＝０と看做し、この空隙に空気を配置しても良い。 (Modification example 4)
As shown in FIG. 29, in the stator 50, each conductor group 81 may not be sealed by the sealing member 57. That is, the structure does not use the sealing member 57 that covers the stator winding 51. In this case, no interconductor member is provided between the conductor groups 81 arranged in the circumferential direction, and a gap is formed. In short, the conductors are not provided between the conductor groups 81 arranged in the circumferential direction. In addition, air may be regarded as a non-magnetic material or an equivalent of a non-magnetic material as Bs = 0, and air may be arranged in this void.
　（変形例５）
　固定子５０おける導線間部材を非磁性材料により構成する場合に、その非磁性材料として、樹脂以外の材料を用いることも可能である。例えば、オーステナイト系のステンレス鋼であるＳＵＳ３０４を用いる等、金属系の非磁性材料を用いてもよい。 (Modification 5)
When the conductor-to-conductor member in 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 metal-based non-magnetic material may be used, such as using SUS304, which is an austenitic stainless steel.
　（変形例６）
　固定子５０が固定子コア５２を具備していない構成としてもよい。この場合、固定子５０は、図１２に示す固定子巻線５１により構成されることになる。なお、固定子コア５２を具備していない固定子５０において、固定子巻線５１を封止材により封止する構成としてもよい。又は、固定子５０が、軟磁性材からなる固定子コア５２に代えて、合成樹脂等の非磁性材からなる円環状の巻線保持部を備える構成であってもよい。 (Modification 6)
The stator 50 may be configured not to include the stator core 52. In this case, the stator 50 is composed of the stator winding 51 shown in FIG. In the stator 50 that does not include the stator core 52, the stator winding 51 may be sealed with a sealing material. Alternatively, the stator 50 may be configured to 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.
　（変形例７）
　上記第１実施形態では、回転子４０の磁石ユニット４２として周方向に並べた複数の磁石９１，９２を用いる構成としたが、これを変更し、磁石ユニット４２として円環状の永久磁石である環状磁石を用いる構成としてもよい。具体的には、図３０に示すように、磁石ホルダ４１の円筒部４３の径方向内側に、環状磁石９５が固定されている。環状磁石９５には、周方向に極性が交互となる複数の磁極が設けられており、ｄ軸及びｑ軸のいずれにおいても一体的に磁石が形成されている。環状磁石９５には、各磁極のｄ軸において配向の向きが径方向となり、各磁極間のｑ軸において配向の向きが周方向となるような円弧状の磁石磁路が形成されている。 (Modification 7)
In the first embodiment, a plurality of magnets 91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40, but this is changed and the magnet unit 42 is an annular permanent magnet. A 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 having alternating polarities in the circumferential direction, and the magnet is integrally formed on both the d-axis and the q-axis. The annular magnet 95 is formed with an arcuate magnet magnetic path such that the direction of orientation is the radial direction on the d-axis of each magnetic pole and the direction of orientation is the circumferential direction on the q-axis between the magnetic poles.
　なお、環状磁石９５では、ｄ軸寄りの部分において磁化容易軸がｄ軸に平行又はｄ軸に平行に近い向きとなり、かつｑ軸寄りの部分において磁化容易軸がｑ軸に直交又はｑ軸に直交に近い向きとなる円弧状の磁石磁路が形成されるように配向がなされていればよい。 In the annular magnet 95, the easy-magnetizing axis is parallel to the d-axis or close to parallel to the d-axis in the portion near the d-axis, and the easy-magnetizing axis is orthogonal to the q-axis or is in the q-axis in the portion near the q-axis. It suffices if the orientation is made so that an arcuate magnet magnetic path having a direction close to orthogonal is formed.
　（変形例８）
　本変形例では、制御装置１１０の制御手法の一部を変更している。本変形例では、主に、第１実施形態で説明した構成に対する相違部分について説明する。 (Modification 8)
In this modification, a part of the control method of the control device 110 is changed. In this modification, the difference from the configuration described in the first embodiment will be mainly described.
　まず、図３１を用いて、図２０に示した操作信号生成部１１６，１２６及び図２１に示した操作信号生成部１３０ａ，１３０ｂ内の処理について説明する。なお、各操作信号生成部１１６，１２６，１３０ａ，１３０ｂにおける処理は基本的には同様である。このため、以下では、操作信号生成部１１６の処理を例にして説明する。 First, using FIG. 31, the processing in the operation signal generation units 116 and 126 shown in FIG. 20 and the operation signal generation units 130a and 130b shown in FIG. 21 will be described. The processing in each operation signal generation unit 116, 126, 130a, 130b is basically the same. Therefore, in the following, the processing of the operation signal generation unit 116 will be described as an example.
　操作信号生成部１１６は、キャリア生成部１１６ａと、Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷとを備えている。本実施形態において、キャリア生成部１１６ａは、キャリア信号ＳｉｇＣとして三角波信号を生成して出力する。 The operation signal generation unit 116 includes a carrier generation unit 116a and U, V, W phase comparators 116bU, 116bV, 116bW. In the present embodiment, the carrier generation unit 116a generates and outputs a triangular wave signal as the carrier signal SigmaC.
　Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷには、キャリア生成部１１６ａより生成されたキャリア信号ＳｉｇＣと、３相変換部１１５により算出されたＵ，Ｖ，Ｗ相指令電圧とが入力される。Ｕ，Ｖ，Ｗ相指令電圧は、例えば正弦波状の波形であり、電気角で位相が１２０°ずつずれている。 The carrier signal Sigma generated by the carrier generation unit 116a and the U, V, W phase command voltage calculated by the three-phase conversion unit 115 are input to the U, V, W phase comparators 116bU, 116bV, 116bW. To. The U, V, and W phase command voltages are, for example, sinusoidal waveforms, and the phases are shifted by 120 ° depending on the electric angle.
　Ｕ，Ｖ，Ｗ相比較器１１６ｂＵ，１１６ｂＶ，１１６ｂＷは、Ｕ，Ｖ，Ｗ相指令電圧とキャリア信号ＳｉｇＣとの大小比較に基づくＰＷＭ（ＰＷＭ：pulse width modulation）制御により、第１インバータ１０１におけるＵ，Ｖ，Ｗ相の上アーム及び下アームの各スイッチＳｐ，Ｓｎの操作信号を生成する。具体的には、操作信号生成部１１６は、Ｕ，Ｖ，Ｗ相指令電圧を電源電圧で規格化した信号と、キャリア信号との大小比較に基づくＰＷＭ制御により、Ｕ，Ｖ，Ｗ相の各スイッチＳｐ，Ｓｎの操作信号を生成する。ドライバ１１７は、操作信号生成部１１６により生成された操作信号に基づいて、第１インバータ１０１におけるＵ，Ｖ，Ｗ相の各スイッチＳｐ，Ｓｎをオンオフさせる。 The U, V, W phase comparators 116bU, 116bV, 116bW are U in the first inverter 101 by PWM (pulse width modulation) control based on the magnitude comparison between the U, V, W phase command voltage and the carrier signal Sigma. , V, W phase upper arm and lower arm switches Sp, Sn operation signals are generated. Specifically, the operation signal generation unit 116 performs each of the U, V, and W phases by PWM control based on the magnitude comparison between the signal obtained by normalizing the U, V, W phase command voltage with the power supply voltage and the carrier signal. Generates operation signals for switches Sp and Sn. The driver 117 turns on / off the U, V, and W phase switches Sp and Sn in the first inverter 101 based on the operation signal generated by the operation signal generation unit 116.
　制御装置１１０は、キャリア信号ＳｉｇＣのキャリア周波数ｆｃ、すなわち各スイッチＳｐ，Ｓｎのスイッチング周波数を変更する処理を行う。キャリア周波数ｆｃは、回転電機１０の低トルク領域又は高回転領域において高く設定され、回転電機１０の高トルク領域において低く設定される。この設定は、各相巻線に流れる電流の制御性の低下を抑制するためになされる。 The control device 110 performs a process of changing the carrier frequency fc of the carrier signal SignC, that is, the switching frequency of each of the switches Sp and Sn. The carrier frequency fc is set high in the low torque region or high rotation region of the rotary electric machine 10 and low in the high torque region of the rotary electric machine 10. This setting is made in order to suppress a decrease in controllability of the current flowing through each phase winding.
　つまり、固定子５０のコアレス化に伴い、固定子５０におけるインダクタンスの低減を図ることができる。ここで、インダクタンスが低くなると、回転電機１０の電気的時定数が小さくなる。その結果、各相巻線に流れる電流のリップルが増加して巻線に流れる電流の制御性が低下し、電流制御が発散する懸念がある。この制御性低下の影響は、巻線に流れる電流（例えば、電流の実効値）が高電流領域に含まれる場合よりも低電流領域に含まれる場合に顕著となり得る。この問題に対処すべく、本変形例において、制御装置１１０はキャリア周波数ｆｃを変更する。 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 rotary electric machine 10 becomes small. As a result, the ripple of the current flowing through each phase winding increases, the controllability of the current flowing through the winding decreases, and there is a concern that the current control diverges. The effect of this decrease in controllability can be more pronounced when the current flowing through the winding (for example, the effective value of the current) is included in the low current region than in the high current region. In order to deal with this problem, in this modification, the control device 110 changes the carrier frequency fc.
　図３２を用いて、キャリア周波数ｆｃを変更する処理について説明する。この処理は、操作信号生成部１１６の処理として、制御装置１１０により、例えば所定の制御周期で繰り返し実行される。 The process of changing the carrier frequency fc will be described with reference to FIG. 32. This process is repeatedly executed by the control device 110, for example, at a predetermined control cycle as the process of the operation signal generation unit 116.
　ステップＳ１０では、各相の巻線５１ａに流れる電流が低電流領域に含まれているか否かを判定する。この処理は、回転電機１０の現在のトルクが低トルク領域であることを判定するための処理である。低電流領域に含まれているか否かの判定手法としては、例えば、以下の第１，第２の方法が挙げられる。 In step S10, it is determined whether or not the current flowing through the winding 51a of each phase is included in the low current region. This process is a process for determining that the current torque of the rotary electric machine 10 is in the low torque region. Examples of the method for determining whether or not the product is included in the low current region include the following first and second methods.
　＜第１の方法＞
　ｄｑ変換部１１２により変換されたｄ軸電流とｑ軸電流とに基づいて、回転電機１０のトルク推定値を算出する。そして、算出したトルク推定値がトルク閾値未満であると判定した場合、巻線５１ａに流れる電流が低電流領域に含まれていると判定し、トルク推定値がトルク閾値以上であると判定した場合、高電流領域に含まれていると判定する。ここで、トルク閾値は、例えば、回転電機１０の起動トルク（拘束トルクともいう）の１／２に設定されていればよい。 <First method>
The torque estimation value of the rotary electric machine 10 is calculated based on the d-axis current and the q-axis current converted by the dq conversion unit 112. When it is determined that the calculated torque estimated value is less than the torque threshold value, it is determined that the current flowing through the winding 51a is included in the low current region, and it is determined that the torque estimated value is equal to or more than the torque threshold value. , Judged as being included in the high current region. Here, the torque threshold value may be set to, for example, 1/2 of the starting torque (also referred to as restraint torque) of the rotary electric machine 10.
　＜第２の方法＞
　角度検出器により検出された回転子４０の回転角度が速度閾値以上であると判定した場合、巻線５１ａに流れる電流が低電流領域に含まれている、すなわち高回転領域であると判定する。ここで、速度閾値は、例えば、回転電機１０の最大トルクがトルク閾値となる場合の回転速度に設定されていればよい。 <Second method>
When it is determined that the rotation angle of the rotor 40 detected by the angle detector is equal to or greater than the speed threshold value, it is determined that the current flowing through the winding 51a is included in the low current region, that is, in the high rotation region. Here, the speed threshold value may be set to, for example, the rotation speed when the maximum torque of the rotary electric machine 10 becomes the torque threshold value.
　ステップＳ１０において否定判定した場合には、高電流領域であると判定し、ステップＳ１１に進む。ステップＳ１１では、キャリア周波数ｆｃを第１周波数ｆＬに設定する。 If a negative determination is made in step S10, it is determined that the current region is high, and the process proceeds to step S11. In step S11, the carrier frequency fc is set to the first frequency fL.
　ステップＳ１０において肯定判定した場合には、ステップＳ１２に進み、キャリア周波数ｆｃを、第１周波数ｆＬよりも高い第２周波数ｆＨに設定する。 If an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to the second frequency fH, which is higher than the first frequency fL.
　以上説明した本変形例によれば、各相巻線に流れる電流が高電流領域に含まれる場合よりも低電流領域に含まれる場合においてキャリア周波数ｆｃが高く設定される。このため、低電流領域において、スイッチＳｐ，Ｓｎのスイッチング周波数を高くすることができ、電流リップルの増加を抑制することができる。これにより、電流制御性の低下を抑制することができる。 According to the present modification described above, the carrier frequency fc is set higher when the current flowing through each phase winding is included in the low current region than when it is included in the high current region. Therefore, in the low current region, the switching frequencies of the switches Sp and Sn can be increased, and the increase in current ripple can be suppressed. As a result, it is possible to suppress a decrease in current controllability.
　一方、各相巻線に流れる電流が高電流領域に含まれる場合、低電流領域に含まれる場合よりもキャリア周波数ｆｃが低く設定される。高電流領域においては、低電流領域よりも巻線に流れる電流の振幅が大きいため、インダクタンスが低くなったことに起因する電流リップルの増加が、電流制御性に及ぼす影響が小さい。このため、高電流領域においては、低電流領域よりもキャリア周波数ｆｃを低く設定することができ、各インバータ１０１，１０２のスイッチング損失を低減することができる。 On the other hand, when the current flowing through each phase winding is included in the high current region, the carrier frequency fc is set lower than when 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 that the increase in current ripple due to the low inductance has a small effect on the current controllability. Therefore, in the high current region, the carrier frequency fc can be set lower than in the low current region, and the switching loss of the inverters 101 and 102 can be reduced.
　本変形例においては、以下に示す形態の実施が可能である。 In this modified example, the following embodiments can be implemented.
　・キャリア周波数ｆｃが第１周波数ｆＬに設定されている場合において、図３２のステップＳ１０において肯定判定されたとき、キャリア周波数ｆｃを、第１周波数ｆＬから第２周波数ｆＨに向かって徐変させてもよい。 When the carrier frequency fc is set to the first frequency fL and a positive determination is made in step S10 of FIG. 32, the carrier frequency fc is gradually changed from the first frequency fL to the second frequency fH. May be good.
　また、キャリア周波数ｆｃが第２周波数ｆＨに設定されている場合において、ステップＳ１０において否定判定されたとき、キャリア周波数ｆｃを、第２周波数ｆＨから第１周波数ｆＬに向かって徐変させてもよい。 Further, when the carrier frequency fc is set to the second frequency fH and a negative determination is made in step S10, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL. ..
　・ＰＷＭ制御に代えて、空間ベクトル変調（ＳＶＭ：space vector modulation）制御によりスイッチの操作信号が生成されてもよい。この場合であっても、上述したスイッチング周波数の変更を適用することができる。 -Instead of PWM control, a switch operation signal may be generated by space vector modulation (SVM) control. Even in this case, the above-mentioned change in switching frequency can be applied.
　（変形例９）
　上記各実施形態では、導線群８１を構成する各相２対ずつの導線が、図３３（ａ）に示すように並列接続されていた。図３３（ａ）は、２対の導線である第１，第２導線８８ａ，８８ｂの電気的接続を示す図である。ここで、図３３（ａ）に示す構成に代えて、図３３（ｂ）に示すように、第１，第２導線８８ａ，８８ｂが直列接続されていてもよい。 (Modification 9)
In each of the above embodiments, two pairs of conductors of each phase constituting the conductor group 81 are connected in parallel as shown in FIG. 33 (a). FIG. 33A is a diagram showing the electrical connection of the first and second conductors 88a and 88b, which are two pairs of conductors. Here, instead of the configuration shown in FIG. 33 (a), as shown in FIG. 33 (b), the first and second conductors 88a and 88b may be connected in series.
　また、３対以上の多層導線が径方向に積層配置されていてもよい。図３４に、４対の導線である第１～第４導線８８ａ～８８ｄが積層配置されている構成を示す。第１～第４導線８８ａ～８８ｄは、固定子コア５２に近い方から、第１，第２，第３，第４導線８８ａ，８８ｂ，８８ｃ，８８ｄの順に径方向に並んで配置されている。 Further, three or more pairs of multi-layer conductors may be laminated in the radial direction. FIG. 34 shows a configuration in which the first to fourth conductors 88a to 88d, which are four pairs of conductors, are laminated and arranged. The first to fourth conductors 88a to 88d are arranged in the radial direction in the order of the first, second, third, and fourth conductors 88a, 88b, 88c, 88d from the side closer to the stator core 52. ..
　ここで、図３３（ｃ）に示すように、第３，第４導線８８ｃ，８８ｄが並列接続されるとともに、この並列接続体の一端に第１導線８８ａが接続され、他端に第２導線８８ｂが接続されていてもよい。並列接続にすると、その並列接続された導線の電流密度を低下させることができ、通電時の発熱を抑制できる。そのため、冷却水通路７４が形成されたハウジング（ユニットベース６１）に筒状の固定子巻線を組み付ける構成において、並列接続されていない第１，第２導線８８ａ，８８ｂがユニットベース６１に当接する固定子コア５２側に配置され、並列接続された第３，第４導線８８ｃ，８８ｄが反固定子コア側に配置されている構成とする。これにより、多層導線構造における各導線８８ａ～８８ｄの冷却性能を均等化することができる。 Here, as shown in FIG. 33 (c), the third and fourth conductors 88c and 88d are connected in parallel, the first conductor 88a is connected to one end of the parallel connection body, and the second conductor is connected to the other end. 88b may be connected. When connected in parallel, the current density of the conductors connected in parallel can be reduced, and heat generation during energization can be suppressed. Therefore, in the configuration in which the tubular stator winding is assembled to the housing (unit base 61) in which the cooling water passage 74 is formed, the first and second conductors 88a and 88b that are not connected in parallel come into contact with the unit base 61. The configuration is such that the third and fourth conductors 88c and 88d arranged in parallel on the stator core 52 side are arranged on the anti-stator core side. Thereby, the cooling performance of each of the conductors 88a to 88d in the multilayer conductor structure can be equalized.
　なお、第１～第４導線８８ａ～８８ｄからなる導線群８１の径方向の厚さ寸法は、１磁極内における１相分の周方向の幅寸法よりも小さいものとされていればよい。 The thickness dimension of the conductor group 81 composed of the first to fourth conductors 88a to 88d in the radial direction may be smaller than the width dimension of one phase in one magnetic pole in the circumferential direction.
　（変形例１０）
　回転電機１０をインナロータ構造（内転構造）としてもよい。この場合、例えばハウジング３０内において、径方向外側に固定子５０が設けられ、その径方向内側に回転子４０が設けられるとよい。また、固定子５０及び回転子４０の軸方向両端のうちその一方の側又はその両方の側にインバータユニット６０が設けられているとよい。図３５は、回転子４０及び固定子５０の横断面図であり、図３６は、図３５に示す回転子４０及び固定子５０の一部を拡大して示す図である。 (Modification example 10)
The rotary electric machine 10 may have an inner rotor structure (additional 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, it is preferable that the inverter unit 60 is provided on one side or both sides of both ends of the stator 50 and the rotor 40 in the axial direction. 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. 35.
　インナロータ構造を前提とする図３５及び図３６の構成は、アウタロータ構造を前提とする図８及び図９の構成に対して、回転子４０及び固定子５０が径方向内外で逆になっていることを除いて、同様の構成となっている。簡単に説明すると、固定子５０は、扁平導線構造の固定子巻線５１と、ティースを持たない固定子コア５２とを有している。固定子巻線５１は、固定子コア５２の径方向内側に組み付けられている。固定子コア５２は、アウタロータ構造の場合と同様に、以下のいずれかの構成を有する。
（Ａ）固定子５０において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニットの周方向の幅寸法をＷｍ、磁石ユニットの残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子５０において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子５０において、周方向における各導線部の間に導線間部材を設けていない構成となっている。 The configurations of FIGS. 35 and 36, which are premised on the inner rotor structure, have the rotor 40 and the stator 50 reversed in the radial direction with respect to the configurations of FIGS. 8 and 9 which are premised on the outer rotor structure. Except for, it has the same configuration. Briefly, the stator 50 has a stator winding 51 having a flat conductor structure and a stator core 52 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.
(A) In the stator 50, a conductor-to-conductor member is provided between each conductor portion in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member at one magnetic pole in the circumferential direction is Wt, and the conductor-to-conductor member is saturated. When the magnetic flux density is Bs and the width dimension of the magnet unit at one magnetic pole in the circumferential direction is Wm and the residual magnetic flux density of the magnet unit is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used.
(B) In the stator 50, a conductor-to-conductor member is provided between the conductors in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
(C) The stator 50 has a configuration in which no interconductor member is provided between the conductors in the circumferential direction.
　また、磁石ユニット４２の各磁石９１，９２についても同様である。つまり、磁石ユニット４２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた磁石９１，９２を用いて構成されている。各磁石９１，９２における磁化方向等の詳細は既述のとおりである。磁石ユニット４２において環状磁石９５（図３０参照）を用いることも可能である。 The same applies to the magnets 91 and 92 of the magnet unit 42. That is, the magnet unit 42 is oriented so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary. Is configured using. Details such as the magnetization directions of the magnets 91 and 92 are as described above. It is also possible to use an annular magnet 95 (see FIG. 30) in the magnet unit 42.
　図３７は、インナロータ型とした場合における回転電機１０の縦断面図であり、これは既述の図２に対応する図面である。図２の構成との相違点を簡単に説明する。図３７において、ハウジング３０の内側には、環状の固定子５０が固定され、その固定子５０の内側には、所定のエアギャップを挟んで回転子４０が回転可能に設けられている。図２と同様に、各軸受２１，２２は、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置されており、これにより、回転子４０が片持ち支持されている。また、回転子４０の磁石ホルダ４１の内側に、インバータユニット６０が設けられている。 FIG. 37 is a vertical cross-sectional view of the rotary electric machine 10 in the case of an inner rotor type, which is a drawing corresponding 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 to the inside of the housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap interposed therebetween. Similar to FIG. 2, 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, whereby the rotor 40 is cantilevered and supported. There is. Further, an inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.
　図３８には、インナロータ構造の回転電機１０として別の構成を示す。図３８において、ハウジング３０には、軸受２１，２２により回転軸１１が回転可能に支持されており、その回転軸１１に対して回転子４０が固定されている。図２等に示す構成と同様に、各軸受２１，２２は、回転子４０の軸方向中央に対して軸方向のいずれか一方側に偏って配置されている。回転子４０は、磁石ホルダ４１と磁石ユニット４２とを有している。 FIG. 38 shows another configuration of the rotary electric machine 10 having an inner rotor structure. In FIG. 38, the rotating shaft 11 is rotatably supported by 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 either one side in the axial direction with respect to the center in the axial direction of the rotor 40. The rotor 40 has a magnet holder 41 and a magnet unit 42.
　図３８の回転電機１０では、図３７の回転電機１０との相違点として、回転子４０の径方向内側にインバータユニット６０が設けられていない構成となっている。磁石ホルダ４１は、磁石ユニット４２の径方向内側となる位置で回転軸１１に連結されている。また、固定子５０は、固定子巻線５１と固定子コア５２とを有しており、ハウジング３０に対して取り付けられている。 The rotary electric machine 10 of FIG. 38 is different from the rotary electric machine 10 of FIG. 37 in that the inverter unit 60 is not provided inside the rotor 40 in the radial direction. The magnet holder 41 is connected to the rotating shaft 11 at a position inside the magnet unit 42 in the radial direction. Further, the stator 50 has a stator winding 51 and a stator core 52, and is attached to the housing 30.
　（変形例１１）
　インナロータ構造の回転電機として別の構成を以下に説明する。図３９は、回転電機２００の分解斜視図であり、図４０は、回転電機２００の側面断面図である。なおここでは、図３９及び図４０の状態を基準に上下方向を示すこととしている。 (Modification 11)
Another configuration as a rotary electric machine having an 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 with reference to the states of FIGS. 39 and 40.
　図３９及び図４０に示すように、回転電機２００は、環状の固定子コア２０１及び多相の固定子巻線２０２を有する固定子２０３と、固定子コア２０１の内側に回転自在に配設される回転子２０４とを備えている。固定子２０３が電機子に相当し、回転子２０４が界磁子に相当する。固定子コア２０１は、多数の珪素鋼板が積層されて構成されており、その固定子コア２０１に対して固定子巻線２０２が取り付けられている。図示は省略するが、回転子２０４は、回転子コアと、磁石ユニットとして複数の永久磁石とを有している。回転子コアには、円周方向に等間隔で複数の磁石挿入孔が設けられている。磁石挿入孔のそれぞれには、隣接する磁極毎に交互に磁化方向が変わるように磁化された永久磁石が装着されている。なお、磁石ユニットの永久磁石は、図２３で説明したようなハルバッハ配列又はそれに類する構成を有するものであるとよい。又は、磁石ユニットの永久磁石は、図９や図３０で説明したような磁極中心であるｄ軸と磁極境界であるｑ軸との間において配向方向（磁化方向）が円弧状に延びている極異方性の特性を備えるものであるとよい。 As shown in FIGS. 39 and 40, the rotary electric machine 200 is rotatably arranged inside the stator core 201 and the stator 203 having an annular stator core 201 and a multi-phase stator winding 202. It is equipped with a rotor 204. The stator 203 corresponds to the armature and the rotor 204 corresponds to the field magnet. The stator core 201 is formed by laminating a large number of silicon steel plates, and a stator winding 202 is attached to the stator core 201. Although not shown, the rotor 204 has a rotor core and a plurality of permanent magnets as magnet units. The rotor core is provided with a plurality of magnet insertion holes at equal intervals in the circumferential direction. Each of the magnet insertion holes is equipped with a permanent magnet magnetized so that the magnetization direction changes alternately for each adjacent magnetic pole. The permanent magnet of the magnet unit may have a Halbach array or a similar configuration as described with reference to FIG. 23. Alternatively, the permanent magnet of the magnet unit has a pole in which the orientation direction (magnetization direction) extends in an arc shape between the d-axis, which is the center of the magnetic pole, and the q-axis, which is the boundary between the magnetic poles, as described with reference to FIGS. 9 and 30. It is preferable that the magnet has anisotropy characteristics.
　ここで、固定子２０３は、以下のいずれかの構成であるとよい。
（Ａ）固定子２０３において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニットの周方向の幅寸法をＷｍ、磁石ユニットの残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子２０３において、周方向における各導線部の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子２０３において、周方向における各導線部の間に導線間部材を設けていない構成となっている。 Here, the stator 203 may have any of the following configurations.
(A) In the stator 203, a conductor-to-conductor member is provided between each conductor portion in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member at one magnetic pole in the circumferential direction is Wt, and the conductor-to-conductor member is saturated. When the magnetic flux density is Bs and the width dimension of the magnet unit at one magnetic pole in the circumferential direction is Wm and the residual magnetic flux density of the magnet unit is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used.
(B) In the stator 203, a conductor-to-conductor member is provided between the conductors in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
(C) The stator 203 has a configuration in which no interconductor member is provided between the conductors in the circumferential direction.
　また、回転子２０４において、磁石ユニットは、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされた複数の磁石を用いて構成されている。 Further, in the rotor 204, the magnet unit is oriented on the d-axis side, which is the center of the magnetic pole, so that the direction of the easy-magnetizing axis is parallel to the d-axis as compared with the side of the q-axis, which is the magnetic pole boundary. It is configured using a plurality of magnets.
　回転電機２００の軸方向の一端側には、環状のインバータケース２１１が設けられている。インバータケース２１１は、ケース下面が固定子コア２０１の上面に接するように配置されている。インバータケース２１１内には、インバータ回路を構成する複数のパワーモジュール２１２と、半導体スイッチング素子のスイッチング動作により生じる電圧・電流の脈動（リップル）を抑制する平滑コンデンサ２１３と、制御部を有する制御基板２１４と、相電流を検出する電流センサ２１５と、回転子２０４の回転数センサであるレゾルバステータ２１６とが設けられている。パワーモジュール２１２は、半導体スイッチング素子であるＩＧＢＴやダイオードを有している。 An annular inverter case 211 is provided on one end side of the rotary electric machine 200 in the axial direction. The inverter case 211 is arranged so that the lower surface of the case is in contact with the upper surface of the stator core 201. Inside the inverter case 211, a plurality of power modules 212 constituting the inverter circuit, a smoothing capacitor 213 that suppresses voltage / current pulsation (ripple) generated by the switching operation of the semiconductor switching element, and a control board 214 having a control unit are provided. A current sensor 215 that detects the phase current and a resolver stator 216 that is a rotation speed sensor of the rotor 204 are provided. The power module 212 has an IGBT and a diode which are semiconductor switching elements.
　インバータケース２１１の周縁には、車両に搭載されるバッテリの直流回路と接続されるパワーコネクタ２１７と、回転電機２００側と車両側制御装置との間で各種信号の受け渡しに用いられる信号コネクタ２１８とが設けられている。インバータケース２１１はトップカバー２１９で覆われている。車載バッテリからの直流電力は、パワーコネクタ２１７を介して入力され、パワーモジュール２１２のスイッチングにより交流に変換されて各相の固定子巻線２０２に送られる。 On the periphery of the inverter case 211, there is a power connector 217 connected to the DC circuit of the battery mounted on the vehicle, and a signal connector 218 used for passing various signals between the rotary electric machine 200 side and the vehicle side control device. Is provided. The inverter case 211 is covered with a top cover 219. The DC power from the in-vehicle battery is input via the power connector 217, converted into AC by switching of the power module 212, and sent to the stator winding 202 of each phase.
　固定子コア２０１の軸方向両側のうちインバータケース２１１の反対側には、回転子２０４の回転軸を回転可能に保持する軸受ユニット２２１と、その軸受ユニット２２１を収容する環状のリアケース２２２とが設けられている。軸受ユニット２２１は、例えば２つ一組の軸受を有しており、回転子２０４の軸方向中央に対して軸方向のいずれか一方側に偏って配置されている。ただし、軸受ユニット２２１における複数の軸受を固定子コア２０１の軸方向両側に分散させて設け、それら各軸受により回転軸を両持ち支持する構成であってもよい。リアケース２２２が車両のギアケースや変速機などの取付部にボルト締結して固定されることで、回転電機２００が車両側に取り付けられるようになっている。 On both sides of the stator core 201 in the axial direction, on the opposite side of the inverter case 211, there are a bearing unit 221 that rotatably holds the rotating shaft of the rotor 204 and an annular rear case 222 that houses the bearing unit 221. It is provided. The bearing unit 221 has, for example, a set of two bearings, and is arranged so as to be biased to either one side in the axial direction with respect to the center in the axial direction of the rotor 204. However, a plurality of bearings in the bearing unit 221 may be provided so as to be dispersed on both sides in the axial direction of the stator core 201, and the rotating shaft may be supported by both bearings. The rotary electric machine 200 can be mounted on the vehicle side by bolting and fixing the rear case 222 to a mounting portion such as a gear case or a transmission of the vehicle.
　インバータケース２１１内には、冷媒を流すための冷却流路２１１ａが形成されている。冷却流路２１１ａは、インバータケース２１１の下面から環状に凹設された空間を固定子コア２０１の上面で閉塞して形成されている。冷却流路２１１ａは、固定子巻線２０２のコイルエンドを囲むように形成されている。冷却流路２１１ａ内には、パワーモジュール２１２のモジュールケース２１２ａが挿入されている。リアケース２２２にも、固定子巻線２０２のコイルエンドを囲むように冷却流路２２２ａが形成されている。冷却流路２２２ａは、リアケース２２２の上面から環状に凹設された空間を固定子コア２０１の下面で閉塞して形成されている。 A cooling flow path 211a for flowing a refrigerant is formed in the inverter case 211. The cooling flow path 211a is formed by closing a space recessed in an annular shape from the lower surface of the inverter case 211 with the upper surface of the stator core 201. The cooling flow path 211a is formed so as to surround the coil end of the stator winding 202. The module case 212a of the power module 212 is inserted in the cooling flow path 211a. The rear case 222 is also formed with a cooling flow path 222a so as to surround the coil end of the stator winding 202. The cooling flow path 222a is formed by closing a space recessed in an annular shape from the upper surface of the rear case 222 with the lower surface of the stator core 201.
　（変形例１２）
　これまでは、回転界磁形の回転電機にて具体化した構成を説明したが、これを変更し、回転電機子形の回転電機にて具体化することも可能である。図４１に、回転電機子形の回転電機２３０の構成を示す。 (Modification 12)
So far, the configuration embodied in the rotating field type rotating electric machine has been described, but it is also possible to change this and embody it in the rotating armature type rotating electric machine. FIG. 41 shows the configuration of the rotary armature type rotary electric machine 230.
　図４１の回転電機２３０において、ハウジング２３１ａ，２３１ｂにはそれぞれ軸受２３２が固定され、その軸受２３２により回転軸２３３が回転自在に支持されている。軸受２３２は、例えば多孔質金属に油を含ませてなる含油軸受である。回転軸２３３には、電機子としての回転子２３４が固定されている。回転子２３４は、回転子コア２３５とその外周部に固定された多相の回転子巻線２３６とを有している。回転子２３４において、回転子コア２３５はスロットレス構造を有し、回転子巻線２３６は扁平導線構造を有している。つまり、回転子巻線２３６は、１相ごとの領域が径方向よりも周方向に長い扁平構造となっている。 In the rotary electric machine 230 of FIG. 41, bearings 232 are fixed to the housings 231a and 231b, respectively, and the rotary shaft 233 is rotatably supported by the bearings 232. The bearing 232 is, for example, an oil-impregnated bearing made by impregnating a porous metal with oil. A rotor 234 as an armature is fixed to the rotating shaft 233. The rotor 234 has a rotor core 235 and a polyphase rotor winding 236 fixed to the outer peripheral portion thereof. In the rotor 234, the rotor core 235 has a slotless structure, and the rotor winding 236 has a flat conductor structure. That is, the rotor winding 236 has a flat structure in which the region for each phase is longer in the circumferential direction than in the radial direction.
　また、回転子２３４の径方向外側には、界磁子としての固定子２３７が設けられている。固定子２３７は、ハウジング２３１ａに固定された固定子コア２３８と、その固定子コア２３８の内周側に固定された磁石ユニット２３９とを有している。磁石ユニット２３９は、周方向に極性が交互となる複数の磁極を含む構成となっており、既述した磁石ユニット４２等と同様に、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。磁石ユニット２３９は、配向が行われた焼結ネオジム磁石を有しており、その固有保磁力は４００［ｋＡ／ｍ］以上、かつ残留磁束密度は１．０［Ｔ］以上となっている。 Further, a stator 237 as a field magnet is provided on the radial outer side of the rotor 234. The stator 237 has a stator core 238 fixed to the housing 231a and a magnet unit 239 fixed to the inner peripheral side of the stator core 238. The magnet unit 239 has a configuration including a plurality of magnetic poles having alternating polarities in the circumferential direction, and is a magnetic pole boundary on the d-axis side, which is the center of the magnetic poles, like the magnet unit 42 described above. It is configured so that the direction of the easy-to-magnetize axis is parallel to the d-axis as compared with the side of the axis. The magnet unit 239 has an oriented sintered neodymium magnet, the intrinsic coercive force thereof is 400 [kA / m] or more, and the residual magnetic flux density is 1.0 [T] or more.
　本例の回転電機２３０は、２極３コイルのブラシ付コアレスモータであり、回転子巻線２３６は３つに分割され、磁石ユニット２３９は２極である。ブラシ付きモータの極数とコイル数は、２：３、４：１０、４：２１などその用途に応じて様々である。 The rotary electric machine 230 of this example is a 2-pole 3-coil brushed coreless motor, the rotor winding 236 is divided into three, and the magnet unit 239 has two poles. The number of poles and the number of coils of the brushed motor varies depending on the application, such as 2: 3, 4:10, 4:21.
　回転軸２３３にはコミュテータ２４１が固定されており、その径方向外側には複数のブラシ２４２が配置されている。コミュテータ２４１は、回転軸２３３に埋め込まれた導線２４３を介して回転子巻線２３６に電気接続されている。これらコミュテータ２４１、ブラシ２４２、導線２４３を通じて、回転子巻線２３６に対する直流電流の流入及び流出が行われる。コミュテータ２４１は、回転子巻線２３６の相数に応じて周方向に適宜分割されて構成されている。なお、ブラシ２４２は、そのまま電気配線を介して蓄電池などの直流電源に接続されていてもよいし、端子台などを介して直流電源に接続されていてもよい。 A commutator 241 is fixed to the rotating shaft 233, and a plurality of brushes 242 are arranged on the outer side in the radial direction thereof. The commutator 241 is electrically connected to the rotor winding 236 via a conductor 243 embedded in the rotating shaft 233. A direct current flows in and out of the rotor winding 236 through the commutator 241, the brush 242, and the conducting wire 243. The commutator 241 is appropriately divided in the circumferential direction according to the number of phases of the rotor winding 236. The brush 242 may be directly connected to a DC power source such as a storage battery via electrical wiring, or may be connected to a DC power source via a terminal block or the like.
　回転軸２３３には、軸受２３２とコミュテータ２４１との間に、シール材としての樹脂ワッシャ２４４が設けられている。樹脂ワッシャ２４４により、含油軸受である軸受２３２からしみ出た油がコミュテータ２４１側に流れ出ることが抑制される。 The rotating shaft 233 is provided with a resin washer 244 as a sealing material between the bearing 232 and the commutator 241. The resin washer 244 suppresses the oil seeping out from the bearing 232, which is an oil-impregnated bearing, from flowing out to the commutator 241 side.
　（変形例１３）
　回転電機１０の固定子巻線５１において、各導線８２を、内外に複数の絶縁被膜を有する構成としてもよい。例えば、絶縁被膜付きの複数の導線（素線）を１本に束ね、それを外層被膜により覆って導線８２を構成するとよい。この場合、素線の絶縁被膜が内側の絶縁被膜を構成し、外層被膜が外側の絶縁被膜を構成する。また特に、導線８２における複数の絶縁被膜のうち外側の絶縁被膜の絶縁能力を、内側の絶縁被膜の絶縁能力よりも高めておくとよい。具体的には、外側の絶縁被膜の厚さを、内側の絶縁被膜の厚さよりも厚くする。例えば、外側の絶縁被膜の厚さを１００μｍ、内側の絶縁被膜の厚さを４０μｍとする。又は、外側の絶縁被膜として、内側の絶縁被膜よりも誘電率の低い材料を用いるとよい。これらは少なくともいずれかが適用されればよい。なお、素線が、複数の導電材の集合体として構成されているとよい。 (Modification 13)
In the stator winding 51 of the rotary electric machine 10, each conducting wire 82 may have a plurality of insulating coatings inside and outside. For example, it is preferable to bundle a plurality of conductors (wires) with an insulating coating into one and cover the conductors with an outer layer coating to form the conductor 82. In this case, the insulating coating of the wire constitutes the inner insulating coating, and the outer layer coating constitutes the outer insulating coating. Further, in particular, it is preferable that the insulating capacity of the outer insulating coating among the plurality of insulating coatings on the conductor 82 is higher than the insulating capacity 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 μm, and the thickness of the inner insulating coating is 40 μm. Alternatively, a material having a lower dielectric constant than the inner insulating coating may be used as the outer insulating coating. At least one of these may be applied. It is preferable that the strands are configured as an aggregate of a plurality of conductive materials.
　上記のとおり導線８２における最外層の絶縁を強くすることにより、高電圧の車両用システムに用いる場合に好適なものとなる。また、気圧の低い高地などでも、回転電機１０の適正な駆動が可能となる。 By strengthening the insulation of the outermost layer of the conductor 82 as described above, it becomes suitable for use in a high-voltage vehicle system. In addition, the rotary electric machine 10 can be properly driven even in highlands where the atmospheric pressure is low.
　（変形例１４）
　内外に複数の絶縁被膜を有する導線８２において、外側の絶縁被膜と内側の絶縁被膜とで、線膨張率（線膨張係数）及び接着強さの少なくともいずれかが異なる構成としてもよい。本変形例における導線８２の構成を図４２に示す。 (Modification 14)
In the conducting wire 82 having a plurality of insulating coatings inside and outside, at least one of the linear expansion coefficient (linear expansion coefficient) and the adhesive strength may be different between the outer insulating coating and the inner insulating coating. The configuration of the conducting wire 82 in this modified example is shown in FIG. 42.
　図４２において、導線８２は、複数（図では４本）の素線１８１と、その複数の素線１８１を囲む例えば樹脂製の外層被膜１８２（外側絶縁被膜）と、外層被膜１８２内において各素線１８１の周りに充填された中間層１８３（中間絶縁被膜）とを有している。素線１８１は、銅材よりなる導電部１８１ａと、絶縁材料よりなる導体被膜１８１ｂ（内側絶縁被膜）とを有している。固定子巻線として見れば、外層被膜１８２により相間が絶縁される。なお、素線１８１が、複数の導電材の集合体として構成されているとよい。 In FIG. 42, the conductor 82 includes a plurality of (four in the figure) strands 181 and, for example, a resin outer layer coating 182 (outer insulating coating) surrounding the plurality of strands 181 and each of the conductors in the outer layer coating 182. It has an intermediate layer 183 (intermediate insulating film) filled around the wire 181. The wire 181 has a conductive portion 181a made of a copper material and a conductor coating 181b (inner insulating coating) made of an insulating material. When viewed as a stator winding, the outer layer coating 182 insulates the phases. It is preferable that the strand 181 is configured as an aggregate of a plurality of conductive materials.
　中間層１８３は、素線１８１の導体被膜１８１ｂよりも高い線膨張率を有し、かつ外層被膜１８２よりも低い線膨張率を有している。つまり、導線８２では、外側ほど線膨張率が高くなっている。一般的に、外層被膜１８２では導体被膜１８１ｂよりも線膨張係数が高いが、それらの間にその中間の線膨張率を有する中間層１８３を設けることにより、その中間層１８３がクッション材として機能し、外層側及び内層側での同時割れを防ぐことができる。 The intermediate layer 183 has a higher coefficient of linear expansion than the conductor coating 181b of the wire 181 and a lower coefficient of linear expansion than the outer layer coating 182. That is, in the conductor 82, the coefficient of linear expansion is higher toward the outside. Generally, the outer layer coating 182 has a higher coefficient of linear expansion than the conductor coating 181b, but by providing an intermediate layer 183 having an intermediate linear expansion coefficient between them, the intermediate layer 183 functions as a cushioning material. , Simultaneous cracking on the outer layer side and the inner layer side can be prevented.
　また、導線８２では、素線１８１において導電部１８１ａと導体被膜１８１ｂとが接着されるとともに、導体被膜１８１ｂと中間層１８３、中間層１８３と外層被膜１８２がそれぞれ接着されており、それら各接着部分では、導線８２の外側ほど、接着強さが弱くなっている。つまり、導電部１８１ａ及び導体被膜１８１ｂの接着強さは、導体被膜１８１ｂ及び中間層１８３の接着強さ、中間層１８３及び外層被膜１８２の接着強さよりも弱くなっている。また、導体被膜１８１ｂ及び中間層１８３の接着強さと、中間層１８３及び外層被膜１８２の接着強さとを比較すると、後者の方（外側の方）が弱いか、又は同等であるとよい。なお、各被膜同士の接着強さの大きさは、例えば２層の被膜を引き剥がす際に要する引っ張り強さ等により把握可能である。上記のごとく導線８２の接着強さが設定されていることで、発熱又は冷却による内外温度差が生じても、内層側及び外層側で共に割れが生じること（共割れ）を抑制することができる。 Further, in the conducting wire 82, the conductive portion 181a and the conductor coating 181b are adhered to each other in the wire 181 and the conductor coating 181b and the intermediate layer 183, and the intermediate layer 183 and the outer layer coating 182 are adhered to each other. Then, the adhesive strength becomes weaker toward the outside of the conductor 82. That is, the adhesive strength of the conductive portion 181a and the conductor coating 181b is weaker than the adhesive strength of the conductor coating 181b and the intermediate layer 183 and the adhesive strength of the intermediate layer 183 and the outer layer coating 182. Further, comparing the adhesive strength of the conductor coating 181b and the intermediate layer 183 with the adhesive strength of the intermediate layer 183 and the outer layer coating 182, it is preferable that the latter (outer side) is weaker or equivalent. The magnitude of the adhesive strength between the coatings can be grasped from, for example, the tensile strength required when peeling off the two layers of coatings. By setting the adhesive strength of the conducting wire 82 as described above, it is possible to suppress cracking (co-cracking) on both the inner layer side and the outer layer side even if an internal / external temperature difference occurs due to heat generation or cooling. ..
　ここで、回転電機の発熱、温度変化は、主に素線１８１の導電部１８１ａから発熱される銅損と、鉄心内から発せられる鉄損として生じるが、それら２種類の損失は、導線８２内の導電部１８１ａ、又は導線８２の外部より伝わるものであり、中間層１８３に発熱源があるわけではない。この場合、中間層１８３が両方に対してクッションとなり得る接着力を持つことで、その同時割れを防ぐことができる。したがって、車両用途など、高耐圧又は温度変化の大きい分野での使用に際しても、好適なる使用が可能となる。 Here, the heat generation and temperature change of the rotary electric machine mainly occur as copper loss generated from the conductive portion 181a of the wire 181 and iron loss generated from the inside of the iron core, and these two types of losses occur in the conducting wire 82. It is transmitted from the outside of the conductive portion 181a or the conducting wire 82 of the above, and the intermediate layer 183 does not have a heat generating source. In this case, the intermediate layer 183 has an adhesive force that can serve as a cushion for both of them, so that simultaneous cracking can be prevented. Therefore, suitable use is possible even when used in fields with high withstand voltage or large temperature changes such as vehicle applications.
　以下に補足する。素線１８１は、例えばエナメル線であってもよく、かかる場合にはＰＡ、ＰＩ、ＰＡＩ等の樹脂被膜層（導体被膜１８１ｂ）を有する。また、素線１８１より外側の外層被膜１８２は、同様のＰＡ、ＰＩ、ＰＡＩ等よりなり、かつ厚みが厚いものであることが望ましい。これにより、線膨張率差による被膜の破壊が抑えられる。なお、外層被膜１８２としては、ＰＡ、ＰＩ、ＰＡＩ等の前記材料を厚くして対応するものとは別に、ＰＰＳ、ＰＥＥＫ、フッ素、ポリカーボネート、シリコン、エポキシ、ポリエチレンナフタレート、ＬＣＰといった、誘電率がＰＩ、ＰＡＩよりも小さいものを使うことも回転機の導体密度を高めるためには望ましい。これらの樹脂であれば、導体被膜１８１ｂ同等のＰＩ，ＰＡＩ被膜よりも薄いか、導体被膜１８１ｂと同等の厚みであっても、その絶縁能力を高くすることができ、これにより導電部の占有率を高めることが可能となる。一般的には、上記樹脂は、誘電率がエナメル線の絶縁被膜より良好な絶縁を有している。当然、成形状態や、混ぜ物によって、その誘電率を悪くする例も存在する。中でも、ＰＰＳ、ＰＥＥＫは、その線膨張係数がエナメル被膜より一般的には大きいが、他樹脂よりも小さいため、第２層の外層被膜として適するのである。 Supplement to the following. The strand 181 may be, for example, an enamel wire, and in such a case, it has a resin coating layer (conductor coating 181b) such as PA, PI, and PAI. Further, it is desirable that the outer layer coating 182 outside the wire 181 is made of the same PA, PI, PAI, etc., and has a large thickness. As a result, the destruction of the coating film due to the difference in linear expansion coefficient is suppressed. The outer layer coating 182 has a dielectric constant such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP, in addition to those made by thickening the above materials such as PA, PI, and PAI. It is also desirable to use one smaller than PI and PAI in order to increase the conductor density of the rotating machine. With these resins, even if they are thinner than the PI and PAI coatings equivalent to the conductor coating 181b or the thickness equivalent to the conductor coating 181b, their dielectric strength can be increased, thereby occupying the conductive portion. Can be increased. In general, the resin has better insulation than the insulating coating of enamel wire in terms of dielectric constant. Naturally, there are cases where the dielectric constant is deteriorated depending on the molding state and the mixture. Among them, PPS and PEEK are suitable as the outer layer coating of the second layer because their linear expansion coefficient is generally larger than that of the enamel coating but smaller than that of other resins.
　また、素線１８１の外側における２種類の被膜（中間絶縁被膜、外側絶縁被膜）と素線１８１のエナメル被膜との接着強さは、素線１８１における銅線とエナメル被膜との間の接着強さよりも弱いことが望ましい。これにより、エナメル被膜と前記２種類の被膜とが一度に破壊される現象が抑制される。 Further, the adhesive strength between the two types of coatings (intermediate insulating coating and outer insulating coating) on the outside of the strand 181 and the enamel coating on the strand 181 is the adhesive strength between the copper wire and the enamel coating on the strand 181. It is desirable to be weaker than that. As a result, the phenomenon that the enamel coating and the two types of coatings are destroyed at once is suppressed.
　固定子に水冷構造、液冷構造、空冷構造が付加されている場合には、基本的に、外層被膜１８２から先に熱応力や衝撃応力が掛かると考えられる。しかし、素線１８１の絶縁層と、前記２種類の被膜とが違う樹脂の場合でも、その被膜を接着しない部位を設けることにより、前記熱応力や衝撃応力を低減することができる。すなわち、素線（エナメル線）と空隙を設け、フッ素、ポリカーボネート、シリコン、エポキシ、ポリエチレンナフタレート、ＬＣＰを配置することで前記絶縁構造がなされる。この場合、エポキシなどからなる低誘電率で、かつ低線膨張係数からなる接着材を用いて、外層被膜と内層被膜とを接着することが望ましい。こうすることで、機械的強度だけでなく、導電部の振動による揺れなどによる摩擦による被膜破壊、または線膨張係数差による外層被膜の破壊を抑えることができる。 When a water-cooled structure, a liquid-cooled structure, or an air-cooled structure is added to the stator, it is considered that thermal stress or impact stress is basically applied to the outer layer coating 182 first. However, even in the case of a resin in which the insulating layer of the wire 181 and the two types of coatings are different, the thermal stress and impact stress can be reduced by providing a portion where the coatings are not adhered. That is, the insulating structure is formed by providing a wire (enamel wire) and a gap and arranging fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, and LCP. In this case, it is desirable to bond the outer layer coating and the inner layer coating using an adhesive material having a low dielectric constant made of epoxy or the like and having a low coefficient of linear expansion. By doing so, it is possible to suppress not only the mechanical strength but also the destruction of the coating film due to friction caused by the vibration of the conductive portion or the destruction of the outer layer coating film due to the difference in the coefficient of linear expansion.
　上記構成の導線８２に対しての、機械的強度、固定等を担う、一般的には固定子巻線周りの最終工程となる最外層固定としては、エポキシ、ＰＰＳ、ＰＥＥＫ、ＬＣＰなどの成形性が良く、誘電率、線膨張係数といった性質がエナメル被膜と近い性質をもった樹脂が好ましい。 Formability of epoxy, PPS, PEEK, LCP, etc. is used as the outermost layer fixing, which is generally the final step around the stator winding, which is responsible for mechanical strength, fixing, etc. to the lead wire 82 having the above configuration. It is preferable to use a resin having properties such as dielectric constant and coefficient of linear expansion similar to those of an enamel film.
　一般的には、ウレタン、シリコンによる樹脂ポッティングが通例なされるが、前記樹脂においてはその線膨張係数がその他の樹脂と比べて倍近い差があり、樹脂をせん断し得る熱応力を発生する。そのため、厳しい絶縁規定が国際的に用いられる６０Ｖ以上の用途には不適である。この点、エポキシ、ＰＰＳ、ＰＥＥＫ、ＬＣＰなどにより射出成型等により容易に作られる最終絶縁工程によれば、上述の各要件を達成することが可能である。 Generally, resin potting with urethane or silicon is usually performed, but the linear expansion coefficient of the resin is almost double that of other resins, and thermal stress that can shear the resin is generated. Therefore, strict insulation regulations are not suitable for applications of 60 V or higher, which are used internationally. In this regard, according to the final insulation step easily made by injection molding or the like using epoxy, PPS, PEEK, LCP or the like, each of the above requirements can be achieved.
　上記以外の変形例を以下に列記する。 Modification examples other than the above are listed below.
　・磁石ユニット４２のうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。具体的には、例えば、図４に示す磁石ユニット４２（具体的には、第１，第２磁石９１，９２）のうち径方向内側の面と、回転子４０の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。 The distance DM between the surface of the magnet unit 42 on the armature side in the radial direction and the axial center of the rotor in the radial direction may be 50 mm or more. Specifically, for example, in the radial direction of the inner surface of the magnet unit 42 (specifically, the first and second magnets 91 and 92) shown in FIG. 4 in the radial direction and the axial center of the rotor 40. The distance DM may be 50 mm or more.
　スロットレス構造の回転電機としては、その出力が数十Ｗから数百Ｗ級の模型用などに使用される小規模なものが知られている。そして、一般的には１０ｋＷを超すような工業用の大型の回転電機でスロットレス構造が採用された事例を本願開示者は把握していない。その理由について本願開示者は検討した。 As a rotary electric machine having a slotless structure, a small-scale one whose output is used for a model of several tens of watts to several hundreds of watts is known. And, the present disclosure person does not understand the case where the slotless structure is adopted in a large industrial rotary electric machine which generally exceeds 10 kW. The discloser of the present application examined the reason.
　近年主流の回転電機は、次の４種類に大別される。それら回転電機とは、ブラシ付きモータ、カゴ型誘導モータ、永久磁石式同期モータ及びリラクタンスモータである。 The mainstream rotary electric machines in recent years are roughly classified into the following four types. These rotary electric machines are a brushed motor, a basket type induction motor, a permanent magnet type synchronous motor, and a reluctance motor.
　ブラシ付きモータには、ブラシを介して励磁電流が供給される。このため、大型機のブラシ付きモータの場合、ブラシが大型化したり、メンテナンスが煩雑になったりしたりする。これにより、半導体技術の目覚ましい発達に伴い、誘導モータ等のブラシレスモータに置換されてきた経緯がある。一方、小型モータの世界では、低い慣性及び経済性の利点から、コアレスモータも多数世の中に供給されている。 Excitation current is supplied to the brushed motor via the brush. For this reason, in the case of a motor with a brush 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 are also supplied to the world because of their low inertia and economic advantages.
　カゴ型誘導モータでは、１次側の固定子巻線で発生させる磁界を２次側の回転子の鉄心で受けてカゴ型導体に集中的に誘導電流を流して反作用磁界を形成することにより、トルクを発生させる原理である。このため、機器の小型高効率の観点からすれば、固定子側及び回転子側ともに鉄心をなくすことは必ずしも得策であるとは言えない。 In a squirrel-cage induction motor, the magnetic field generated by the stator winding on the primary side is received by the iron core of the rotor on the secondary side, and an induced current is intensively passed through the squirrel-cage conductor to form a reaction magnetic field. This is the principle of generating torque. Therefore, from the viewpoint of small size and high efficiency of the device, it is not always a good idea to eliminate the iron core on both the stator side and the rotor side.
　リラクタンスモータは、当に鉄心のリラクタンス変化を活用するモータであり、原理的に鉄心をなくすことは望ましくない。 The reluctance motor is a motor that utilizes the reluctance change of the iron core, and it is not desirable to eliminate the iron core in principle.
　永久磁石式同期モータでは、近年ＩＰＭ（つまり埋め込み磁石型回転子）が主流であり、特に大型機においては、特殊事情がない限りＩＰＭである場合が多い。 In recent years, IPM (that is, embedded magnet type rotor) has become the mainstream of permanent magnet synchronous motors, and in large machines in particular, IPM is often used unless there are special circumstances.
　ＩＰＭは、磁石トルク及びリラクタンストルクを併せ持つ特性を有しており、インバータ制御により、それらトルクの割合が適時調整されながら運転される。このため、ＩＰＭは小型で制御性に優れるモータである。 IPM has the characteristic of having both magnet torque and reluctance torque, and is operated while the ratio of those torques is adjusted in a timely manner by inverter control. Therefore, the IPM is a small motor with excellent controllability.
　本願開示者の分析により、磁石トルク及びリラクタンストルクを発生する回転子表面のトルクを、磁石ユニットのうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭ、すなわち、一般的なインナロータの固定子鉄心の半径を横軸にとって描くと図４３に示すものとなる。 According to the analysis of the discloser of the present application, the torque on the surface of the rotor that generates the magnet torque and the relaxation torque is determined by the distance DM in the radial direction between the surface of the magnet unit on the armature side in the radial direction and the axial center of the rotor, that is, The radius of the stator core of a general inner rotor is drawn with the horizontal axis as shown in FIG. 43.
　磁石トルクは、下式（ｅｑ１）に示すように、永久磁石の発生する磁界強度によりそのポテンシャルが決定されるのに対し、リラクタンストルクは、下式（ｅｑ２）に示すように、インダクタンス、特にｑ軸インダクタンスの大きさがそのポテンシャルを決定する。 The potential of the magnet torque is determined by the magnetic field strength generated by the permanent magnet as shown in the following equation (eq1), whereas the reluctance torque is determined by the inductance, especially q, as shown in the following equation (eq2). The magnitude of the shaft inductance determines its potential.
　磁石トルク＝ｋ・Ψ・Ｉｑ　　　　　　　　　　　　・・・・・・・（ｅｑ１）
　リラクタンストルク＝ｋ・（Ｌｑ－Ｌｄ）・Ｉｑ・Ｉｄ　・・・・・（ｅｑ２）
　ここで、永久磁石の磁界強度と巻線のインダクタンスの大きさとをＤＭで比較してみた。永久磁石の発する磁界強度、すなわち磁束量Ψは、固定子と対向する面の永久磁石の総面積に比例する。円筒型の回転子であれば円筒の表面積になる。厳密には、Ｎ極とＳ極とが存在するので、円筒表面の半分の専有面積に比例する。円筒の表面積は、円筒の半径と、円筒長さとに比例する。つまり、円筒長さが一定であれば、円筒の半径に比例する。 Magnet torque = k ・ Ψ ・ Iq ・ ・ ・ ・ ・ ・ ・ (eq1)
Reluctance torque = k ・ (Lq-Ld) ・ Iq ・ Id ・ ・ ・ ・ ・ (eq2)
Here, the magnetic field strength of the permanent magnet and the magnitude of the inductance of the winding are compared by DM. The magnetic field strength generated by the permanent magnet, that is, the amount of magnetic flux Ψ, is proportional to the total area of the permanent magnet on the surface facing the stator. If it is a cylindrical rotor, it will be the surface area of the cylinder. Strictly speaking, since there are N pole and S pole, 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.
　一方、巻線のインダクタンスＬｑは、鉄心形状に依存はするものの感度は低く、むしろ固定子巻線の巻数の２乗に比例するため、巻数の依存性が高い。なお、μを磁気回路の透磁率、Ｎを巻数、Ｓを磁気回路の断面積、δを磁気回路の有効長さとする場合、インダクタンスＬ＝μ・Ｎ＾２×Ｓ／δである。巻線の巻数は、巻線スペースの大きさに依存するため、円筒型モータであれば、固定子の巻線スペース、すなわちスロット面積に依存することになる。図４４に示すように、スロット面積は、スロットの形状が略四角形であるため、周方向の長さ寸法ａ及び径方向の長さ寸法ｂとの積ａ×ｂに比例する。 On the other hand, the inductance Lq of the winding depends on the shape of the iron core, but its sensitivity is low, and rather it is proportional to the square of the number of turns of the stator winding, so the dependence on the number of turns is high. When μ is the magnetic permeability of the magnetic circuit, N is the number of turns, S is the cross-sectional area of the magnetic circuit, and δ is the effective length of the magnetic circuit, the inductance L = μ · N ^ 2 × S / δ. Since the number of turns of the winding depends on the size of the winding space, in the case of a cylindrical motor, it depends on the winding space of the stator, that is, the slot area. As shown in FIG. 44, since the slot shape is substantially quadrangular, the slot area is proportional to the product a × b of the circumferential length dimension a and the radial length dimension b.
　スロットの周方向の長さ寸法は、円筒の直径が大きいほど大きくなるため、円筒の直径に比例する。スロットの径方向の長さ寸法は、当に円筒の直径に比例する。つまり、スロット面積は、円筒の直径の２乗に比例する。また、上式（ｅｑ２）からも分かる通り、リラクタンストルクは、固定子電流の２乗に比例するため、いかに大電流を流せるかで回転電機の性能が決まり、その性能は固定子のスロット面積に依存する。以上より、円筒の長さが一定なら、リラクタンストルクは円筒の直径の２乗に比例する。このことを踏まえ、磁石トルク及びリラクタンストルクとＤＭとの関係性をプロットした図が図４３である。 The length dimension in the circumferential direction of the slot increases as the diameter of the cylinder increases, so it is proportional to the diameter of the cylinder. The radial length dimension of the slot is exactly proportional to the diameter of the cylinder. That is, the slot area is proportional to the square of the diameter of the cylinder. Also, as can be seen from the above equation (eq2), the reluctance torque is proportional to the square of the stator current, so the performance of the rotating electric machine is determined by how large the current can flow, and that performance depends on the slot area of the stator. Dependent. From the above, if the length of the cylinder is constant, the reluctance torque is proportional to the square of the diameter of the cylinder. Based on this, FIG. 43 is a diagram plotting the relationship between the magnet torque and the reluctance torque and DM.
　図４３に示すように、磁石トルクはＤＭに対して直線的に増加し、リラクタンストルクはＤＭに対して２次関数的に増加する。ＤＭが比較的小さい場合は磁石トルクが支配的であり、固定子鉄心半径が大きくなるに連れてリラクタンストルクが支配的であることがわかる。本願開示者は、図４３における磁石トルク及びリラクタンストルクの交点が、所定の条件下において、おおよそ固定子鉄心半径＝５０ｍｍの近傍であるとの結論に至った。つまり、固定子鉄心半径が５０ｍｍを十分に超えるような１０ｋＷ級のモータでは、リラクタンストルクを活用することが現在の主流であるため鉄心を無くすことは困難であり、このことが大型機の分野においてスロットレス構造が採用されない理由の１つであると推定される。 As shown in FIG. 43, the magnet torque increases linearly with respect to DM, and the reluctance torque increases quadratically with respect to DM. It can be seen that the magnet torque is dominant when the DM is relatively small, and the reluctance torque is dominant as the stator core radius increases. The discloser of the present application has concluded that the intersection of the magnet torque and the reluctance torque in FIG. 43 is approximately in the vicinity of the stator core radius = 50 mm under predetermined conditions. In other words, it is difficult to eliminate the iron core in a 10 kW class motor whose stator core radius sufficiently exceeds 50 mm because it is the current mainstream to utilize reluctance torque, and this is the field of large machines. It is presumed to be one of the reasons why the slotless structure is not adopted.
　固定子に鉄心が使用される回転電機の場合、鉄心の磁気飽和が常に課題となる。特にラジアルギャップ型の回転電機では、回転軸の縦断面形状は１磁極当たり扇型となり、機器内周側程磁路幅が狭くなりスロットを形成するティース部分の内周側寸法が回転電機の性能限界を決める。いかに高性能な永久磁石を使おうとも、この部分で磁気飽和が発生すると、永久磁石の性能を十分にひきだすことができない。この部分で磁気飽和を発生させないためには、内周径を大きく設計することになり結果的に機器の大型化に至ってしまうのである。 In the case of a rotary electric machine in which an iron core is used for the stator, magnetic saturation of the iron core is always an issue. In particular, in a radial gap type rotary electric machine, the vertical cross-sectional shape of the rotating shaft is a fan shape per magnetic pole, and the magnetic path width becomes narrower toward the inner peripheral side of the device, and the inner peripheral side dimension of the teeth part forming the slot is the performance of the rotary electric machine. Set limits. No matter how high-performance permanent magnets are used, if magnetic saturation occurs in this part, the performance of the permanent magnets cannot be fully brought out. In order not to generate magnetic saturation in this part, the inner circumference must be designed to be large, resulting in an increase in the size of the equipment.
　例えば、分布巻の回転電機では、３相巻線であれば、１磁極あたり３つ乃至６つのティースで分担して磁束を流すのだが、周方向前方のティースに磁束が集中しがちであるため、３つ乃至６つのティースに均等に磁束が流れるわけではない。この場合、一部（例えば１つ又は２つ）のティースに集中的に磁束が流れながら、回転子の回転に伴って磁気飽和するティースも周方向に移動してゆく。これがスロットリップルを生む要因にもなる。 For example, in a distributed winding rotary electric machine, in the case of a three-phase winding, the magnetic flux is shared by three to six teeth per magnetic pole, but the magnetic flux tends to concentrate on the teeth in the circumferential direction. The magnetic flux does not flow evenly over the three to six teeth. In this case, while the magnetic flux flows intensively through some (for example, one or two) teeth, the teeth that are magnetically saturated with the rotation of the rotor also move in the circumferential direction. This also causes slot ripple.
　以上から、ＤＭが５０ｍｍ以上となるスロットレス構造の回転電機において、磁気飽和を解消するために、ティースを廃止したい。しかし、ティースが廃止されると、回転子及び固定子における磁気回路の磁気抵抗が増加し、回転電機のトルクが低下してしまう。磁気抵抗増加の理由としては、例えば、回転子と固定子との間のエアギャップが大きくなることがある。このため、上述したＤＭが５０ｍｍ以上となるスロットレス構造の回転電機において、トルクを増強することについて改善の余地がある。したがって、上述したＤＭが５０ｍｍ以上となるスロットレス構造の回転電機に、上述したトルクを増強できる構成を適用するメリットが大きい。 From the above, we would like to abolish teeth in order to eliminate magnetic saturation in slotless rotating electric machines with DM of 50 mm or more. 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, in the above-mentioned rotary electric machine having a slotless structure in which the DM is 50 mm or more, there is room for improvement in increasing the torque. Therefore, there is a great merit of applying the above-mentioned configuration capable of increasing torque to the rotary electric machine having a slotless structure in which the DM is 50 mm or more.
　なお、アウタロータ構造の回転電機に限らず、インナロータ構造の回転電機についても、磁石ユニットのうち径方向において電機子側の面と、回転子の軸心との径方向における距離ＤＭが５０ｍｍ以上とされていてもよい。 Not only the rotary electric machine having an outer rotor structure but also the rotary electric machine having an inner rotor structure has a distance DM of 50 mm or more in the radial direction between the surface of the magnet unit on the armature side and the axial center of the rotor. You may be.
　・回転電機１０の固定子巻線５１において、導線８２の直線部８３を径方向に単層で設ける構成としてもよい。また、径方向内外に複数層で直線部８３を配置する場合に、その層数は任意でよく、３層、４層、５層、６層等で設けてもよい。 -In the stator winding 51 of the rotary electric machine 10, the straight portion 83 of the conducting wire 82 may be provided in a single layer in the radial direction. Further, when the linear portion 83 is arranged in a plurality of layers inside and outside the radial direction, the number of layers may be arbitrary, and may be provided in three layers, four layers, five layers, six layers and the like.
　・例えば図２の構成では、回転軸１１を、軸方向で回転電機１０の一端側及び他端側の両方に突出するように設けたが、これを変更し、一端側にのみ突出する構成としてもよい。この場合、回転軸１１は、軸受ユニット２０により片持ち支持される部分を端部とし、その軸方向外側に延びるように設けられるとよい。本構成では、インバータユニット６０の内部に回転軸１１が突出しない構成となるため、インバータユニット６０の内部空間、詳しくは筒状部７１の内部空間をより広く用いることができることとなる。 -For example, in the configuration of FIG. 2, the rotating shaft 11 is provided so as to project to both one end side and the other end side of the rotary electric machine 10 in the axial direction. May be good. In this case, the rotating shaft 11 may be provided so as to extend outward in the axial direction, with a portion that is cantilevered by the bearing unit 20 as an end portion. In this configuration, since the rotating shaft 11 does not protrude inside the inverter unit 60, the internal space of the inverter unit 60, specifically the internal space of the tubular portion 71, can be used more widely.
　・上記構成の回転電機１０では、軸受２１，２２において非導電性グリースを用いる構成としたが、これを変更し、軸受２１，２２において導電性グリースを用いる構成としてもよい。例えば、金属粒子やカーボン粒子等が含まれた導電性グリースを用いる構成とする。 -In the rotary electric machine 10 having the above configuration, the bearings 21 and 22 are configured to use non-conductive grease, but this may be changed to a configuration in which the bearings 21 and 22 use conductive grease. For example, a conductive grease containing metal particles, carbon particles, or the like is used.
　・回転軸１１を回転自在に支持する構成として、回転子４０の軸方向一端側及び他端側の２カ所に軸受を設ける構成としてもよい。この場合、図１の構成で言えば、インバータユニット６０を挟んで一端側及び他端側の２カ所に軸受が設けられるとよい。 -As a configuration for rotatably supporting the rotating shaft 11, bearings may be provided at two locations, one end side and the other end side in the axial direction of the rotor 40. In this case, in the configuration of FIG. 1, it is preferable that bearings are provided at two locations on one end side and the other end side of the inverter unit 60.
　・上記構成の回転電機１０では、回転子４０において磁石ホルダ４１の中間部４５が内側肩部４９ａと感情の外側肩部４９ｂを有する構成としたが、これらの肩部４９ａ，４９ｂを無くし、平坦な面を有する構成としてもよい。 In the rotary electric machine 10 having the above configuration, in the rotor 40, the intermediate portion 45 of the magnet holder 41 has an inner shoulder portion 49a and an emotional outer shoulder portion 49b. However, these shoulder portions 49a and 49b are eliminated and the rotor portion is flat. It may be configured to have various surfaces.
　・上記構成の回転電機１０では、固定子巻線５１の導線８２において導体８２ａを複数の素線８６の集合体として構成したが、これを変更し、導線８２として断面矩形状の角形導線を用いる構成としてもよい。また、導線８２として断面円形状又は断面楕円状の丸形導線を用いる構成としてもよい。 In the rotary electric machine 10 having the above configuration, the conductor 82a is configured as an aggregate of a plurality of strands 86 in the conductor 82 of the stator winding 51, but this is changed and a square conductor having a rectangular cross section is used as the conductor 82. It may be configured. Further, as the conducting wire 82, a round conducting wire having a circular cross section or an elliptical cross section may be used.
　・上記構成の回転電機１０では、固定子５０の径方向内側にインバータユニット６０を設ける構成としたが、これに代えて、固定子５０の径方向内側にインバータユニット６０を設けない構成としてもよい。この場合、固定子５０の径方向内側となる内部領域を空間としておくことが可能である。また、その内部領域に、インバータユニット６０とは異なる部品を配することが可能である。 -In the rotary electric machine 10 having the above configuration, the inverter unit 60 is provided inside the stator 50 in the radial direction, but instead of this, the inverter unit 60 may not be provided inside the stator 50 in the radial direction. .. In this case, it is possible to set an internal region inside the stator 50 in the radial direction as a space. Further, it is possible to arrange parts different from the inverter unit 60 in the internal region.
　・上記構成の回転電機１０において、ハウジング３０を具備しない構成としてもよい。この場合、例えばホイールや他の車両部品の一部において、回転子４０、固定子５０等が保持される構成であってもよい。 -The rotary electric machine 10 having the above configuration may not include the housing 30. In this case, for example, the rotor 40, the stator 50, and the like may be held in a part of the wheel or other vehicle parts.
　（車両用インホイールモータとしての実施形態）
　次に、回転電機を、車両の車輪に一体にインホイールモータとして設けた実施形態について説明する。図４５は、インホイールモータ構造の車輪４００及びその周辺構造を示す斜視図であり、図４６は、車輪４００及びその周辺構造の縦断面図であり、図４７は、車輪４００の分解斜視図である。これら各図は、いずれも車輪４００を車両内側から見た斜視図である。なお、車両においては、本実施形態のインホイールモータ構造を種々の形態で適用することが可能であり、例えば車両前後にそれぞれ２つの車輪を有する車両では、車両前側の２輪、車両後側の２輪、又は車両前後の４輪に本実施形態のインホイールモータ構造を適用することが可能である。ただし、車両前後の少なくとも一方が１輪である車両への適用も可能である。なお、インホイールモータは、車両用駆動ユニットとしての適用例である。 (Embodiment as an in-wheel motor for a vehicle)
Next, an embodiment in which the rotary electric machine is provided integrally with the wheels of the vehicle as an in-wheel motor will be described. 45 is a perspective view showing the wheel 400 having an in-wheel motor structure and its peripheral structure, FIG. 46 is a vertical sectional view of the wheel 400 and its peripheral structure, and FIG. 47 is an exploded perspective view of the wheel 400. is there. Each of these figures is a perspective view of the wheel 400 as viewed from the inside of the vehicle. In the vehicle, the in-wheel motor structure of the present embodiment can be applied in various forms. For example, in a vehicle having two wheels in front of and behind the vehicle, two wheels on the front side of the vehicle and two wheels on the rear side of the vehicle. It is possible to apply the in-wheel motor structure of the present embodiment to two wheels or four wheels in front of and behind the vehicle. However, it can also be applied to a vehicle in which at least one of the front and rear of the vehicle is one wheel. The in-wheel motor is an application example as a vehicle drive unit.
　図４５～図４７に示すように、車輪４００は、例えば周知の空気入りタイヤであるタイヤ４０１と、タイヤ４０１の内周側に固定されたホイール４０２と、ホイール４０２の内周側に固定された回転電機５００とを備えている。回転電機５００は、固定子（ステータ）を含む部分である固定部と、回転子（ロータ）を含む部分である回転部とを有し、固定部が車体側に固定されるとともに、回転部がホイール４０２に固定されており、回転部の回転によりタイヤ４０１及びホイール４０２が回転する。なお、回転電機５００において固定部及び回転部を含む詳細な構成は後述する。 As shown in FIGS. 45 to 47, the wheel 400 is fixed to, for example, the tire 401, which is a well-known pneumatic tire, the wheel 402 fixed to the inner peripheral side of the tire 401, and the inner peripheral side of the wheel 402. It is equipped with a rotary electric machine 500. The rotary electric machine 500 has a fixed portion which is a portion including a stator (stator) and a rotating portion which is a portion including a rotor (rotor), and the fixed portion is fixed to the vehicle body side and the rotating portion is formed. It is fixed to the wheel 402, and the tire 401 and the wheel 402 rotate due to the rotation of the rotating portion. The detailed configuration of the rotary electric machine 500 including the fixed portion and the rotating portion will be described later.
　また、車輪４００には、周辺装置として、不図示の車体に対して車輪４００を保持するサスペンション装置と、車輪４００の向きを可変とするステアリング装置と、車輪４００の制動を行うブレーキ装置とが取り付けられている。 Further, as peripheral devices, a suspension device for holding the wheels 400 with respect to a vehicle body (not shown), a steering device for changing the direction of the wheels 400, and a braking device for braking the wheels 400 are attached to the wheels 400. Has been done.
　サスペンション装置は、独立懸架式サスペンションであり、例えばトレーリングアーム式、ストラット式、ウィッシュボーン式、マルチリンク式など任意の形式の適用が可能である。本実施形態では、サスペンション装置として、車体中央側に延びる向きでロアアーム４１１が設けられるとともに、上下方向に延びる向きでサスペンションアーム４１２及びスプリング４１３が設けられている。サスペンションアーム４１２は、例えばショックアブソーバとして構成されているとよい。ただしその詳細な図示は省略する。ロアアーム４１１及びサスペンションアーム４１２はそれぞれ、車体側に接続されるとともに、回転電機５００の固定部に固定された円板状のベースプレート４０５に接続されている。図４６に示すように、回転電機５００側（ベースプレート４０５側）には、ロアアーム４１１及びサスペンションアーム４１２が支持軸４１４，４１５により互いに同軸の状態で支持されている。 The suspension device is an independent suspension type suspension, and any type such as trailing arm type, strut type, wishbone type, and multi-link type can be applied. In the present embodiment, as the suspension device, the lower arm 411 is provided so as to extend toward the center of the vehicle body, and the suspension arm 412 and the spring 413 are provided so as to extend in the vertical direction. The suspension arm 412 may be configured as, for example, a shock absorber. However, the detailed illustration is omitted. The lower arm 411 and the suspension arm 412 are each connected to the vehicle body side and to a disk-shaped base plate 405 fixed to a fixed portion of the rotary electric machine 500. As shown in FIG. 46, the lower arm 411 and the suspension arm 412 are supported on the rotary electric machine 500 side (base plate 405 side) by the support shafts 414 and 415 in a coaxial state with each other.
　また、ステアリング装置としては、例えばラック＆ピニオン式構造、ボール＆ナット式構造の適用や、油圧式パワーステアリングシステム、電動式パワーステアリングシステムの適用が可能である。本実施形態では、ステアリング装置として、ラック装置４２１とタイロッド４２２とが設けられており、ラック装置４２１がタイロッド４２２を介して回転電機５００側のベースプレート４０５に接続されている。この場合、不図示のステアリングシャフトの回転に伴いラック装置４２１が作動すると、タイロッド４２２が車両左右方向に移動する。これにより、車輪４００が、ロアアーム４１１及びサスペンションアーム４１２の支持軸４１４，４１５を中心として回転し、車輪方向が変更される。 Further, as the steering device, for example, a rack & pinion type structure, a ball & nut type structure, a hydraulic power steering system, and an electric power steering system can be applied. In the present embodiment, a rack device 421 and a tie rod 422 are provided as steering devices, and the rack device 421 is connected to the base plate 405 on the rotary electric machine 500 side via the tie rod 422. In this case, when the rack device 421 operates with the rotation of the steering shaft (not shown), the tie rod 422 moves in the left-right direction of the vehicle. As a result, the wheel 400 rotates around the support shafts 414 and 415 of the lower arm 411 and the suspension arm 412, and the wheel direction is changed.
　ブレーキ装置としては、ディスクブレーキやドラムブレーキの適用が好適である。本実施形態では、ブレーキ装置として、回転電機５００の回転軸５０１に固定されたディスクロータ４３１と、回転電機５００側のベースプレート４０５に固定されたブレーキキャリパ４３２とが設けられている。ブレーキキャリパ４３２ではブレーキパッドが油圧等により作動されるようになっており、ブレーキパッドがディスクロータ４３１に押し付けられることにより、摩擦による制動力を生じさせて車輪４００の回転が停止される。 As a braking device, it is preferable to apply a disc brake or a drum brake. In the present embodiment, as the brake device, a disc rotor 431 fixed to the rotary shaft 501 of the rotary electric machine 500 and a brake caliper 432 fixed to the base plate 405 on the rotary electric machine 500 side are provided. In the brake caliper 432, the brake pads are operated by flood control or the like, and when the brake pads are pressed against the disc rotor 431, a braking force due to friction is generated and the rotation of the wheels 400 is stopped.
　また、車輪４００には、回転電機５００から延びる電気配線Ｈ１や冷却用配管Ｈ２を収容する収容ダクト４４０が取り付けられている。収容ダクト４４０は、回転電機５００の固定部側の端部から回転電機５００の端面に沿って延び、かつサスペンションアーム４１２を避けるように設けられ、その状態でサスペンションアーム４１２に固定されている。これにより、サスペンションアーム４１２における収容ダクト４４０の接続部位は、ベースプレート４０５との位置関係が固定されたものとなる。そのため、電気配線Ｈ１や冷却用配管Ｈ２において車両の振動などに起因して生じるストレスを抑制できるようになっている。なお、電気配線Ｈ１は、不図示の車載電源部や車載ＥＣＵに接続され、冷却用配管Ｈ２は、不図示のラジエータに接続される。 Further, the wheel 400 is attached with an accommodation duct 440 that accommodates the electric wiring H1 extending from the rotary electric machine 500 and the cooling pipe H2. The accommodating duct 440 extends from the end of the rotary electric machine 500 on the fixed portion side along the end surface of the rotary electric machine 500 and is provided so as to avoid the suspension arm 412, and is fixed to the suspension arm 412 in that state. As a result, the connection portion of the accommodation duct 440 in the suspension arm 412 has a fixed positional relationship with the base plate 405. Therefore, it is possible to suppress the stress caused by the vibration of the vehicle in the electric wiring H1 and the cooling pipe H2. The electrical wiring H1 is connected to an in-vehicle power supply unit and an in-vehicle ECU (not shown), and the cooling pipe H2 is connected to a radiator (not shown).
　次に、インホイールモータとして用いられる回転電機５００の構成を詳細に説明する。本実施形態では、回転電機５００をインホイールモータに適用した事例を示している。回転電機５００は、従来技術のように減速機を擁した車両駆動ユニットのモータと比べて、優れた動作効率、出力を備える。すなわち、回転電機５００を従来技術に比べて、コストダウンにより実用的な価格を実現できるような用途に採用すれば、車両駆動ユニット以外の用途のモータとしても使ってもよい。そのような場合であっても、インホイールモータに適用した場合と同様に、優れた性能を発揮する。なお、動作効率とは、車両の燃費を導出する走行モードでの試験時の際に使われる指標を指す。 Next, the configuration of the 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 the motor of a vehicle drive unit having a speed reducer as in the prior art. That is, if the rotary electric machine 500 is adopted in an application in which a practical price can be realized by reducing the cost as compared with the conventional technology, it may be used as a motor for applications other than the vehicle drive unit. Even in such a case, the excellent performance is exhibited as in the case of applying it to an in-wheel motor. The operating efficiency refers to an index used during a test in a driving mode that derives the fuel efficiency of the vehicle.
　回転電機５００の概要を図４８～図５１に示す。図４８は、回転電機５００を回転軸５０１の突出側（車両内側）から見た側面図であり、図４９は、回転電機５００の縦断面図（図４８の４９－４９線断面図）であり、図５０は、回転電機５００の横断面図（図４９の５０－５０線断面図）であり、図５１は、回転電機５００の構成要素を分解した分解断面図である。以下の記載では、回転軸５０１が、図５１においては車体の外側方向に延びる方向を軸方向とし、回転軸５０１から放射状に延びる方向を径方向とし、図４８においては回転軸５０１の中央、言い換えれば回転部分の回転中心、を通る断面４９を作るために引いた中心線上の、回転部分の回転中心以外の任意の点より、円周状に延びる２つの方向をいずれも周方向としている。言い換えると、周方向は、断面４９上の任意の点を起点とした時計回りの方向、又は反時計回りの方向のいずれの方向であってもよい。また、車両搭載状態からすれば、図４９において右側が車両外側であり、左側が車両内側である。言い換えると、同車両搭載状態からすれば、後述する回転子５１０は、回転子カバー６７０よりも車体の外側方向に配置される。 The outline of the rotary electric machine 500 is shown in FIGS. 48 to 51. FIG. 48 is a side view of the rotary electric machine 500 as viewed from the protruding side (inside the vehicle) of the rotary shaft 501, and FIG. 49 is a vertical sectional view of the rotary electric machine 500 (cross-sectional view taken along lines 49-49 of FIG. 48). 50 is a cross-sectional view of the rotary electric machine 500 (a cross-sectional view taken along the line 50-50 of FIG. 49), and FIG. 51 is an exploded cross-sectional view of the components of the rotary electric machine 500. In the following description, in FIG. 51, the direction in which the rotating shaft 501 extends outward of the vehicle body is the axial direction, the direction extending radially from the rotating shaft 501 is the radial direction, and in FIG. 48, the center of the rotating shaft 501, in other words. For example, the circumferential direction is defined as two directions extending in a circumferential shape from an arbitrary point other than the rotation center of the rotating portion on the center line drawn to form a cross section 49 passing through the rotation center of the rotating portion. 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, from the vehicle-mounted state, the right side is the outside of the vehicle and the left side is the inside of the vehicle in FIG. 49. In other words, from the vehicle-mounted state, the rotor 510, which will be described later, is arranged in the outer direction of the vehicle body with respect to the rotor cover 670.
　本実施形態に係る回転電機５００は、アウタロータ式の表面磁石型回転電機である。回転電機５００は、大別して、回転子５１０と、固定子５２０と、インバータユニット５３０と、軸受５６０と、回転子カバー６７０とを備えている。これら各部材は、いずれも回転子５１０に一体に設けられた回転軸５０１に対して同軸に配置され、所定順序で軸方向に組み付けられることで回転電機５００が構成されている。 The rotary electric machine 500 according to the present embodiment is an outer rotor type surface magnet type rotary electric machine. The rotary electric machine 500 is roughly classified into a rotor 510, a stator 520, an inverter unit 530, a bearing 560, and a rotor cover 670. Each of these members is arranged coaxially with respect to the rotating shaft 501 integrally provided on the rotor 510, and is assembled in the axial direction in a predetermined order to form the rotating electric machine 500.
　回転電機５００において、回転子５１０及び固定子５２０はそれぞれ円筒状をなしており、エアギャップを挟んで互いに対向配置されている。回転子５１０が回転軸５０１と共に一体回転することにより、固定子５２０の径方向外側にて回転子５１０が回転する。回転子５１０が「界磁子」に相当し、固定子５２０が「電機子」に相当する。 In the rotary electric machine 500, the rotor 510 and the stator 520 each have a cylindrical shape, and are arranged so as to face each other with an air gap in between. As the rotor 510 rotates integrally with the rotation shaft 501, the rotor 510 rotates on the radial outer side of the stator 520. The rotor 510 corresponds to the "field magnet" and the stator 520 corresponds to the "armature".
　回転子５１０は、略円筒状の回転子キャリア５１１と、その回転子キャリア５１１に固定された環状の磁石ユニット５１２とを有している。回転子キャリア５１１に回転軸５０１が固定されている。 The rotor 510 has a substantially cylindrical rotor carrier 511 and an annular magnet unit 512 fixed to the rotor carrier 511. The rotation shaft 501 is fixed to the rotor carrier 511.
　回転子キャリア５１１は、円筒部５１３を有している。円筒部５１３の内周面には磁石ユニット５１２が固定されている。つまり、磁石ユニット５１２は、回転子キャリア５１１の円筒部５１３に径方向外側から包囲された状態で設けられている。また、円筒部５１３は、その軸方向に対向する第１端と第２端とを有している。第１端は、車体の外側の方向に位置し、第２端は、ベースプレート４０５が存在する方向に位置する。回転子キャリア５１１において、円筒部５１３の第１端には端板５１４が連続して設けられている。すなわち円筒部５１３と端板５１４とは一体の構造である。円筒部５１３の第２端は開放されている。回転子キャリア５１１は、例えば機械強度が充分な冷間圧延鋼板（ＳＰＣＣやＳＰＣＣより板厚が厚いＳＰＨＣ）、鍛造用鋼、炭素繊維強化プラスチック（ＣＦＲＰ）などにより形成されている。 The rotor carrier 511 has a cylindrical portion 513. A magnet unit 512 is fixed to the inner peripheral surface of the cylindrical portion 513. That is, the magnet unit 512 is provided in a state of being surrounded by the cylindrical portion 513 of the rotor carrier 511 from the outside in the radial direction. Further, the cylindrical portion 513 has a first end and a second end facing each other in the axial direction thereof. The first end is located in the direction outside the vehicle body, and the second end is located in the direction in which the base plate 405 is present. 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 513 and the end plate 514 have an integral structure. The second end of the cylindrical portion 513 is open. The rotor carrier 511 is formed of, for example, a cold-rolled steel plate having sufficient mechanical strength (SPCC or SPHC thicker than SPCC), forging steel, carbon fiber reinforced plastic (CFRP), or the like.
　回転軸５０１の軸長は、回転子キャリア５１１の軸方向の寸法よりも長い。言い換えると、回転軸５０１は、回転子キャリア５１１の開放端側（車両内側方向）に突出しており、その突出側の端部に、上述のブレーキ装置等が取り付けられるようになっている。 The axial length of the rotating shaft 501 is longer than the axial dimension of the rotor carrier 511. In other words, the rotating shaft 501 projects toward the open end side (inward direction of the vehicle) of the rotor carrier 511, and the above-mentioned brake device or the like is attached to the protruding end side.
　回転子キャリア５１１の端板５１４にはその中央部に貫通孔５１４ａが形成されている。回転軸５０１は、端板５１４の貫通孔５１４ａに挿通された状態で、回転子キャリア５１１に固定されている。回転軸５０１は、回転子キャリア５１１が固定される部分に、軸方向に交差（直交）する向きに延びるフランジ５０２を有しており、そのフランジと端板５１４の車両外側の面とが面接合されている状態で、回転子キャリア５１１に対して回転軸５０１が固定されている。なお、車輪４００においては、回転軸５０１のフランジ５０２から車両外側方向に立設されたボルト等の締結具を用いてホイール４０２が固定されるようになっている。 A through hole 514a is formed in the central portion of the end plate 514 of the rotor carrier 511. The rotary shaft 501 is fixed to the rotor carrier 511 in a state of being inserted into the through hole 514a of the end plate 514. The rotating shaft 501 has a flange 502 extending in a direction intersecting (orthogonal) in the axial direction at a portion where the rotor carrier 511 is fixed, and the flange and the outer surface of the end plate 514 are surface-joined. In this state, the rotation shaft 501 is fixed to the rotor carrier 511. In the wheel 400, the wheel 402 is fixed by using a fastener such as a bolt erected from the flange 502 of the rotating shaft 501 toward the outside of the vehicle.
　また、磁石ユニット５１２は、回転子５１０の周方向に沿って極性が交互に変わるように配置された複数の永久磁石により構成されている。これにより、磁石ユニット５１２は、周方向に複数の磁極を有する。永久磁石は、例えば接着により回転子キャリア５１１に固定されている。磁石ユニット５１２は、第１実施形態の図８，図９において磁石ユニット４２として説明した構成を有しており、永久磁石として、固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結ネオジム磁石を用いて構成されている。 Further, the magnet unit 512 is composed of a plurality of permanent magnets arranged so that the polarities alternate along the circumferential direction of the rotor 510. As a result, the magnet unit 512 has a plurality of magnetic poles in the circumferential direction. The permanent magnet is fixed to the rotor carrier 511 by, for example, adhesion. The magnet unit 512 has the configuration described as the magnet unit 42 in FIGS. 8 and 9 of the first embodiment, and as a permanent magnet, has an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux. It is constructed by using a sintered neodymium magnet having a density Br of 1.0 [T] or more.
　磁石ユニット５１２は、図９等の磁石ユニット４２と同様に、それぞれ極異方性磁石でありかつ極性が互いに異なる第１磁石９１及び第２磁石９２を有している。図８及び図９で説明したように、各磁石９１，９２ではそれぞれ、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じた配向により円弧状の磁石磁路が形成されている。なお、各磁石９１，９２において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。要するに、磁石ユニット５１２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。 Similar to the magnet unit 42 shown in FIG. 9, the magnet unit 512 has a first magnet 91 and a second magnet 92, which are polar anisotropic magnets and have different polarities. As described with reference to FIGS. 8 and 9, the directions of the easy magnetization axes of the magnets 91 and 92 differ between the d-axis side (the portion closer to the d-axis) and the q-axis side (the portion closer to the q-axis), respectively. On the d-axis side, the direction of the easy-magnetization axis is close to the direction parallel to the d-axis, and on the q-axis side, the direction of the easy-magnetization axis is close to the direction orthogonal to the q-axis. Then, an arcuate magnet magnetic path is formed by the orientation according to the direction of the easily magnetized axis. In each of the magnets 91 and 92, the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side, and the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side. In short, the magnet unit 512 is configured so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary. ..
　各磁石９１，９２によれば、ｄ軸での磁石磁束が強化され、かつｑ軸付近での磁束変化が抑えられる。これにより、各磁極においてｑ軸からｄ軸にかけての表面磁束変化がなだらかになる磁石９１，９２を好適に実現できるものとなっている。磁石ユニット５１２として、図２２及び図２３に示す磁石ユニット４２の構成や、図３０に示す磁石ユニット４２の構成を用いることも可能である。 According to the magnets 91 and 92, the magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed. As a result, magnets 91 and 92 in which the change in surface magnetic flux from the q-axis to the d-axis at each magnetic pole is gentle can be preferably realized. As the magnet unit 512, the configuration of the magnet unit 42 shown in FIGS. 22 and 23 and the configuration of the magnet unit 42 shown in FIG. 30 can also be used.
　なお、磁石ユニット５１２は、回転子キャリア５１１の円筒部５１３の側、すなわち外周面側に、複数の電磁鋼板が軸方向に積層されて構成された回転子コア（バックヨーク）を有していてもよい。つまり、回転子キャリア５１１の円筒部５１３の径方向内側に回転子コアを設けるとともに、その回転子コアの径方向内側に永久磁石（磁石９１，９２）を設ける構成とすることも可能である。 The magnet unit 512 has a rotor core (back yoke) formed by laminating a plurality of electromagnetic steel sheets in the axial direction on the side of the cylindrical portion 513 of the rotor carrier 511, that is, on the outer peripheral surface side. May be good. That is, it is also possible to provide the rotor core on the radial inside of the cylindrical portion 513 of the rotor carrier 511 and to provide the permanent magnets (magnets 91, 92) on the radial inside of the rotor core.
　図４７に示すように、回転子キャリア５１１の円筒部５１３には、周方向の所定間隔にて、軸方向に延びる向きで凹部５１３ａが形成されている。この凹部５１３ａは例えばプレス加工により形成されており、図５２に示すように、円筒部５１３の内周面側には、凹部５１３ａの裏側となる位置に凸部５１３ｂが形成されている。一方、磁石ユニット５１２の外周面側には、円筒部５１３の凸部５１３ｂに合わせて凹部５１２ａが形成されており、その凹部５１２ａ内に円筒部５１３の凸部５１３ｂが入り込むことで、磁石ユニット５１２の周方向の位置ずれが抑制されるようになっている。つまり、回転子キャリア５１１側の凸部５１３ｂは、磁石ユニット５１２の回り止め部として機能する。なお、凸部５１３ｂの形成方法は、プレス加工以外であってもよく任意である。 As shown in FIG. 47, the cylindrical portion 513 of the rotor carrier 511 is formed with recesses 513a in a direction extending in the axial direction at predetermined intervals in the circumferential direction. The concave portion 513a is formed by, for example, press working, and as shown in FIG. 52, a convex portion 513b is formed on the inner peripheral surface side of the cylindrical portion 513 at a position on the back side of the concave portion 513a. On the other hand, on the outer peripheral surface side of the magnet unit 512, a concave portion 512a is formed in accordance with the convex portion 513b of the cylindrical portion 513, and the convex portion 513b of the cylindrical portion 513 enters the concave portion 512a, whereby the magnet unit 512 The displacement in the circumferential direction of the magnet is suppressed. That is, the convex portion 513b on the rotor carrier 511 side functions as a detent portion of the magnet unit 512. The method of forming the convex portion 513b may be any method other than press working.
　図５２には、磁石ユニット５１２における磁石磁路の方向が矢印により示されている。磁石磁路は、磁極境界であるｑ軸を跨ぐようにして円弧状に延び、かつ磁極中心であるｄ軸では、ｄ軸に平行又は平行に近い向きとなっている。磁石ユニット５１２には、その内周面側に、ｑ軸に相当する位置ごとに凹部５１２ｂが形成されている。この場合、磁石ユニット５１２では、固定子５２０に近い側（図の下側）と遠い側（図の上側）とで磁石磁路の長さが異なり、固定子５２０に近い側の方が磁石磁路長が短くなっており、その磁石磁路長が最短となる位置に凹部５１２ｂが形成されている。つまり、磁石ユニット５１２では磁石磁路長が短い場所において十分な磁石磁束を生じさせることが困難になることを考慮して、その磁石磁束の弱い場所で磁石を削除するようにしている。 In FIG. 52, the direction of the magnetic path of the magnet in the magnet unit 512 is indicated by an arrow. The magnet magnetic path extends in an arc shape so as to straddle the q-axis which is the magnetic pole boundary, and the d-axis which is the center of the magnetic pole is in a direction parallel to or close to parallel to the d-axis. The magnet unit 512 is formed with recesses 512b at positions corresponding to the q-axis on the inner peripheral surface side thereof. In this case, in the magnet unit 512, the length of the magnet magnetic path differs between the side closer to the stator 520 (lower side in the figure) and the side farther from the stator 520 (upper side in the figure), and the side closer to the stator 520 is magnetized. The path length is shortened, and the recess 512b is formed at a position where the magnetic path length is the shortest. That is, in consideration of the fact that it is difficult for the magnet unit 512 to generate a sufficient magnet magnetic flux in a place where the magnet magnetic path length is short, the magnet is deleted in a place where the magnet magnetic flux is weak.
　ここで、磁石の実効磁束密度Ｂｄは、磁石内部を通る磁気回路の長さが長いほど高くなる。また、パーミアンス係数Ｐｃと磁石の実効磁束密度Ｂｄとは、そのうち一方が高くなると他方が高くなる関係にある。上記図５２の構成によれば、磁石の実効磁束密度Ｂｄの高さの指標となるパーミアンス係数Ｐｃの低下を抑制しつつ、磁石量の削減を図ることができる。なお、Ｂ－Ｈ座標において、磁石の形状に応じたパーミアンス直線と減磁曲線との交点が動作点であり、その動作点の磁束密度が磁石の実効磁束密度Ｂｄである。本実施形態の回転電機５００では、固定子５２０の鉄量を少なくした構成としており、かかる構成においてｑ軸を跨いだ磁気回路を設定する手法は極めて有効である。 Here, the effective magnetic flux density Bd of the magnet increases as the length of the magnetic circuit passing through the inside of the magnet becomes longer. Further, the permeance coefficient Pc and the effective magnetic flux density Bd of the magnet are in a relationship that the higher one is, the higher the other is. According to the configuration of FIG. 52, the amount of magnets can be reduced while suppressing a decrease in the permeance coefficient Pc, which is an index of the height of the effective magnetic flux density Bd of the magnet. In the BH coordinates, the intersection of the permeance straight line and the demagnetization curve according to the shape of the magnet is the operating point, and the magnetic flux density at the operating point is the effective magnetic flux density Bd of the magnet. The rotary electric machine 500 of the present embodiment has a configuration in which the amount of iron in the stator 520 is reduced, and in such a configuration, a method of setting a magnetic circuit straddling the q-axis is extremely effective.
　また、磁石ユニット５１２の凹部５１２ｂは、軸方向に延びる空気通路として用いることができる。そのため、空冷性能を高めることも可能となる。 Further, the recess 512b of the magnet unit 512 can be used as an air passage extending in the axial direction. Therefore, it is possible to improve the air cooling performance.
　次に、固定子５２０の構成を説明する。固定子５２０は、固定子巻線５２１と固定子コア５２２とを有している。図５３は、固定子巻線５２１と固定子コア５２２とを分解して示す斜視図である。 Next, the configuration of the stator 520 will be described. The stator 520 has a stator winding 521 and a stator core 522. FIG. 53 is a perspective view showing the stator winding 521 and the stator core 522 in an exploded manner.
　固定子巻線５２１は、略筒状（環状）に巻回形成された複数の相巻線よりなり、その固定子巻線５２１の径方向内側にベース部材としての固定子コア５２２が組み付けられている。本実施形態では、Ｕ相、Ｖ相及びＷ相の相巻線を用いることで、固定子巻線５２１が３相の相巻線として構成されている。各相巻線は、径方向に内外２層の導線５２３により構成されている。固定子５２０は、既述の固定子５０と同様に、スロットレス構造と固定子巻線５２１の扁平導線構造とを有することを特徴としており、図８～図１６に示された固定子５０と同様又は類似の構成を有している。 The stator winding 521 is composed of a plurality of phase windings formed by winding in a substantially tubular shape (annular shape), and a stator core 522 as a base member is assembled inside the stator winding 521 in the radial direction. There is. In the present embodiment, the stator winding 521 is configured as a three-phase phase winding by using U-phase, V-phase, and W-phase phase windings. Each phase winding is composed of two inner and outer layers of conducting wires 523 in the radial direction. The stator 520 is characterized by having a slotless structure and a flat conductor structure of the stator winding 521, similarly to the stator 50 described above, with the stator 50 shown in FIGS. 8 to 16. It has a similar or similar configuration.
　固定子コア５２２の構成について説明する。固定子コア５２２は、既述の固定子コア５２と同様に、軸方向に複数の電磁鋼板が積層され、かつ径方向に所定の厚さを有する円筒状をなしており、固定子コア５２２において回転子５１０側となる径方向外側に固定子巻線５２１が組み付けられている。固定子コア５２２の外周面は凹凸のない曲面状をなしており、固定子巻線５２１が組み付けられた状態では、固定子コア５２２の外周面に、固定子巻線５２１を構成する導線５２３が周方向に並べて配置されている。固定子コア５２２はバックコアとして機能する。 The configuration of the stator core 522 will be described. Similar to the stator core 52 described above, the stator core 522 has a cylindrical shape in which a plurality of electromagnetic steel sheets are laminated in the axial direction and has a predetermined thickness in the radial direction. The stator winding 521 is assembled on the outer side in the radial direction on the rotor 510 side. The outer peripheral surface of the stator core 522 has a curved shape without unevenness, and when the stator winding 521 is assembled, the conductor 523 constituting the stator winding 521 is attached to the outer peripheral surface of the stator core 522. They are arranged side by side in the circumferential direction. The stator core 522 functions as a back core.
　固定子５２０は、以下の（Ａ）～（Ｃ）のいずれかを用いたものであるとよい。
（Ａ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石ユニット５１２の周方向の幅寸法をＷｍ、磁石ユニット５１２の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子５２０において、周方向における各導線５２３の間に導線間部材を設けていない構成となっている。 The stator 520 may use any of the following (A) to (C).
(A) In the stator 520, a conductor-to-conductor member is provided between each conductor 523 in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member in one magnetic pole in the circumferential direction is Wt, and the conductor-to-conductor member is saturated. When the magnetic flux density is Bs, the width dimension of the magnet unit 512 at one magnetic pole in the circumferential direction is Wm, and the residual magnetic flux density of the magnet unit 512 is Br, a magnetic material having a relationship of Wt × Bs ≦ Wm × Br is used. There is.
(B) In the stator 520, a conductor-to-conductor member is provided between each conductor 523 in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
(C) The stator 520 has a configuration in which no interconductor member is provided between the conductors 523 in the circumferential direction.
　こうした固定子５２０の構成によれば、固定子巻線としての各導線部の間に磁気経路を確立するためのティース（鉄心）が設けられる一般的なティース構造の回転電機に比べて、インダクタンスが低減される。具体的には、インダクタンスを１／１０以下にすることが可能となっている。この場合、インダクタンスの低下に伴いインピーダンスが低下することから、回転電機５００において入力電力に対する出力電力を大きくし、ひいてはトルク増加に貢献できるものとなっている。また、インピーダンス成分の電圧を利用してトルク出力を行う（言い換えればリラクタンストルクを利用する）埋込み磁石型回転子を用いた回転電機に比べて、大出力の回転電機を提供することが可能となっている。 According to such a configuration of the stator 520, the inductance is higher than that of a rotating electric machine having a general teeth structure in which a tooth (iron core) for establishing a magnetic path is provided between each conducting portion as a stator winding. It will be reduced. Specifically, the inductance can be reduced to 1/10 or less. In this case, since the impedance decreases as the inductance decreases, the output power with respect to the input power of the rotary electric machine 500 can be increased, which in turn can contribute to the increase in torque. In addition, it is possible to provide a rotary electric machine with a higher output than a rotary electric machine using an embedded magnet type rotor that outputs torque using the voltage of the impedance component (in other words, uses reluctance torque). ing.
　本実施形態では、固定子巻線５２１が、固定子コア５２２と共に樹脂等からなるモールド材（絶縁部材）により一体にモールドされており、周方向に並ぶ各導線５２３の間には、モールド材が介在する構成となっている。かかる構成からすると、本実施形態の固定子５２０は、上記（Ａ）～（Ｃ）のうち（Ｂ）の構成に相当する。また、周方向に隣り合う各導線５２３は、周方向の端面同士が互いに当接するか、又は微小な間隔を隔てて近接配置されており、この構成から言えば上記（Ｃ）の構成であってもよい。なお、上記（Ａ）の構成を採用する場合には、軸方向における導線５２３の向きに合わせて、すなわち例えばスキュー構造の固定子巻線５２１であればスキュー角度に合わせて、固定子コア５２２の外周面に突部が設けられているとよい。 In the present embodiment, the stator winding 521 is integrally molded together with the stator core 522 by a molding material (insulating member) made of resin or the like, and the molding material is formed between the conducting wires 523 arranged in the circumferential direction. It has an intervening configuration. Based on such a configuration, the stator 520 of the present embodiment corresponds to the configuration of (B) among the above (A) to (C). Further, the conductor wires 523 adjacent to each other in the circumferential direction are in contact with each other in the circumferential direction, or are arranged close to each other at a minute interval. May be good. When the configuration (A) is adopted, the stator core 522 is aligned with the direction of the conducting wire 523 in the axial direction, that is, according to the skew angle of the stator winding 521 having a skew structure, for example. It is preferable that a protrusion is provided on the outer peripheral surface.
　次に、固定子巻線５２１の構成を、図５４を用いて説明する。図５４は、固定子巻線５２１を平面状に展開して示す正面図であり、図５４（ａ）には径方向において外層に位置する各導線５２３を示し、図５４（ｂ）には径方向において内層に位置する各導線５２３を示す。 Next, the configuration of the stator winding 521 will be described with reference to FIG. 54. FIG. 54 is a front view showing the stator winding 521 developed in a plane, FIG. 54 (a) shows each conducting wire 523 located in the outer layer in the radial direction, and FIG. 54 (b) shows the diameter. Each conductor 523 located in the inner layer in the direction is shown.
　固定子巻線５２１は、分布巻きにより円環状に巻回形成されている。固定子巻線５２１では、径方向内外２層に導線材が巻回され、かつ内層側及び外層側の各導線５２３にて互いに異なる方向へのスキューが施されている（図５４（ａ）、図５４（ｂ）参照）。各導線５２３は、それぞれ相互に絶縁されている。導線５２３は、複数の素線８６の集合体として構成されているとよい（図１３参照）。また、同相でかつ通電方向を同じとする導線５２３が、周方向に例えば２本ずつ並べて設けられている。固定子巻線５２１では、径方向に２層かつ周方向に２本（すなわち計４本）の各導線５２３により同相の１つの導線部が構成され、その導線部が１磁極内で１つずつ設けられている。 The stator winding 521 is wound in an annular shape by distributed winding. In the stator winding 521, the conductor material is wound around the inner and outer two layers in the radial direction, and the conductors 523 on the inner layer side and the outer layer side are skewed in different directions (FIG. 54 (a), FIG. See FIG. 54 (b)). Each conductor 523 is isolated from each other. The conductor 523 may be configured as an aggregate of a plurality of strands 86 (see FIG. 13). Further, for example, two conducting wires 523 having the same phase and the same energizing direction are provided side by side in the circumferential direction. In the stator winding 521, one conductor portion having the same phase is formed by each conductor 523 having two layers in the radial direction and two conductors in the circumferential direction (that is, a total of four conductors), and the conductor portions are one by one in one magnetic pole. It is provided.
　導線部では、その径方向の厚さ寸法を、１磁極内における１相分の周方向の幅寸法よりも小さいものとし、これにより固定子巻線５２１を扁平導線構造とすることが望ましい。具体的には,例えば、固定子巻線５２１において、径方向に２層かつ周方向に４本（すなわち計８本）の各導線５２３により同相の１つの導線部を構成するとよい。又は、図５０に示す固定子巻線５２１の導線断面において、周方向の幅寸法が径方向の厚さ寸法よりも大きくなっているとよい。固定子巻線５２１として、図１２に示す固定子巻線５１を用いることも可能である。ただしこの場合には、回転子キャリア５１１内に固定子巻線のコイルエンドを収容するスペースを確保する必要がある。 It is desirable that the thickness dimension of the conductor portion in the radial direction be smaller than the width dimension in the circumferential direction of one phase in one magnetic pole, whereby the stator winding 521 has a flat conductor structure. Specifically, for example, in the stator winding 521, one conductor portion having two layers in the radial direction and four conductors 523 in the circumferential direction (that is, a total of eight conductors) may form one conductor portion having the same phase. Alternatively, in the conductor cross section of the stator winding 521 shown in FIG. 50, the width dimension in the circumferential direction may be larger than the thickness dimension in the radial direction. As the stator winding 521, the stator winding 51 shown in FIG. 12 can also be used. However, in this case, it is necessary to secure a space in the rotor carrier 511 for accommodating the coil end of the stator winding.
　固定子巻線５２１では、固定子コア５２２に対して径方向内外に重なるコイルサイド５２５において所定角度で傾斜させて導線５２３が周方向に並べて配置されるとともに、固定子コア５２２よりも軸方向外側となる両側のコイルエンド５２６において軸方向内側への反転（折り返し）が行われて連続結線がなされている。図５４（ａ）には、コイルサイド５２５となる範囲とコイルエンド５２６となる範囲とがそれぞれ示されている。内層側の導線５２３と外層側の導線５２３とはコイルエンド５２６にて互いに接続されており、これにより、コイルエンド５２６で導線５２３が軸方向に反転される都度（折り返される都度）、導線５２３が内層側と外層側とで交互に切り替わるようになっている。要するに、固定子巻線５２１では、周方向に連続する各導線５２３において、電流の向きが反転するのに合わせて内外層の切り替えが行われる構成となっている。 In the stator winding 521, the conductor wires 523 are arranged side by side in the circumferential direction at a coil side 525 that overlaps the stator core 522 in the radial direction at a predetermined angle, and are axially outside the stator core 522. The coil ends 526 on both sides are inverted (folded back) inward in the axial direction to form a continuous connection. FIG. 54A shows a range of the coil side 525 and a range of the coil end 526, respectively. The conductor 523 on the inner layer side and the conductor 523 on the outer layer side are connected to each other at the coil end 526, so that the conductor 523 is rotated at the coil end 526 each time the conductor 523 is inverted in the axial direction (each time it is folded back). The inner layer side and the outer layer side are switched alternately. In short, the stator winding 521 has a configuration in which the inner and outer layers are switched in accordance with the reversal of the direction of the current in each of the conducting wires 523 that are continuous in the circumferential direction.
　また、固定子巻線５２１では、軸方向の両端となる端部領域と、その端部領域に挟まれた中央領域とでスキュー角度が異なる２種類のスキューが施されている。すなわち、図５５に示すように、導線５２３において、中央領域のスキュー角度θｓ１と端部領域のスキュー角度θｓ２とが異なっており、スキュー角度θｓ１がスキュー角度θｓ２よりも小さくなる構成となっている。軸方向において、端部領域は、コイルサイド５２５を含む範囲で定められている。スキュー角度θｓ１，スキュー角度θｓ２は、軸方向に対して各導線５２３が傾斜している傾斜角度である。中央領域のスキュー角度θｓ１は、固定子巻線５２１の通電により生じる磁束の高調波成分を削減するのに適正な角度範囲で定められているとよい。 Further, in the stator winding 521, two types of skews are applied in which the skew angles are different between the end region which is both ends in the axial direction and the central region sandwiched between the end regions. That is, as shown in FIG. 55, in the conducting wire 523, the skew angle θs1 in the central region and the skew angle θs2 in the end region are different, and the skew angle θs1 is smaller than the skew angle θs2. In the axial direction, the end region is defined to include the coil side 525. The skew angle θs1 and the skew angle θs2 are inclination angles at which each conducting wire 523 is inclined with respect to the axial direction. The skew angle θs1 in the central region may be set in an angle range appropriate for reducing the harmonic component of the magnetic flux generated by the energization of the stator winding 521.
　固定子巻線５２１における各導線５２３のスキュー角度を中央領域と端部領域とで相違させ、中央領域のスキュー角度θｓ１を端部領域のスキュー角度θｓ２よりも小さくすることで、コイルエンド５２６の縮小を図りつつも、固定子巻線５２１の巻線係数を大きくすることができる。言い換えれば、所望の巻線係数を確保しつつも、コイルエンド５２６の長さ、すなわち固定子コア５２２から軸方向にはみ出た部分の導線長を短くすることができる。これにより、回転電機５００の小型化を図りつつ、トルク向上を実現することができる。 The coil end 526 is reduced by making the skew angle of each conductor 523 in the stator winding 521 different between the central region and the end region and making the skew angle θs1 in the central region smaller than the skew angle θs2 in the end region. However, the winding coefficient of the stator winding 521 can be increased. In other words, the length of the coil end 526, that is, the conductor length of the portion protruding in the axial direction from the stator core 522 can be shortened while ensuring a desired winding coefficient. As a result, it is possible to improve the torque while reducing the size of the rotary electric machine 500.
　ここで、中央領域のスキュー角度θｓ１としての適正範囲を説明する。固定子巻線５２１において１磁極内に導線５２３がＸ本配置されている場合には、固定子巻線５２１の通電によりＸ次の高調波成分が生じることが考えられる。相数をＳ、対数をｍとする場合、Ｘ＝２×Ｓ×ｍである。本願開示者は、Ｘ次の高調波成分が、Ｘ－１次の高調波成分とＸ＋１次の高調波成分との合成波を構成する成分であるため、Ｘ－１次の高調波成分又はＸ＋１次の高調波成分の少なくともいずれかを低減することにより、Ｘ次の高調波成分を低減できることに着目した。この着目を踏まえ、本願開示者は、電気角で「３６０°／（Ｘ＋１）～３６０°／（Ｘ－１）」の角度範囲内にスキュー角度θｓ１を設定することにより、Ｘ次の高調波成分を低減できることを見出した。 Here, an appropriate range as the skew angle θs1 in the central region will be described. When X conductor wires 523 are arranged in one magnetic pole in the stator winding 521, it is conceivable that the Xth harmonic component is generated by energization of the stator winding 521. When the number of phases is S and the logarithm is m, X = 2 × S × m. According to the disclosure of the present application, since the Xth-order harmonic component is a component that constitutes a composite wave of the X-1st-order harmonic component and the X + 1st-order harmonic component, the X-1st-order harmonic component or the X + 1 It was noted that the Xth harmonic component can be reduced by reducing at least one of the following harmonic components. Based on this focus, the discloser of the present application sets the skew angle θs1 within the angle range of “360 ° / (X + 1) to 360 ° / (X-1)” in terms of the electric angle, thereby setting the X-th order harmonic component. It was found that can be reduced.
　例えばＳ＝３、ｍ＝２である場合、Ｘ＝１２次の高調波成分を低減すべく、「３６０°／１３～３６０°／１１」の角度範囲内にスキュー角度θｓ１を設定する。つまり、スキュー角度θｓ１は、２７．７°～３２．７°の範囲内の角度で設定されるとよい。 For example, when S = 3 and m = 2, the skew angle θs1 is set within the angle range of “360 ° / 13 to 360 ° / 11” in order to reduce the harmonic component of the X = 12th order. That is, the skew angle θs1 is preferably set at an angle within the range of 27.7 ° to 32.7 °.
　中央領域のスキュー角度θｓ１が上記のように設定されることにより、その中央領域において、ＮＳ交互の磁石磁束を積極的に鎖交させることができ、固定子巻線５２１の巻線係数を高くすることができる。 By setting the skew angle θs1 in the central region as described above, the magnet magnetic fluxes alternating with NS can be positively interlocked in the central region, and the winding coefficient of the stator winding 521 is increased. be able to.
　端部領域のスキュー角度θｓ２は、上述した中央領域のスキュー角度θｓ１よりも大きい角度である。この場合、スキュー角度θｓ２の角度範囲は、「θｓ１＜θｓ２＜９０°」である。 The skew angle θs2 in the end region is larger than the skew angle θs1 in the central region described above. In this case, the angle range of the skew angle θs2 is “θs1 <θs2 <90 °”.
　また、固定子巻線５２１において、内層側の導線５２３と外層側の導線５２３とは、各導線５２３の端部どうしの溶接や接着により繋げられているか、又は折り曲げにより繋げられているとよい。固定子巻線５２１では、軸方向両側の各コイルエンド５２６のうち一方側（すなわち軸方向一端側）にて各相巻線の端部が電力変換器（インバータ）にバスバー等を介して電気的に接続される構成となっている。そのためここでは、バスバー接続側のコイルエンド５２６とその反対側のコイルエンド５２６とを区別しつつ、コイルエンド５２６において各導線同士が繋げられている構成を説明する。 Further, in the stator winding 521, the conductor 523 on the inner layer side and the conductor 523 on the outer layer side may be connected by welding or adhesion between the ends of the conductors 523, or may be connected by bending. In the stator winding 521, the end of each phase winding is electrically connected to a power converter (inverter) via a bus bar or the like on one side (that is, one end side in the axial direction) of each coil end 526 on both sides in the axial direction. It is configured to be connected to. Therefore, here, the configuration in which the conductors are connected to each other at the coil end 526 will be described while distinguishing between the coil end 526 on the bus bar connection side and the coil end 526 on the opposite side.
　第１の構成としては、バスバー接続側のコイルエンド５２６において各導線５２３を溶接にて繋げるとともに、その反対側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げる構成とする。溶接以外の手段とは、例えば導線材の折り曲げによる繋ぎが考えられる。バスバー接続側のコイルエンド５２６では、各相巻線の端部にバスバーが溶接にて接続されることが想定される。そのため、それと同じコイルエンド５２６において各導線５２３を溶接にて繋げる構成とすることで、各溶接部を一連の工程で行わせることができ、作業効率の向上を図ることができる。 The first configuration is such that each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by means other than welding at the coil end 526 on the opposite side. As a means other than welding, for example, a connection by bending a conducting wire material can be considered. At the coil end 526 on the bus bar connection side, it is assumed that the bus bar is connected by welding to the end of each phase winding. Therefore, by connecting each conducting wire 523 by welding at the same coil end 526, each welded portion can be performed in a series of steps, and work efficiency can be improved.
　第２の構成としては、バスバー接続側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げるとともに、その反対側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成とする。この場合、仮にバスバー接続側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成であると、その溶接部とバスバーとの接触を避けるべく、バスバーとコイルエンド５２６との間の離間距離を十分に取る必要が生じるが、本構成とすることで、バスバーとコイルエンド５２６との間の離間距離を小さくすることができる。これにより、軸方向における固定子巻線５２１の長さ又はバスバーに関する規制を緩めることができる。 The second configuration is such that each conductor 523 is connected by means other than welding at the coil end 526 on the bus bar connection side, and each conductor 523 is connected by welding at the coil end 526 on the opposite side. In this case, if each conductor 523 is connected by welding at the coil end 526 on the bus bar connection side, the separation distance between the bus bar and the coil end 526 is sufficient to avoid contact between the welded portion and the bus bar. However, with this configuration, the separation distance between the bus bar and the coil end 526 can be reduced. Thereby, the regulation regarding the length of the stator winding 521 in the axial direction or the bus bar can be relaxed.
　第３の構成としては、軸方向両側のコイルエンド５２６において各導線５２３を溶接にて繋げる構成とする。この場合、溶接前に用意する導線材はいずれも短い線長のものでよく、曲げ工程の削減による作業効率の向上を図ることができる。 The third configuration is such that each conductor 523 is connected by welding at the coil ends 526 on both sides in the axial direction. In this case, all of the conductors prepared before welding may have a short wire length, and the work efficiency can be improved by reducing the bending process.
　第４の構成としては、軸方向両側のコイルエンド５２６において各導線５２３を溶接以外の手段にて繋げる構成とする。この場合、固定子巻線５２１において溶接が行われる部位を極力減らすことができ、溶接工程での絶縁剥離が生じることの懸念を低減できる。 As the fourth configuration, each conductor 523 is connected at the coil ends 526 on both sides in the axial direction by means other than welding. In this case, the portion of the stator winding 521 to be welded can be reduced as much as possible, and the concern that insulation peeling may occur in the welding process can be reduced.
　また、円環状の固定子巻線５２１を製作する工程において、平面状に整列された帯状巻線を製作し、その後にその帯状巻線を環状に成形するとよい。この場合、平面状の帯状巻線となっている状態で、必要に応じてコイルエンド５２６での導線同士の溶接を行うとよい。平面状の帯状巻線を環状に成形する際には、固定子コア５２２と同径の円柱治具を用いてその円柱治具に巻き付けるようにして帯状巻線を環状に成形するとよい。又は、帯状巻線を固定子コア５２２に直接巻き付けるようにしてよい。 Further, in the process of manufacturing the annular stator winding 521, it is preferable to manufacture the strip-shaped windings arranged in a plane shape, and then to form the strip-shaped windings in an annular shape. In this case, it is preferable to weld the conductors at the coil end 526 in a state where the winding is a flat strip. When forming a flat band-shaped winding in an annular shape, it is preferable to use a cylindrical jig having the same diameter as the stator core 522 and wind the strip-shaped winding around the cylindrical jig to form the band-shaped winding in an annular shape. Alternatively, the strip winding may be wound directly around the stator core 522.
　なお、固定子巻線５２１の構成を以下のように変更することも可能である。 It is also possible to change the configuration of the stator winding 521 as follows.
　例えば、図５４（ａ），（ｂ）に示す固定子巻線５２１において、中央領域及び端部領域のスキュー角度を同一とする構成であってもよい。 For example, in the stator winding 521 shown in FIGS. 54 (a) and 54 (b), the skew angles of the central region and the end region may be the same.
　また、図５４（ａ），（ｂ）に示す固定子巻線５２１において、周方向に隣り合う同相の導線５２３の端部同士を、軸方向に直交する向きに延びる渡り線部により接続する構成であってもよい。 Further, in the stator windings 521 shown in FIGS. 54 (a) and 54 (b), the ends of the in-phase conducting wires 523 adjacent to each other in the circumferential direction are connected by a crossover portion extending in a direction orthogonal to the axial direction. It may be.
　固定子巻線５２１の層数は、２×ｎ層（ｎは自然数）であればよく、固定子巻線５２１を、２層以外に４層、６層等にすることも可能である。 The number of layers of the stator winding 521 may be 2 × n layers (n is a natural number), and the stator winding 521 can be made into 4 layers, 6 layers, or the like in addition to the 2 layers.
　次に、電力変換ユニットであるインバータユニット５３０について説明する。ここでは、インバータユニット５３０の分解断面図である図５６及び図５７を併せ用いて、インバータユニット５３０の構成を説明する。なお、図５７では、図５６に示す各部材を２つのサブアセンブリとして示している。 Next, the inverter unit 530, which is a power conversion unit, will be described. Here, the configuration of the inverter unit 530 will be described with reference to FIGS. 56 and 57, which are exploded sectional views of the inverter unit 530. In FIG. 57, each member shown in FIG. 56 is shown as two subassemblies.
　インバータユニット５３０は、インバータハウジング５３１と、そのインバータハウジング５３１に組み付けられる複数の電気モジュール５３２と、それら各電気モジュール５３２を電気的に接続するバスバーモジュール５３３とを有している。 The inverter unit 530 has an inverter housing 531, a plurality of electric modules 532 assembled to the inverter housing 531 and a bus bar module 533 for electrically connecting each of the electric modules 532.
　インバータハウジング５３１は、円筒状をなす外壁部材５４１と、外周径が外壁部材５４１よりも小径の円筒状をなし、外壁部材５４１の径方向内側に配置される内壁部材５４２と、内壁部材５４２の軸方向一端側に固定されるボス形成部材５４３とを有している。これら各部材５４１～５４３は、導電性材料により構成されているとよく、例えば炭素繊維強化プラスチック（ＣＦＲＰ）により構成されている。インバータハウジング５３１は、外壁部材５４１と内壁部材５４２とが径方向内外に重ねて組み合わされ、かつ内壁部材５４２の軸方向一端側にボス形成部材５４３が組み付けられることで構成されている。その組み付け状態が図５７に示す状態である。 The inverter housing 531 has a cylindrical outer wall member 541, an inner wall member 542 having an outer peripheral diameter smaller than that of the outer wall member 541 and arranged inside the outer wall member 541 in the radial direction, and a shaft of the inner wall member 542. It has a boss forming member 543 fixed to one end side in the direction. Each of these members 541 to 543 is preferably made of a conductive material, for example, made of carbon fiber reinforced plastic (CFRP). The inverter housing 531 is configured such that the outer wall member 541 and the inner wall member 542 are overlapped and combined in the radial direction inside and outside, and the boss forming member 543 is assembled on one end side in the axial direction of the inner wall member 542. The assembled state is the state shown in FIG. 57.
　インバータハウジング５３１の外壁部材５４１の径方向外側には固定子コア５２２が固定される。これにより、固定子５２０とインバータユニット５３０とが一体化されるようになっている。 The stator core 522 is fixed to the radial outside of the outer wall member 541 of the inverter housing 531. As a result, the stator 520 and the inverter unit 530 are integrated.
　図５６に示すように、外壁部材５４１には、その内周面に複数の凹部５４１ａ，５４１ｂ，５４１ｃが形成されるとともに、内壁部材５４２には、その外周面に複数の凹部５４２ａ，５４２ｂ，５４２ｃが形成されている。そして、外壁部材５４１及び内壁部材５４２が互いに組み付けられることにより、これら両者の間には３つの中空部５４４ａ，５４４ｂ，５４４ｃが形成されている（図５７参照）。このうち、中央の中空部５４４ｂは、冷媒としての冷却水を流通させる冷却水通路５４５として用いられる。また、中空部５４４ｂ（冷却水通路５４５）を挟んで両側の中空部５４４ａ，５４４ｃにはシール材５４６が収容されている。このシール材５４６により、中空部５４４ｂ（冷却水通路５４５）が密閉化されている。冷却水通路５４５については後で詳しく説明する。 As shown in FIG. 56, the outer wall member 541 is formed with a plurality of recesses 541a, 541b, 541c on the inner peripheral surface thereof, and the inner wall member 542 is formed with a plurality of recesses 542a, 542b, 542c on the outer peripheral surface thereof. Is formed. Then, by assembling the outer wall member 541 and the inner wall member 542 to each other, three hollow portions 544a, 544b, and 544c are formed between them (see FIG. 57). Of these, the central hollow portion 544b is used as a cooling water passage 545 for circulating cooling water as a refrigerant. Further, the sealing material 546 is housed in the hollow portions 544a and 544c on both sides of the hollow portion 544b (cooling water passage 545). The hollow portion 544b (cooling water passage 545) is sealed by the sealing material 546. The cooling water passage 545 will be described in detail later.
　また、ボス形成部材５４３には、円板リング状の端板５４７と、その端板５４７からハウジング内部に向けて突出するボス部５４８とが設けられている。ボス部５４８は、中空筒状に設けられている。例えば図５１に示すように、ボス形成部材５４３は、軸方向における内壁部材５４２の第１端とそれに対向する回転軸５０１の突出側（すなわち車両内側）の第２端とのうち、第２端に固定されている。なお、図４５～図４７に示す車輪４００においては、インバータハウジング５３１（より詳しくはボス形成部材５４３の端板５４７）にベースプレート４０５が固定されるようになっている。 Further, the boss forming member 543 is provided with a disk ring-shaped end plate 547 and a boss portion 548 protruding from the end plate 547 toward the inside of the housing. The boss portion 548 is provided in a hollow tubular shape. For example, as shown in FIG. 51, the boss forming member 543 is the second end of the first end of the inner wall member 542 in the axial direction and the second end on the protruding side (that is, inside the vehicle) of the rotating shaft 501 facing the first end. It is fixed to. In the wheels 400 shown in FIGS. 45 to 47, the base plate 405 is fixed to the inverter housing 531 (more specifically, the end plate 547 of the boss forming member 543).
　インバータハウジング５３１は、軸心を中心として径方向に二重の周壁を有する構成となっており、その二重の周壁のうち外側の周壁が外壁部材５４１及び内壁部材５４２により形成され、内側の周壁がボス部５４８により形成されている。なお、以下の説明では、外壁部材５４１及び内壁部材５４２により形成された外側の周壁を「外側周壁ＷＡ１」、ボス部５４８により形成された内側の周壁を「内側周壁ＷＡ２」とも言う。 The inverter housing 531 has a configuration having a double peripheral wall in the radial direction about the axis, and the outer peripheral wall of the double peripheral wall is formed by the outer wall member 541 and the inner wall member 542, and the inner peripheral wall is formed. Is formed by the boss portion 548. In the following description, the outer peripheral wall formed by the outer wall member 541 and the inner wall member 542 is also referred to as "outer peripheral wall WA1", and the inner peripheral wall formed by the boss portion 548 is also referred to as "inner peripheral wall WA2".
　インバータハウジング５３１には、外側周壁ＷＡ１と内側周壁ＷＡ２との間に環状空間が形成されており、その環状空間内に、周方向に並べて複数の電気モジュール５３２が配置されている。電気モジュール５３２は、接着やビス締め等により内壁部材５４２の内周面に固定されている。本実施形態では、インバータハウジング５３１が「ハウジング部材」に相当し、電気モジュール５３２が「電気部品」に相当する。 In the inverter housing 531, an annular space is formed between the outer peripheral wall WA1 and the inner peripheral wall WA2, and a plurality of electric modules 532 are arranged side by side in the circumferential direction in the annular space. The electric module 532 is fixed to the inner peripheral surface of the inner wall member 542 by adhesion, screw tightening, or the like. In this embodiment, the inverter housing 531 corresponds to the "housing member" and the electric module 532 corresponds to the "electric component".
　内側周壁ＷＡ２（ボス部５４８）の内側には軸受５６０が収容されており、その軸受５６０により回転軸５０１が回転自在に支持されている。軸受５６０は、車輪中心部において車輪４００を回転可能に支えるハブベアリングである。軸受５６０は、回転子５１０や固定子５２０、インバータユニット５３０に対して軸方向に重複する位置に設けられている。本実施形態の回転電機５００では、回転子５１０において配向に伴い磁石ユニット５１２の薄型化が可能であること、固定子５２０においてスロットレス構造や扁平導線構造が採用されていることにより、磁気回路部の径方向の厚み寸法を縮小して、磁気回路部よりも径方向内側の中空空間を拡張することが可能となっている。これにより、径方向に積層された状態での磁気回路部やインバータユニット５３０、軸受５６０の配置が可能となっている。ボス部５４８は、その内側に軸受５６０を保持する軸受保持部となっている。 A bearing 560 is housed inside the inner peripheral wall WA2 (boss portion 548), and the rotating shaft 501 is rotatably supported by the bearing 560. The bearing 560 is a hub bearing that rotatably supports the wheel 400 at the center of the wheel. The bearing 560 is provided at a position where the rotor 510, the stator 520, and the inverter unit 530 overlap in the axial direction. In the rotary electric machine 500 of the present embodiment, the magnet unit 512 can be made thinner in accordance with the orientation of the rotor 510, and the stator 520 adopts a slotless structure or a flat lead wire structure. It is possible to expand the hollow space inside the magnetic circuit portion in the radial direction by reducing the thickness dimension in the radial direction of the magnet. This makes it possible to arrange the magnetic circuit unit, the inverter unit 530, and the bearing 560 in a state of being stacked in the radial direction. The boss portion 548 is a bearing holding portion that holds the bearing 560 inside the boss portion 548.
　軸受５６０は、例えばラジアル玉軸受であり、筒状をなす内輪５６１と、その内輪５６１よりも大径の筒状をなし内輪５６１の径方向外側に配置された外輪５６２と、それら内輪５６１及び外輪５６２の間に配置された複数の玉５６３とを有している。軸受５６０は、外輪５６２がボス形成部材５４３に組み付けられることでインバータハウジング５３１に固定されるとともに、内輪５６１が回転軸５０１に固定されている。これら内輪５６１、外輪５６２及び玉５６３は、いずれも炭素鋼等の金属材料よりなる。 The bearing 560 is, for example, a radial ball bearing, and has a tubular inner ring 561, an outer ring 562 having a diameter larger than that of the inner ring 561 and arranged radially outside the inner ring 561, and the inner ring 561 and the outer ring. It has a plurality of balls 563 arranged between 562. The bearing 560 is fixed to the inverter housing 531 by assembling the outer ring 562 to the boss forming member 543, and the inner ring 561 is fixed to the rotating shaft 501. The inner ring 561, the outer ring 562, and the ball 563 are all made of a metal material such as carbon steel.
　また、軸受５６０の内輪５６１は、回転軸５０１を収容する筒部５６１ａと、その筒部５６１ａの軸方向一端部から、軸方向に交差（直交）する向きに延びるフランジ５６１ｂとを有している。フランジ５６１ｂは、回転子キャリア５１１の端板５１４に内側から当接する部位であり、回転軸５０１に軸受５６０が組み付けられた状態では、回転軸５０１のフランジ５０２と内輪５６１のフランジ５６１ｂとにより挟まれた状態で、回転子キャリア５１１が保持されるようになっている。この場合、回転軸５０１のフランジ５０２及び内輪５６１のフランジ５６１ｂは、軸方向に対する交差の角度が互いに同じであり（本実施形態ではいずれも直角であり）、これら各フランジ５０２，５６１ｂの間に挟まれた状態で、回転子キャリア５１１が保持されている。 Further, the inner ring 561 of the bearing 560 has a tubular portion 561a for accommodating the rotating shaft 501 and a flange 561b extending in an axially intersecting (orthogonal) direction from one end in the axial direction of the tubular portion 561a. .. The flange 561b is a portion that comes into contact with the end plate 514 of the rotor carrier 511 from the inside, and is sandwiched between the flange 502 of the rotating shaft 501 and the flange 561b of the inner ring 561 when the bearing 560 is assembled to the rotating shaft 501. In this state, the rotor carrier 511 is held. In this case, the flange 502 of the rotating shaft 501 and the flange 561b of the inner ring 561 have the same angle of intersection with respect to the axial direction (both are right angles in the present embodiment), and are sandwiched between the flanges 502 and 561b. The rotor carrier 511 is held in this state.
　軸受５６０の内輪５６１により回転子キャリア５１１を内側から支える構成によれば、回転軸５０１に対する回転子キャリア５１１の角度を適正角度に保持でき、ひいては回転軸５０１に対する磁石ユニット５１２の平行度を良好に保つことができる。これにより、回転子キャリア５１１を径方向に拡張した構成にあっても、振動等に対する耐性を高めることができる。 According to the configuration in which the rotor carrier 511 is supported from the inside by the inner ring 561 of the bearing 560, the angle of the rotor carrier 511 with respect to the rotating shaft 501 can be maintained at an appropriate angle, and the parallelism of the magnet unit 512 with respect to the rotating shaft 501 is improved. Can be kept. As a result, resistance to vibration and the like can be increased even in a configuration in which the rotor carrier 511 is expanded in the radial direction.
　次に、インバータハウジング５３１内に収容される電気モジュール５３２について説明する。 Next, the electric module 532 housed in the inverter housing 531 will be described.
　複数の電気モジュール５３２は、電力変換器を構成する半導体スイッチング素子や平滑用コンデンサといった電気部品を、複数に分割して個々にモジュール化したものであり、その電気モジュール５３２には、パワー素子である半導体スイッチング素子を有するスイッチモジュール５３２Ａと、平滑用コンデンサを有するコンデンサモジュール５３２Ｂとが含まれている。 The plurality of electric modules 532 are obtained by dividing electric components such as semiconductor switching elements and smoothing capacitors constituting a power converter into a plurality of individual modules, and the electric module 532 is a power element. A switch module 532A having a semiconductor switching element and a capacitor module 532B having a smoothing capacitor are included.
　図４９及び図５０に示すように、内壁部材５４２の内周面には、電気モジュール５３２を取り付けるための平坦面を有する複数のスペーサ５４９が固定され、そのスペーサ５４９に電気モジュール５３２が取り付けられている。つまり、内壁部材５４２の内周面が曲面であるのに対し、電気モジュール５３２の取付面が平坦面であることから、スペーサ５４９により内壁部材５４２の内周面側に平坦面を形成し、その平坦面に電気モジュール５３２を固定する構成としている。 As shown in FIGS. 49 and 50, a plurality of spacers 549 having a flat surface for attaching the electric module 532 are fixed to the inner peripheral surface of the inner wall member 542, and the electric module 532 is attached to the spacer 549. There is. That is, since the inner peripheral surface of the inner wall member 542 is a curved surface, the mounting surface of the electric module 532 is a flat surface, so that the spacer 549 forms a flat surface on the inner peripheral surface side of the inner wall member 542. The electric module 532 is fixed to a flat surface.
　なお、内壁部材５４２と電気モジュール５３２との間にスペーサ５４９を介在させる構成は必須ではなく、内壁部材５４２の内周面を平坦面にする、又は電気モジュール５３２の取付面を曲面することにより内壁部材５４２に対して電気モジュール５３２を直接取り付けることも可能である。また、内壁部材５４２の内周面に対して非接触の状態で、電気モジュール５３２をインバータハウジング５３１に固定することも可能である。例えば、ボス形成部材５４３の端板５４７に対して電気モジュール５３２を固定する。スイッチモジュール５３２Ａを内壁部材５４２の内周面に接触状態で固定するとともに、コンデンサモジュール５３２Ｂを内壁部材５４２の内周面に非接触状態で固定することも可能である。 It should be noted that the configuration in which the spacer 549 is interposed between the inner wall member 542 and the electric module 532 is not essential, and the inner wall is made by flattening the inner peripheral surface of the inner wall member 542 or by making the mounting surface of the electric module 532 curved. It is also possible to attach the electric module 532 directly to the member 542. It is also possible to fix the electric module 532 to the inverter housing 531 in a state of non-contact with the inner peripheral surface of the inner wall member 542. For example, the electric module 532 is fixed to the end plate 547 of the boss forming member 543. It is also possible to fix the switch module 532A to the inner peripheral surface of the inner wall member 542 in a contact state, and to fix the capacitor module 532B to the inner peripheral surface of the inner wall member 542 in a non-contact state.
　なお、内壁部材５４２の内周面にスペーサ５４９が設けられる場合、外側周壁ＷＡ１及びスペーサ５４９が「筒状部」に相当する。また、スペーサ５４９が用いられない場合、外側周壁ＷＡ１が「筒状部」に相当する。 When the spacer 549 is provided on the inner peripheral surface of the inner wall member 542, the outer peripheral wall WA1 and the spacer 549 correspond to the "cylindrical portion". When the spacer 549 is not used, the outer peripheral wall WA1 corresponds to the "cylindrical portion".
　上述したとおりインバータハウジング５３１の外側周壁ＷＡ１には、冷媒としての冷却水を流通させる冷却水通路５４５が形成されており、その冷却水通路５４５を流れる冷却水により各電気モジュール５３２が冷却されるようになっている。なお、冷媒として、冷却水に代えて冷却用オイルを用いることも可能である。冷却水通路５４５は、外側周壁ＷＡ１に沿って環状に設けられており、冷却水通路５４５内を流れる冷却水は、各電気モジュール５３２を経由しながら上流側から下流側に流通する。本実施形態では、冷却水通路５４５が、径方向内外に各電気モジュール５３２に重なり、かつこれら各電気モジュール５３２を囲むように環状に設けられている。 As described above, the outer peripheral wall WA1 of the inverter housing 531 is formed with a cooling water passage 545 through which cooling water as a refrigerant flows, so that each electric module 532 is cooled by the cooling water flowing through the cooling water passage 545. It has become. It is also possible to use cooling oil as the refrigerant instead of the cooling water. The cooling water passage 545 is provided in an annular shape along the outer peripheral wall WA1, and the cooling water flowing in the cooling water passage 545 flows from the upstream side to the downstream side via each electric module 532. In the present embodiment, the cooling water passage 545 is provided in an annular shape so as to overlap each of the electric modules 532 in the radial direction and to surround each of the electric modules 532.
　内壁部材５４２には、冷却水通路５４５に冷却水を流入させる入口通路５７１と、冷却水通路５４５から冷却水を流出させる出口通路５７２とが設けられている。上述したように内壁部材５４２の内周面には複数の電気モジュール５３２が固定されており、かかる構成において、周方向に隣り合う電気モジュール間の間隔が１カ所だけ他よりも拡張され、その拡張された部分に、内壁部材５４２の一部が径方向内側に突出されて突出部５７３が形成されている。そして、その突出部５７３に、径方向に沿って横並びの状態で入口通路５７１及び出口通路５７２が設けられている。 The inner wall member 542 is provided with an inlet passage 571 for flowing cooling water into the cooling water passage 545 and an outlet passage 572 for discharging cooling water from the cooling water passage 545. As described above, a plurality of electric modules 532 are fixed to the inner peripheral surface of the inner wall member 542, and in such a configuration, the distance between the electric modules adjacent to each other in the circumferential direction is expanded by only one place, and the expansion thereof. A part of the inner wall member 542 is projected inward in the radial direction to form a protruding portion 573. The protruding portion 573 is provided with an inlet passage 571 and an outlet passage 572 in a state of being arranged side by side along the radial direction.
　インバータハウジング５３１での各電気モジュール５３２の配置の状態を図５８に示す。なお、図５８は、図５０と同一の縦断面図である。 FIG. 58 shows the arrangement state of each electric module 532 in the inverter housing 531. Note that FIG. 58 is the same vertical cross-sectional view as that of FIG. 50.
　図５８に示すように、各電気モジュール５３２は、周方向における電気モジュール同士の間隔を、第１間隔ＩＮＴ１又は第２間隔ＩＮＴ２として周方向に並べて配置されている。第２間隔ＩＮＴ２は、第１間隔ＩＮＴ１よりも広い間隔である。各間隔ＩＮＴ１，ＩＮＴ２は、例えば周方向に隣り合う２つ電気モジュール５３２の中心位置同士の間の距離である。この場合、突出部５７３を挟まずに周方向に隣り合う電気モジュール同士の間隔は第１間隔ＩＮＴ１となり、突出部５７３を挟んで周方向に隣り合う電気モジュール同士の間隔は第２間隔ＩＮＴ２となっている。つまり、周方向に隣り合う電気モジュール同士の間隔が一部で拡げられており、その拡げられた間隔（第２間隔ＩＮＴ２）の例えば中央となる部分に突出部５７３が設けられている。 As shown in FIG. 58, the electric modules 532 are arranged side by side in the circumferential direction with the distance between the electric modules in the circumferential direction as the first interval INT1 or the second interval INT2. The second interval INT2 is a wider interval than the first interval INT1. Each interval INT1 and INT2 is, for example, the distance between the center positions of two electric modules 532 adjacent to each other in the circumferential direction. In this case, the distance between the electric modules adjacent to each other in the circumferential direction without sandwiching the protrusion 573 is the first interval INT1, and the distance between the electric modules adjacent to each other in the circumferential direction across the protrusion 573 is the second interval INT2. ing. That is, the distance between the electric modules adjacent to each other in the circumferential direction is partially expanded, and the protruding portion 573 is provided at, for example, the central portion of the expanded distance (second interval INT2).
　各間隔ＩＮＴ１，ＩＮＴ２は、回転軸５０１を中心とする同一円上において、周方向に隣り合う２つ電気モジュール５３２の中心位置同士の間の円弧の距離であってもよい。又は、周方向における電気モジュール同士の間隔は、回転軸５０１を中心とする角度間隔θｉ１，θｉ２で定義されていてもよい（θｉ１＜θｉ２）。 Each interval INT1 and INT2 may be the distance of an arc between the center positions of two electric modules 532 adjacent to each other in the circumferential direction on the same circle centered on the rotation axis 501. Alternatively, the distance between the electric modules in the circumferential direction may be defined by the angular distances θi1 and θi2 centered on the rotation axis 501 (θi1 <θi2).
　なお、図５８に示す構成では、第１間隔ＩＮＴ１で並ぶ各電気モジュール５３２が周方向に互いに離間する状態（非接触の状態）で配置されているが、この構成に代えて、それら各電気モジュール５３２が周方向に互いに接触する状態で配置されていてもよい。 In the configuration shown in FIG. 58, the electric modules 532 arranged at the first interval INT1 are arranged in a state of being separated from each other in the circumferential direction (non-contact state), but instead of this configuration, the electric modules are arranged. The 532s may be arranged so as to be in contact with each other in the circumferential direction.
　図４８に示すように、ボス形成部材５４３の端板５４７には、入口通路５７１及び出口通路５７２の通路端部が形成された水路ポート５７４が設けられている。入口通路５７１及び出口通路５７２には、冷却水を循環させる循環経路５７５が接続されるようになっている。循環経路５７５は冷却水配管よりなる。循環経路５７５にはポンプ５７６と放熱装置５７７とが設けられ、ポンプ５７６の駆動に伴い冷却水通路５４５と循環経路５７５とを通じて冷却水が循環する。ポンプ５７６は電動ポンプである。放熱装置５７７は、例えば冷却水の熱を大気放出するラジエータである。 As shown in FIG. 48, the end plate 547 of the boss forming member 543 is provided with a water channel port 574 in which the passage ends of the inlet passage 571 and the outlet passage 57 2 are formed. A circulation path 575 for circulating cooling water is connected to the inlet passage 571 and the outlet passage 572. The circulation path 575 comprises a cooling water pipe. A pump 576 and a heat radiating device 575 are provided in the circulation path 575, and the cooling water circulates through the cooling water passage 545 and the circulation path 575 as the pump 576 is driven. Pump 576 is an electric pump. The heat radiating device 577 is, for example, a radiator that releases the heat of the cooling water to the atmosphere.
　図５０に示すように、外側周壁ＷＡ１の外側には固定子５２０が配置され、内側には電気モジュール５３２が配置されていることから、外側周壁ＷＡ１に対しては、その外側から固定子５２０の熱が伝わるとともに、内側から電気モジュール５３２の熱が伝わることになる。この場合、冷却水通路５４５を流れる冷却水により固定子５２０と電気モジュール５３２とを同時に冷やすことが可能となっており、回転電機５００における発熱部品の熱を効率良く放出することができる。 As shown in FIG. 50, since the stator 520 is arranged on the outside of the outer peripheral wall WA1 and the electric module 532 is arranged on the inner side, the stator 520 is arranged from the outside of the outer peripheral wall WA1. As the heat is transferred, the heat of the electric module 532 is transferred from the inside. 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 parts in the rotary electric machine 500 can be efficiently released.
　ここで、電力変換器の電気的構成を図５９を用いて説明する。 Here, the electrical configuration of the power converter will be described with reference to FIG. 59.
　図５９に示すように、固定子巻線５２１はＵ相巻線、Ｖ相巻線及びＷ相巻線よりなり、その固定子巻線５２１にインバータ６００が接続されている。インバータ６００は、相数と同じ数の上下アームを有するフルブリッジ回路により構成されており、相ごとに上アームスイッチ６０１及び下アームスイッチ６０２からなる直列接続体が設けられている。これら各スイッチ６０１，６０２は駆動回路６０３によりそれぞれオンオフされ、そのオンオフにより各相の巻線が通電される。各スイッチ６０１，６０２は、例えばＭＯＳＦＥＴやＩＧＢＴ等の半導体スイッチング素子により構成されている。また、各相の上下アームには、スイッチ６０１，６０２の直列接続体に並列に、スイッチング時に要する電荷を各スイッチ６０１，６０２に供給する電荷供給用のコンデンサ６０４が接続されている。 As shown in FIG. 59, the stator winding 521 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 600 is connected to the stator winding 521. 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 including an upper arm switch 601 and a lower arm switch 602 is provided for each phase. Each of these switches 601, 602 is turned on and off by the drive circuit 603, and the windings of each phase are energized by the on / off. Each switch 601, 602 is composed of a semiconductor switching element such as a MOSFET or an IGBT. Further, the upper and lower arms of each phase are connected in parallel with the series connection body of the switches 601, 602 to a charge supply capacitor 604 for supplying the charges required for switching to the switches 601, 602.
　制御装置６０７は、ＣＰＵや各種メモリからなるマイコンを備えており、回転電機５００における各種の検出情報や、力行駆動及び発電の要求に基づいて、各スイッチ６０１，６０２のオンオフにより通電制御を実施する。制御装置６０７は、例えば所定のスイッチング周波数（キャリア周波数）でのＰＷＭ制御や、矩形波制御により各スイッチ６０１，６０２のオンオフ制御を実施する。制御装置６０７は、回転電機５００に内蔵された内蔵制御装置であってもよいし、回転電機５００の外部に設けられた外部制御装置であってもよい。 The control device 607 includes a microcomputer composed of a CPU and various memories, and performs energization control by turning on / off the switches 601 and 602 based on various detection information in the rotary electric machine 500 and requests for power running and power generation. .. The control device 607 performs on / off control of each switch 601 and 602 by, for example, PWM control at a predetermined switching frequency (carrier frequency) and rectangular wave control. The control device 607 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.
　ちなみに、本実施形態の回転電機５００では、固定子５２０のインダクタンス低減が図られていることから電気的時定数が小さくなっており、その電気的時定数が小さい状況下では、スイッチング周波数（キャリア周波数）を高くし、かつスイッチング速度を速くすることが望ましい。この点において、各相のスイッチ６０１，６０２の直列接続体に並列に電荷供給用のコンデンサ６０４が接続されていることで配線インダクタンスが低くなり、スイッチング速度を速くした構成であっても適正なサージ対策が可能となる。 By the way, in the rotary electric machine 500 of the present embodiment, the electric time constant is small because the inductance of the stator 520 is reduced, and in a situation where the electric time constant is small, the switching frequency (carrier frequency). ) Is increased and the switching speed is increased. In this respect, since the charge supply capacitor 604 is connected in parallel to the series connection of the switches 601, 602 of each phase, the wiring inductance becomes low, and an appropriate surge even in a configuration in which the switching speed is increased. Countermeasures are possible.
　インバータ６００の高電位側端子は直流電源６０５の正極端子に接続され、低電位側端子は直流電源６０５の負極端子（グランド）に接続されている。また、インバータ６００の高電位側端子及び低電位側端子には、直流電源６０５に並列に平滑用のコンデンサ６０６が接続されている。 The high potential side terminal of the inverter 600 is connected to the positive electrode terminal of the DC power supply 605, and the low potential side terminal is connected to the negative electrode terminal (ground) of the DC power supply 605. Further, 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.
　スイッチモジュール５３２Ａは、発熱部品として各スイッチ６０１，６０２（半導体スイッチング素子）や、駆動回路６０３（具体的には駆動回路６０３を構成する電気素子）、電荷供給用のコンデンサ６０４を有している。また、コンデンサモジュール５３２Ｂは、発熱部品として平滑用のコンデンサ６０６を有している。スイッチモジュール５３２Ａの具体的な構成例を図６０に示す。 The switch module 532A has each switch 601, 602 (semiconductor switching element), a drive circuit 603 (specifically, an electric element constituting the drive circuit 603), and a capacitor 604 for electric charge supply as heat generating parts. Further, the capacitor module 532B has a smoothing capacitor 606 as a heat generating component. A specific configuration example of the switch module 532A is shown in FIG.
　図６０に示すように、スイッチモジュール５３２Ａは、収容ケースとしてのモジュールケース６１１を有するとともに、そのモジュールケース６１１内に収容された１相分のスイッチ６０１，６０２と、駆動回路６０３と、電荷供給用のコンデンサ６０４とを有している。なお、駆動回路６０３は、専用ＩＣ又は回路基板として構成されてスイッチモジュール５３２Ａに設けられている。 As shown in FIG. 60, the switch module 532A has a module case 611 as a storage case, and one phase of switches 601, 602 housed in the module case 611, a drive circuit 603, and a charge supply. It has a capacitor 604 and. The drive circuit 603 is configured as a dedicated IC or a circuit board and is provided in the switch module 532A.
　モジュールケース６１１は、例えば樹脂等の絶縁材料よりなり、その側面がインバータユニット５３０の内壁部材５４２の内周面に当接した状態で、外側周壁ＷＡ１に固定されている。モジュールケース６１１内には樹脂等のモールド材が充填されている。モジュールケース６１１内において、スイッチ６０１，６０２と駆動回路６０３、スイッチ６０１，６０２とコンデンサ６０４は、それぞれ配線６１２により電気的に接続されている。なお詳しくは、スイッチモジュール５３２Ａは、スペーサ５４９を介して外側周壁ＷＡ１に取り付けられるが、スペーサ５４９の図示を省略している。 The module case 611 is made of an insulating material such as resin, and is fixed to the outer peripheral wall WA1 with its side surface in contact with the inner peripheral surface of the inner wall member 542 of the inverter unit 530. The module case 611 is filled with a molding material such as resin. In the module case 611, the switches 601, 602 and the drive circuit 603, and the switches 601, 602 and the capacitor 604 are electrically connected by wiring 612, respectively. More specifically, the switch module 532A is attached to the outer peripheral wall WA1 via the spacer 549, but the spacer 549 is not shown.
　スイッチモジュール５３２Ａが外側周壁ＷＡ１に固定された状態では、スイッチモジュール５３２Ａにおいて外側周壁ＷＡ１に近い側、すなわち冷却水通路５４５に近い側ほど冷却性が高いため、その冷却性に応じてスイッチ６０１，６０２、駆動回路６０３及びコンデンサ６０４の配列の順序が定められている。具体的には、発熱量を比べると、大きいものからスイッチ６０１，６０２、コンデンサ６０４、駆動回路６０３の順序となるため、その発熱量の大きさ順序に合わせて、外側周壁ＷＡ１に近い側からスイッチ６０１，６０２、コンデンサ６０４、駆動回路６０３の順序でこれらが配置されている。なお、スイッチモジュール５３２Ａの接触面は、内壁部材５４２の内周面における接触可能面より小さいとよい。 When the switch module 532A is fixed to the outer peripheral wall WA1, the side of the switch module 532A closer to the outer peripheral wall WA1, that is, the side closer to the cooling water passage 545 has higher cooling performance. , The order of arrangement of the drive circuit 603 and the capacitor 604 is defined. Specifically, when comparing the calorific value, the order is from the largest to the switches 601, 602, the capacitor 604, and the drive circuit 603. Therefore, the switches are switched from the side closer to the outer peripheral wall WA1 according to the order of the calorific value. These are arranged in the order of 601, 602, the capacitor 604, and the drive circuit 603. The contact surface of the switch module 532A is preferably smaller than the contactable surface on the inner peripheral surface of the inner wall member 542.
　なお、コンデンサモジュール５３２Ｂについては詳細な図示を省略するが、コンデンサモジュール５３２Ｂでは、スイッチモジュール５３２Ａと同じ形状及び大きさのモジュールケース内に、コンデンサ６０６が収容されて構成されている。コンデンサモジュール５３２Ｂは、スイッチモジュール５３２Ａと同様に、モジュールケース６１１の側面がインバータハウジング５３１の内壁部材５４２の内周面に当接した状態で、外側周壁ＷＡ１に固定されている。 Although detailed illustration of the capacitor module 532B is omitted, the capacitor module 532B is configured such that the capacitor 606 is housed in a module case having the same shape and size as the switch module 532A. Similar to the switch module 532A, the capacitor module 532B is fixed to the outer peripheral wall WA1 in a state where the side surface of the module case 611 is in contact with the inner peripheral surface of the inner wall member 542 of the inverter housing 531.
　スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂは、インバータハウジング５３１の外側周壁ＷＡ１の径方向内側において必ずしも同心円上に並んでいなくてもよい。例えばスイッチモジュール５３２Ａがコンデンサモジュール５３２Ｂよりも径方向内側に配置される構成、又はその逆となるように配置される構成であってもよい。 The switch module 532A and the capacitor module 532B do not necessarily have to be arranged concentrically on the radial inside of the outer peripheral wall WA1 of the inverter housing 531. For example, the switch module 532A may be arranged radially inside the capacitor module 532B, or vice versa.
　回転電機５００の駆動時には、スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂと冷却水通路５４５との間で、外側周壁ＷＡ１の内壁部材５４２を介して熱交換が行われる。これにより、スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂにおける冷却が行われる。 When the rotary electric machine 500 is driven, heat exchange is performed between the switch module 532A and the condenser module 532B and the cooling water passage 545 via the inner wall member 542 of the outer peripheral wall WA1. As a result, the switch module 532A and the capacitor module 532B are cooled.
　各電気モジュール５３２は、その内部に冷却水を引き込み、モジュール内部にて冷却水による冷却を行わせる構成であってもよい。ここでは、スイッチモジュール５３２Ａの水冷構造を、図６１（ａ），（ｂ）を用いて説明する。図６１（ａ）は、外側周壁ＷＡ１を横切る方向で、スイッチモジュール５３２Ａの断面構造を示す縦断面図であり、図６１（ｂ）は、図６１（ａ）の６１Ｂ－６１Ｂ線断面図である。 Each electric module 532 may have a configuration in which cooling water is drawn into the module and the cooling water is used to cool the inside of the module. Here, the water cooling structure of the switch module 532A will be described with reference to FIGS. 61 (a) and 61 (b). FIG. 61 (a) is a vertical sectional view showing a cross-sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1, and FIG. 61 (b) is a sectional view taken along line 61B-61B of FIG. 61 (a). ..
　図６１（ａ），（ｂ）に示すように、スイッチモジュール５３２Ａは、図６０と同様にモジュールケース６１１と、１相分のスイッチ６０１，６０２と、駆動回路６０３と、コンデンサ６０４とを有することに加え、一対の配管部６２１，６２２及び冷却器６２３からなる冷却装置を有している。冷却装置において、一対の配管部６２１，６２２は、外側周壁ＷＡ１の冷却水通路５４５から冷却器６２３へ冷却水を流入させる流入側の配管部６２１と、冷却器６２３から冷却水通路５４５へ冷却水を流出させる流出側の配管部６２２とからなる。冷却器６２３は、冷却対象物に応じて設けられ、冷却装置では１段又は複数段の冷却器６２３が用いられる。図６１（ａ），（ｂ）の構成では、冷却水通路５４５から離れる方向、すなわちインバータユニット５３０の径方向に、互いに離間した状態で２段の冷却器６２３が設けられており、一対の配管部６２１，６２２を介してそれら各冷却器６２３に対して冷却水が供給される。冷却器６２３は、例えば内部が空洞になっている。ただし、冷却器６２３の内部にインナフィンが設けられていてもよい。 As shown in FIGS. 61 (a) and 61 (b), the switch module 532A has a module case 611, one- phase switches 601, 602, a drive circuit 603, and a capacitor 604, as in FIG. 60. In addition, it has a cooling device including a pair of piping portions 621 and 622 and a cooler 623. In the cooling device, the pair of piping portions 621 and 622 are the piping portion 621 on the inflow side for flowing the cooling water from the cooling water passage 545 of the outer peripheral wall WA1 to the cooler 623, and the cooling water from the cooler 623 to the cooling water passage 545. It is composed of a piping portion 622 on the outflow side that allows the outflow. The cooler 623 is provided according to the object to be cooled, and a one-stage or a plurality of stages of the cooler 623 is used in the cooling device. In the configurations of FIGS. 61 (a) and 61 (b), two-stage coolers 623 are provided in a direction away from the cooling water passage 545, that is, in the radial direction of the inverter unit 530, in a state of being separated from each other, and a pair of pipes. Cooling water is supplied to each of the coolers 623 via the sections 621 and 622. The cooler 623 has, for example, a hollow inside. However, an inner fin may be provided inside the cooler 623.
　２段の冷却器６２３を備える構成では、（１）１段目の冷却器６２３の外側周壁ＷＡ１側、（２）１段目及び２段目の冷却器６２３の間、（３）２段目の冷却器６２３の反外側周壁側が、それぞれ冷却対象の電気部品を配置する場所であり、これら各場所は、冷却性能の高いものから順から（２）、（１）、（３）となっている。つまり、２つの冷却器６２３に挟まれた場所が最も冷却性能が高く、いずれか１つの冷却器６２３に隣接する場所では、外側周壁ＷＡ１（冷却水通路５４５）に近い方が冷却性能が高くなっている。これを加味し、図６１（ａ），（ｂ）に示す構成では、スイッチ６０１，６０２が、（２）１段目及び２段目の冷却器６２３の間に配置され、コンデンサ６０４が、（１）１段目の冷却器６２３の外側周壁ＷＡ１側に配置され、駆動回路６０３が、（３）２段目の冷却器６２３の反外側周壁側に配置されている。なお、図示しないが、駆動回路６０３とコンデンサ６０４とが逆の配置であってもよい。 In the configuration including the two-stage cooler 623, (1) the outer peripheral wall WA1 side of the first-stage cooler 623, (2) between the first-stage and second-stage coolers 623, and (3) the second stage. The opposite outer peripheral wall side of the cooler 623 is a place where the electric parts to be cooled are arranged, and each of these places is (2), (1), (3) in order from the one having the highest cooling performance. There is. That is, the place sandwiched between the two coolers 623 has the highest cooling performance, and in the place adjacent to any one of the coolers 623, the place closer to the outer peripheral wall WA1 (cooling water passage 545) has higher cooling performance. ing. Taking this into consideration, in the configurations shown in FIGS. 61 (a) and 61 (b), the switches 601, 602 are arranged between (2) the first-stage and second-stage coolers 623, and the condenser 604 is (2). 1) The drive circuit 603 is arranged on the outer peripheral wall WA1 side of the first-stage cooler 623, and the drive circuit 603 is arranged on the anti-outer peripheral wall side of the second-stage cooler 623. Although not shown, the drive circuit 603 and the capacitor 604 may be arranged in reverse.
　いずれの場合であってもモジュールケース６１１内において、スイッチ６０１，６０２と駆動回路６０３、スイッチ６０１，６０２とコンデンサ６０４は、それぞれ配線６１２により電気的に接続されている。また、スイッチ６０１，６０２が駆動回路６０３とコンデンサ６０４との間に位置するため、スイッチ６０１，６０２から駆動回路６０３に向かって延びる配線６１２と、スイッチ６０１，６０２からコンデンサ６０４に向かって延びる配線６１２は互いに逆方向に延びる関係である。 In any case, in the module case 611, the switches 601, 602 and the drive circuit 603, and the switches 601, 602 and the capacitor 604 are electrically connected by wiring 612, respectively. Further, since the switches 601, 602 are located between the drive circuit 603 and the capacitor 604, the wiring 612 extending from the switches 601, 602 toward the drive circuit 603 and the wiring 612 extending from the switches 601, 602 toward the capacitor 604 Is a relationship that extends in opposite directions.
　図６１（ｂ）に示すように、一対の配管部６２１，６２２は、周方向、すなわち冷却水通路５４５の上流側及び下流側に並べて配置されており、上流側に位置する流入側の配管部６２１から冷却器６２３に冷却水が流入され、その後、下流側に位置する流出側の配管部６２２から冷却水が流出される。なお、冷却装置への冷却水の流入を促すべく、冷却水通路５４５には、周方向に見て、流入側の配管部６２１と流出側の配管部６２１との間となる位置に、冷却水の流れを規制する規制部６２４が設けられているとよい。規制部６２４は、冷却水通路５４５を遮断する遮断部、又は冷却水通路５４５の通路面積を小さくする絞り部であるとよい。 As shown in FIG. 61B, the pair of piping portions 621 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 the piping portions on the inflow side located on the upstream side. Cooling water flows into the cooler 623 from 621, and then the cooling water flows out from the outflow side piping portion 622 located on the downstream side. In order to promote the inflow of the cooling water into the cooling device, the cooling water is provided in the cooling water passage 545 at a position between the inflow side piping portion 621 and the outflow side piping portion 621 when viewed in the circumferential direction. It is preferable that a regulation unit 624 is provided to regulate the flow of the water. The regulating portion 624 may be a blocking portion that shuts off the cooling water passage 545 or a throttle portion that reduces the passage area of the cooling water passage 545.
　図６２には、スイッチモジュール５３２Ａの別の冷却構造を示す。図６２（ａ）は、外側周壁ＷＡ１を横切る方向で、スイッチモジュール５３２Ａの断面構造を示す縦断面図であり、図６２（ｂ）は、図６２（ａ）の６２Ｂ－６２Ｂ線断面図である。 FIG. 62 shows another cooling structure of the switch module 532A. 62 (a) is a vertical sectional view showing a cross-sectional structure of the switch module 532A in a direction crossing the outer peripheral wall WA1, and FIG. 62 (b) is a sectional view taken along line 62B-62B of FIG. 62 (a). ..
　図６２（ａ），（ｂ）の構成では、上述した図６１（ａ），（ｂ）の構成との相違点として、冷却装置における一対の配管部６２１，６２２の配置が異なっており、一対の配管部６２１，６２２が軸方向に並べて配置されている。また、図６２（ｃ）に示すように、冷却水通路５４５は、流入側の配管部６２１に連通される通路部分と、流出側の配管部６２２に連通される通路部分とが軸方向に分離して設けられ、それら各通路部分が各配管部６２１，６２２及び各冷却器６２３を通じて連通されている。 The configurations of FIGS. 62 (a) and 62 (b) differ from the configurations of FIGS. 61 (a) and 61 (b) described above in that the pair of piping portions 621 and 622 in the cooling device are arranged differently. The piping portions 621 and 622 of the above are arranged side by side in the axial direction. Further, as shown in FIG. 62 (c), in the cooling water passage 545, the passage portion communicating with the inflow side piping portion 621 and the passage portion communicating with the outflow side piping portion 622 are separated in the axial direction. Each of these passage portions communicates with each other through each piping portion 621, 622 and each cooler 623.
　その他に、スイッチモジュール５３２Ａとして、次の構成を用いることも可能である。 In addition, the following configuration can be used as the switch module 532A.
　図６３（ａ）に示す構成では、図６１（ａ）の構成と比べて、冷却器６２３が２段から１段に変更されている。この場合、モジュールケース６１１内において冷却性能の最も高い場所が図６１（ａ）とは異なっており、冷却器６２３の径方向両側（図の左右方向両側）のうち外側周壁ＷＡ１側の場所が最も冷却性能が高く、次いで、冷却器６２３の反外側周壁側の場所、冷却器６２３から離れた場所の順に冷却性能が低くなっている。これを加味し、図６３（ａ）に示す構成では、スイッチ６０１，６０２が、冷却器６２３の径方向両側（図の左右方向両側）のうち外側周壁ＷＡ１側の場所に配置され、コンデンサ６０４が、冷却器６２３の反外側周壁側の場所に配置され、駆動回路６０３が、冷却器６２３から離れた場所に配置されている。 In the configuration shown in FIG. 63 (a), the cooler 623 is changed from two stages to one stage as compared with the configuration shown in FIG. 61 (a). In this case, the location with the highest cooling performance in the module case 611 is different from that in FIG. 61 (a), and the location on the outer peripheral wall WA1 side of the radial sides of the cooler 623 (both sides in the left-right direction in the figure) is the highest. The cooling performance is high, and then the cooling performance is lowered in the order of the place on the opposite outer peripheral wall side of the cooler 623 and the place away from the cooler 623. Taking this into consideration, in the configuration shown in FIG. 63 (a), the switches 601, 602 are arranged on the outer peripheral wall WA1 side of the radial sides of the cooler 623 (both sides in the left-right direction in the figure), and the condenser 604 is installed. , The drive circuit 603 is arranged at a place on the opposite outer peripheral wall side of the cooler 623, and is arranged at a place away from the cooler 623.
　また、スイッチモジュール５３２Ａにおいて、モジュールケース６１１内に１相分のスイッチ６０１，６０２と、駆動回路６０３と、コンデンサ６０４とを収容する構成を変更することも可能である。例えば、モジュールケース６１１内に１相分のスイッチ６０１，６０２と、駆動回路６０３及びコンデンサ６０４のいずれ一方とを収容する構成としてもよい。 Further, in the switch module 532A, it is possible to change the configuration in which the switches 601, 602 for one phase, the drive circuit 603, and the capacitor 604 are housed in the module case 611. For example, the module case 611 may accommodate one of the switches 601, 602 for one phase, the drive circuit 603, and the capacitor 604.
　図６３（ｂ）では、モジュールケース６１１内に、一対の配管部６２１，６２２と２段の冷却器６２３とを設けるとともに、スイッチ６０１，６０２を、１段目及び２段目の冷却器６２３の間に配置し、コンデンサ６０４又は駆動回路６０３を、１段目の冷却器６２３の外側周壁ＷＡ１側に配置する構成としている。また、スイッチ６０１，６０２と駆動回路６０３とを一体化して半導体モジュールとし、その半導体モジュールとコンデンサ６０４とを、モジュールケース６１１内に収容する構成とすることも可能である。 In FIG. 63 (b), a pair of piping portions 621 and 622 and a two-stage cooler 623 are provided in the module case 611, and switches 601, 602 are installed in the first-stage and second-stage coolers 623. The capacitor 604 or the drive circuit 603 is arranged between them, and is arranged on the outer peripheral wall WA1 side of the first stage cooler 623. Further, it is also possible to integrate the switches 601, 602 and the drive circuit 603 into a semiconductor module, and to accommodate the semiconductor module and the capacitor 604 in the module case 611.
　なお、図６３（ｂ）では、スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に配置される冷却器６２３のうち少なくとも一方の冷却器６２３においてスイッチ６０１，６０２とは逆側にコンデンサが配置されているとよい。すなわち、１段目の冷却器６２３の外側周壁ＷＡ１側と、２段目の冷却器６２３の反周壁側とのうち一方にのみコンデンサ６０４を配置する構成、又は両方にコンデンサ６０４を配置する構成が可能である。 In FIG. 63 (b), in the switch module 532A, the condenser is arranged on the opposite side of the switches 601, 602 in at least one of the coolers 623 arranged on both sides of the switches 601, 602. It should be done. That is, there is a configuration in which the condenser 604 is arranged only on one of the outer peripheral wall WA1 side of the first-stage cooler 623 and the opposite peripheral wall side of the second-stage cooler 623, or a configuration in which the condenser 604 is arranged on both sides. It is possible.
　本実施形態では、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとのうちスイッチモジュール５３２Ａのみについて、冷却水通路５４５からモジュール内部に冷却水を引き込む構成としている。ただし、その構成を変更し、両方のモジュール５３２Ａ，５３２Ｂに、冷却水通路５４５から冷却水を引き込む構成としてもよい。 In this embodiment, of the switch module 532A and the condenser module 532B, only the switch module 532A is configured to draw cooling water from the cooling water passage 545 into the module. However, the configuration may be changed so that cooling water is drawn into both modules 532A and 532B from the cooling water passage 545.
　また、各電気モジュール５３２の外面に冷却水を直接当てる状態にして、各電気モジュール５３２を冷却する構成とすることも可能である。例えば、図６４に示すように、外側周壁ＷＡ１に電気モジュール５３２を埋め込むことで、電気モジュール５３２の外面に冷却水を当てる構成とする。この場合、電気モジュール５３２の一部を冷却水通路５４５内に浸漬させる構成や、冷却水通路５４５を図５８等の構成よりも径方向に拡張して電気モジュール５３２の全てを冷却水通路５４５内に浸漬させる構成が考えられる。冷却水通路５４５内に電気モジュール５３２を浸漬させる場合、浸漬されるモジュールケース６１１（モジュールケース６１１の浸漬部分）にフィンを設けると、冷却性能を更に向上させることができる。 It is also possible to cool each electric module 532 by directly applying cooling water to the outer surface of each electric module 532. For example, as shown in FIG. 64, by embedding the electric module 532 in the outer peripheral wall WA1, the cooling water is applied to the outer surface of the electric module 532. In this case, a part of the electric module 532 is immersed in the cooling water passage 545, or the cooling water passage 545 is expanded in the radial direction from the configuration shown in FIG. It is conceivable to immerse it in. When the electric module 532 is immersed in the cooling water passage 545, the cooling performance can be further improved by providing fins in the module case 611 (the immersed portion of the module case 611) to be immersed.
　また、電気モジュール５３２には、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとが含まれ、それら両者を比べた場合に発熱量に差異がある。この点を考慮して、インバータハウジング５３１における各電気モジュール５３２の配置を工夫することも可能である。 Further, the electric module 532 includes a switch module 532A and a capacitor module 532B, and there is a difference in the amount of heat generated when both of them are compared. In consideration of this point, it is possible to devise the arrangement of each electric module 532 in the inverter housing 531.
　例えば、図６５に示すように、複数個のスイッチモジュール５３２Ａを、分散させず周方向に並べ、かつ冷却水通路５４５の上流側、すなわち入口通路５７１に近い側に配置する。この場合、入口通路５７１から流入した冷却水は、先ずは３つのスイッチモジュール５３２Ａの冷却に用いられ、その後に各コンデンサモジュール５３２Ｂの冷却に用いられる。なお、図６５では、先の図６２（ａ），（ｂ）のように一対の配管部６２１，６２２が軸方向に並べて配置されているが、これに限らず、先の図６１（ａ），（ｂ）のように一対の配管部６２１，６２２が周方向に並べて配置されていてもよい。 For example, as shown in FIG. 65, a plurality of switch modules 532A are arranged in the circumferential direction without being dispersed, and arranged on the upstream side of the cooling water passage 545, that is, on the side close to the inlet passage 571. In this case, the cooling water flowing in from the inlet passage 571 is first used for cooling the three switch modules 532A, and then used for cooling each capacitor module 532B. In FIG. 65, the pair of piping portions 621 and 622 are arranged side by side in the axial direction as shown in FIGS. 62 (a) and 62 (b), but the present invention is not limited to this, and FIG. 61 (a) above is not limited to this. , (B), a pair of piping portions 621 and 622 may be arranged side by side in the circumferential direction.
　次に、各電気モジュール５３２及びバスバーモジュール５３３における電気的な接続に関する構成を説明する。図６６は、図４９の６６－６６線断面図であり、図６７は、図４９の６７－６７線断面図である。図６８は、バスバーモジュール５３３を単体で示す斜視図である。ここではこれら各図を併せ用いて、各電気モジュール５３２及びバスバーモジュール５３３の電気接続に関する構成を説明する。 Next, the configuration related to the electrical connection in each electric module 532 and the bus bar module 533 will be described. FIG. 66 is a cross-sectional view taken along the line 66-66 of FIG. 49, and FIG. 67 is a cross-sectional view taken along the line 67-67 of FIG. FIG. 68 is a perspective view showing the bus bar module 533 as a single unit. Here, the configuration related to the electrical connection of each electric module 532 and the bus bar module 533 will be described with reference to each of these figures.
　図６６に示すように、インバータハウジング５３１には、内壁部材５４２に設けられた突出部５７３（すなわち、冷却水通路５４５に通じる入口通路５７１及び出口通路５７２が設けられた突出部５７３）の周方向に隣となる位置に、３つのスイッチモジュール５３２Ａが周方向に並べて配置されるとともに、さらにその隣に、６つのコンデンサモジュール５３２Ｂが周方向に並べて配置されている。その概要として、インバータハウジング５３１では、外側周壁ＷＡ１の内側が周方向に１０個（すなわち、モジュール数＋１）の領域に等分に分けられ、そのうち９つの領域にそれぞれ電気モジュール５３２が１つずつ配置されるとともに、残り１つの領域に突出部５７３が設けられている。３つのスイッチモジュール５３２Ａは、Ｕ相用モジュール、Ｖ相用モジュール、Ｗ相用モジュールである。 As shown in FIG. 66, the inverter housing 531 is provided with a protruding portion 573 provided on the inner wall member 542 (that is, a protruding portion 573 provided with an inlet passage 571 and an outlet passage 57 2 leading to the cooling water passage 545) in the circumferential direction. Three switch modules 532A are arranged side by side in the circumferential direction at positions adjacent to the above, and six capacitor modules 532B are arranged side by side in the circumferential direction next to the three switch modules 532A. As an outline, in the inverter housing 531, the inside of the outer peripheral wall WA1 is equally divided into 10 regions (that is, the number of modules + 1) in the circumferential direction, and one electric module 532 is arranged in each of the nine regions. At the same time, a protrusion 573 is provided in the remaining one area. The three switch modules 532A are a U-phase module, a V-phase module, and a W-phase module.
　図６６や前述の図５６、図５７等に示すように、各電気モジュール５３２（スイッチモジュール５３２Ａ及びコンデンサモジュール５３２Ｂ）は、モジュールケース６１１から延びる複数のモジュール端子６１５を有している。モジュール端子６１５は、各電気モジュール５３２における電気的な入出力を行わせるモジュール入出力端子である。モジュール端子６１５は、軸方向に延びる向きで設けられており、より具体的には、モジュールケース６１１から回転子キャリア５１１の奥側（車両外側）に向けて延びるように設けられている（図５１参照）。 As shown in FIG. 66 and the above-mentioned FIGS. 56 and 57, each electric module 532 (switch module 532A and capacitor module 532B) has a plurality of module terminals 615 extending from the module case 611. The module terminal 615 is a module input / output terminal for performing electrical input / output in each electric module 532. The module terminal 615 is provided so as to extend in the axial direction, and more specifically, the module terminal 615 is provided so as to extend from the module case 611 toward the back side (outside the vehicle) of the rotor carrier 511 (FIG. 51). reference).
　各電気モジュール５３２のモジュール端子６１５は、それぞれバスバーモジュール５３３に接続されている。モジュール端子６１５の数は、スイッチモジュール５３２Ａとコンデンサモジュール５３２Ｂとで異なっており、スイッチモジュール５３２Ａには４つのモジュール端子６１５が設けられ、コンデンサモジュール５３２Ｂには２つのモジュール端子６１５が設けられている。 The module terminals 615 of each electric module 532 are connected to the bus bar module 533, respectively. The number of module terminals 615 differs between the switch module 532A and the capacitor module 532B. The switch module 532A is provided with four module terminals 615, and the capacitor module 532B is provided with two module terminals 615.
　また、図６８に示すように、バスバーモジュール５３３は、円環状をなす環状部６３１と、その環状部６３１から延び、電源装置やＥＣＵ（電子制御装置）等の外部装置との接続を可能とする３本の外部接続端子６３２と、固定子巻線５２１における各相の巻線端部に接続される巻線接続端子６３３とを有している。バスバーモジュール５３３が「端子モジュール」に相当する。 Further, as shown in FIG. 68, the bus bar module 533 extends from the annular portion 631 forming an annular shape and the annular portion 631 to enable connection with an external device such as a power supply device or an ECU (electronic control device). It has three external connection terminals 632 and a winding connection terminal 633 connected to the winding end of each phase in the stator winding 521. The bus bar module 533 corresponds to the "terminal module".
　環状部６３１は、インバータハウジング５３１において外側周壁ＷＡ１の径方向内側であり、かつ各電気モジュール５３２の軸方向片側となる位置に配置されている。環状部６３１は、例えば樹脂等の絶縁部材により成形された円環状の本体部と、その内部に埋設された複数のバスバーとを有する。その複数のバスバーは、各電気モジュール５３２のモジュール端子６１５や、各外部接続端子６３２、固定子巻線５２１の各相巻線に接続されている。その詳細は後述する。 The annular portion 631 is arranged in the inverter housing 531 at a position on the inner side in the radial direction of the outer peripheral wall WA1 and on one side in the axial direction of each electric module 532. The annular portion 631 has an annular main body formed of, for example, an insulating member such as a resin, and a plurality of bus bars embedded therein. The plurality of bus bars are connected to the module terminal 615 of each electric module 532, each external connection terminal 632, and each phase winding of the stator winding 521. The details will be described later.
　外部接続端子６３２は、電源装置に接続される高電位側の電力端子６３２Ａ及び低電位側の電力端子６３２Ｂと、外部ＥＣＵに接続される１本の信号端子６３２Ｃとからなる。これら各外部接続端子６３２（６３２Ａ～６３２Ｃ）は、周方向に一列に並び、かつ環状部６３１の径方向内側において軸方向に延びるように設けられている。図５１に示すように、バスバーモジュール５３３が各電気モジュール５３２と共にインバータハウジング５３１に組み付けられた状態では、外部接続端子６３２の一端がボス形成部材５４３の端板５４７から突出するように構成されている。具体的には、図５６、図５７に示すように、ボス形成部材５４３の端板５４７には挿通孔５４７ａが設けられており、その挿通孔５４７ａに円筒状のグロメット６３５が取り付けられるとともに、グロメット６３５を挿通させた状態で外部接続端子６３２が設けられている。グロメット６３５は、密閉コネクタとしても機能する。 The external connection terminal 632 includes a high potential side power terminal 632A and a low potential side power terminal 632B connected to the power supply device, and one signal terminal 632C connected to the external ECU. Each of these external connection terminals 632 (632A to 632C) is provided so as to be arranged in a line in the circumferential direction and to extend in the radial direction inside the annular portion 631 in the radial direction. As shown in FIG. 51, when the bus bar module 533 is assembled to the inverter housing 531 together with each electric module 532, one end of the external connection terminal 632 is configured to protrude from the end plate 547 of the boss forming member 543. .. Specifically, as shown in FIGS. 56 and 57, the end plate 547 of the boss forming member 543 is provided with an insertion hole 547a, and a cylindrical grommet 635 is attached to the insertion hole 547a, and the grommet is attached. The external connection terminal 632 is provided with the 635 inserted. The grommet 635 also functions as a sealed connector.
　巻線接続端子６３３は、固定子巻線５２１の各相の巻線端部に接続される端子であり、環状部６３１から径方向外側に延びるように設けられている。巻線接続端子６３３は、固定子巻線５２１におけるＵ相巻線の端部に接続される巻線接続端子６３３Ｕ、Ｖ相巻線の端部に接続される巻線接続端子６３３Ｖ、Ｗ相巻線の端部にそれぞれ接続に接続される巻線接続端子６３３Ｗを有する。これらの各巻線接続端子６３３、各相巻線に流れる電流（Ｕ相電流、Ｖ相電流、Ｗ相電流）を検出する電流センサ６３４が設けられているとよい（図７０参照）。 The winding connection terminal 633 is a terminal connected to the winding end of each phase of the stator winding 521, and is provided so as to extend radially outward from the annular portion 631. The winding connection terminal 633 is a winding connection terminal 633U connected to the end of the U-phase winding in the stator winding 521, a winding connection terminal 633V connected to the end of the V-phase winding, and a W-phase winding. Each end of the wire has a winding connection terminal 633W connected to the connection. It is preferable that each of these winding connection terminals 633 and a current sensor 634 for detecting the current (U-phase current, V-phase current, W-phase current) flowing through each phase winding are provided (see FIG. 70).
　なお、電流センサ６３４は、電気モジュール５３２の外部であって、各巻線接続端子６３３の周辺に配置されてもよいし、電気モジュール５３２の内部に配置されてもよい。 The current sensor 634 may be arranged outside the electric module 532 and around each winding connection terminal 633, or may be arranged inside the electric module 532.
　ここで、各電気モジュール５３２とバスバーモジュール５３３との接続を、図６９及び図７０を用いてより具体的に説明する。図６９は、各電気モジュール５３２を平面状に展開して示すとともに、それら各電気モジュール５３２とバスバーモジュール５３３との電気的な接続状態を模式的に示す図である。図７０は、各電気モジュール５３２を円環状に配置した状態での各電気モジュール５３２とバスバーモジュール５３３との接続を模式的に示す図である。なお、図６９には、電力伝送用の経路を実線で示し、信号伝送系の経路を一点鎖線で示している。図７０には、電力伝送用の経路のみを示している。 Here, the connection between each electric module 532 and the bus bar module 533 will be described more specifically with reference to FIGS. 69 and 70. FIG. 69 is a diagram showing each electric module 532 developed in a plane and schematically showing an electrical connection state between each electric module 532 and a bus bar module 533. FIG. 70 is a diagram schematically showing the connection between each electric module 532 and the bus bar module 533 in a state where each electric module 532 is arranged in an annular shape. In FIG. 69, the path for power transmission is shown by a solid line, and the path of the signal transmission system is shown by a chain double-dashed line. FIG. 70 shows only the path for power transmission.
　バスバーモジュール５３３は、電力伝送用のバスバーとして、第１バスバー６４１と第２バスバー６４２と第３バスバー６４３とを有している。このうち第１バスバー６４１が高電位側の電力端子６３２Ａに接続され、第２バスバー６４２が低電位側の電力端子６３２Ｂに接続されている。また、３つの第３バスバー６４３が、Ｕ相の巻線接続端子６３３Ｕ、Ｖ相の巻線接続端子６３３Ｖ、Ｗ相の巻線接続端子６３３Ｗにそれぞれ接続されている。 The bus bar module 533 has a first bus bar 641, a second bus bar 642, and a third bus bar 643 as bus bars for power transmission. Of these, the first bus bar 641 is connected to the power terminal 632A on the high potential side, and the second bus bar 642 is connected to the power terminal 632B on the low potential side. Further, three third bus bars 643 are connected to the U-phase winding connection terminal 633U, the V-phase winding connection terminal 633V, and the W-phase winding connection terminal 633W, respectively.
　また、巻線接続端子６３３や第３バスバー６４３は、回転電機１０の動作により発熱しやすい部位である。このため、巻線接続端子６３３と第３バスバー６４３との間に図示しない端子台を介在させるとともに、この端子台を、冷却水通路５４５を有するインバータハウジング５３１に当接させてもよい。又は、巻線接続端子６３３や第３バスバー６４３をクランク状に曲げることで、巻線接続端子６３３や第３バスバー６４３を冷却水通路５４５を有するインバータハウジング５３１に当接させてもよい。 Further, the winding connection terminal 633 and the third bus bar 643 are parts that easily generate heat due to the operation of the rotary electric machine 10. Therefore, a terminal block (not shown) may be interposed between the winding connection terminal 633 and the third bus bar 643, and the terminal block may be brought into contact with the inverter housing 531 having the cooling water passage 545. Alternatively, the winding connection terminal 633 or the third bus bar 643 may be bent into a crank shape to bring the winding connection terminal 633 or the third bus bar 643 into contact with the inverter housing 531 having the cooling water passage 545.
　このような構成であれば、巻線接続端子６３３や第３バスバー６４３で発生した熱を冷却水通路５４５内の冷却水に放熱することができる。 With such a configuration, the heat generated at the winding connection terminal 633 and the third bus bar 643 can be dissipated to the cooling water in the cooling water passage 545.
　なお、図７０では、第１バスバー６４１及び第２バスバー６４２を、円環形状をなすバスバーとして示すが、これら各バスバー６４１，６４２は必ずしも円環形状で繋がっていなくてもよく、周方向の一部が途切れた略Ｃ字状をなしていてもよい。また、各巻線接続端子６３３Ｕ，６３３Ｖ，６３３Ｗは、各相に対応するスイッチモジュール５３２Ａに個々に接続されればよいため、バスバーモジュール５３３を介することなく、直接的に各スイッチモジュール５３２Ａ（実際にはモジュール端子６１５）に接続される構成であってもよい。 In FIG. 70, the first bus bar 641 and the second bus bar 642 are shown as bus bars having a ring shape, but each of these bus bars 641 and 642 does not necessarily have to be connected in a ring shape and is one in the circumferential direction. It may have a substantially C-shape with a broken portion. Further, since each winding connection terminal 633U, 633V, 633W may be individually connected to the switch module 532A corresponding to each phase, each switch module 532A (actually, actually) does not go through the bus bar module 533. It may be configured to be connected to the module terminal 615).
　一方、各スイッチモジュール５３２Ａは、正極側端子、負極側端子、巻線用端子及び信号用端子からなる４つのモジュール端子６１５を有している。このうち正極側端子は第１バスバー６４１に接続され、負極側端子は第２バスバー６４２に接続され、巻線用端子は第３バスバー６４３に接続されている。 On the other hand, each switch module 532A has four module terminals 615 including a positive electrode side terminal, a negative electrode side terminal, a winding terminal, and a signal terminal. Of these, the positive electrode side terminal is connected to the first bus bar 641, the negative electrode side terminal is connected to the second bus bar 642, and the winding terminal is connected to the third bus bar 643.
　また、バスバーモジュール５３３は、信号伝送系のバスバーとして第４バスバー６４４を有している。各スイッチモジュール５３２Ａの信号用端子が第４バスバー６４４に接続されるとともに、その第４バスバー６４４が信号端子６３２Ｃに接続されている。 Further, the bus bar module 533 has a fourth bus bar 644 as a bus bar of the signal transmission system. The signal terminal of each switch module 532A is connected to the fourth bus bar 644, and the fourth bus bar 644 is connected to the signal terminal 632C.
　本実施形態では、各スイッチモジュール５３２Ａに対する制御信号を信号端子６３２Ｃを介して外部ＥＣＵから入力する構成としている。つまり、各スイッチモジュール５３２Ａ内の各スイッチ６０１，６０２は、信号端子６３２Ｃを介して入力される制御信号によりオンオフする。そのため、各スイッチモジュール５３２Ａが、途中で回転電機内蔵の制御装置を経由することなく信号端子６３２Ｃに対して接続される構成となっている。ただし、この構成を変更し、回転電機に制御装置を内蔵させ、その制御装置からの制御信号が各スイッチモジュール５３２Ａに入力される構成とすることも可能である。かかる構成を図７１に示す。 In this embodiment, the control signal for each switch module 532A is input from the external ECU via the signal terminal 632C. That is, each of the switches 601, 602 in each switch module 532A is turned on and off by a control signal input via the signal terminal 632C. Therefore, each switch module 532A is connected to the signal terminal 632C without going through a control device built in the rotary electric machine on the way. However, it is also possible to change this configuration so that the rotary electric machine has a built-in control device and the control signal from the control device is input to each switch module 532A. Such a configuration is shown in FIG.
　図７１の構成では、制御装置６５２が実装された制御基板６５１を有し、その制御装置６５２が各スイッチモジュール５３２Ａに接続されている。また、制御装置６５２には信号端子６３２Ｃが接続されている。この場合、制御装置６５２は、例えば上位制御装置である外部ＥＣＵから力行又は発電に関する指令信号を入力し、その指令信号に基づいて各スイッチモジュール５３２Ａのスイッチ６０１，６０２を適宜オンオフさせる。 In the configuration of FIG. 71, the control board 651 on which the control device 652 is mounted is provided, and the control device 652 is connected to each switch module 532A. Further, a signal terminal 632C is connected to the control device 652. In this case, the control device 652 inputs a command signal related to power running or power generation from, for example, an external ECU which is a higher-level control device, and appropriately turns on / off the switches 601, 602 of each switch module 532A based on the command signal.
　インバータユニット５３０においては、バスバーモジュール５３３よりも車両外側（回転子キャリア５１１の奥側）に制御基板６５１が配置されるとよい。又は、各電気モジュール５３２とボス形成部材５４３の端板５４７との間に制御基板６５１が配置されるとよい。制御基板６５１は、各電気モジュール５３２に対して少なくとも一部が軸方向に重複するように配置されるとよい。 In the inverter unit 530, it is preferable that the control board 651 is arranged on the outside of the vehicle (inside the rotor carrier 511) of the bus bar module 533. Alternatively, the control board 651 may be arranged between each electric module 532 and the end plate 547 of the boss forming member 543. The control board 651 may be arranged so that at least a part thereof overlaps with each electric module 532 in the axial direction.
　また、各コンデンサモジュール５３２Ｂは、正極側端子及び負極側端子からなる２つのモジュール端子６１５を有しており、正極側端子は第１バスバー６４１に接続され、負極側端子は第２バスバー６４２に接続されている。 Further, each capacitor module 532B has two module terminals 615 composed of a positive electrode side terminal and a negative electrode side terminal, the positive electrode side terminal is connected to the first bus bar 641, and the negative electrode side terminal is connected to the second bus bar 642. Has been done.
　図４９及び図５０に示すように、インバータハウジング５３１内には、周方向に各電気モジュール５３２と並ぶ位置に、冷却水の入口通路５７１及び出口通路５７２を有する突出部５７３が設けられるとともに、その突出部５７３に対して径方向に隣り合うようにして外部接続端子６３２が設けられている。換言すれば、突出部５７３と外部接続端子６３２とが、周方向に同じ角度位置に設けられている。本実施形態では、突出部５７３の径方向内側の位置に外部接続端子６３２が設けられている。また、インバータハウジング５３１の車両内側から見れば、ボス形成部材５４３の端板５４７に、径方向に並べて水路ポート５７４と外部接続端子６３２とが設けられている（図４８参照）。 As shown in FIGS. 49 and 50, a projecting portion 573 having an inlet passage 571 and an outlet passage 572 for cooling water is provided in the inverter housing 531 at a position aligned with each electric module 532 in the circumferential direction. The external connection terminal 632 is provided so as to be adjacent to the protruding portion 573 in the radial direction. In other words, the protrusion 573 and the external connection terminal 632 are provided at the same angular position in the circumferential direction. In the present embodiment, the external connection terminal 632 is provided at a position inside the protruding portion 573 in the radial direction. Further, when viewed from the inside of the vehicle of the inverter housing 531, the end plate 547 of the boss forming member 543 is provided with the water channel port 574 and the external connection terminal 632 arranged in the radial direction (see FIG. 48).
　この場合、複数の電気モジュール５３２と共に突出部５７３及び外部接続端子６３２を周方向に並べて配置したことにより、インバータユニット５３０としての小型化、ひいては回転電機５００としての小型化が可能となっている。 In this case, by arranging the protrusion 573 and the external connection terminal 632 side by side in the circumferential direction together with the plurality of electric modules 532, the inverter unit 530 can be downsized, and the rotary electric machine 500 can be downsized.
　車輪４００の構造を示す図４５及び図４７で見ると、水路ポート５７４に冷却用配管Ｈ２が接続されるとともに、外部接続端子６３２に電気配線Ｈ１が接続され、その状態で、電気配線Ｈ１及び冷却用配管Ｈ２が収容ダクト４４０に収容されている。 Looking at FIGS. 45 and 47 showing the structure of the wheel 400, the cooling pipe H2 is connected to the water channel port 574, and the electric wiring H1 is connected to the external connection terminal 632. The pipe H2 is housed in the storage duct 440.
　なお、上記構成では、インバータハウジング５３１内において外部接続端子６３２の隣に、３つのスイッチモジュール５３２Ａを周方向に並べて配置するととともに、さらにその隣に、６つのコンデンサモジュール５３２Ｂを周方向に並べて配置する構成としたが、これを変更してもよい。例えば、外部接続端子６３２から最も離れた位置、すなわち回転軸５０１を挟んで反対側となる位置に、３つのスイッチモジュール５３２Ａを並べて配置する構成としてもよい。また、各スイッチモジュール５３２Ａの両隣にコンデンサモジュール５３２Ｂが配置されるように、各スイッチモジュール５３２Ａを分散配置することも可能である。 In the above configuration, the three switch modules 532A are arranged side by side in the circumferential direction next to the external connection terminal 632 in the inverter housing 531, and the six capacitor modules 532B are arranged side by side in the circumferential direction next to the three switch modules 532A. Although it is configured, this may be changed. For example, the three switch modules 532A may be arranged side by side at a position farthest from the external connection terminal 632, that is, a position opposite to the rotation shaft 501. It is also possible to disperse each switch module 532A so that the capacitor modules 532B are arranged on both sides of each switch module 532A.
　外部接続端子６３２から最も離れた位置、すなわち回転軸５０１を挟んで反対側となる位置に各スイッチモジュール５３２Ａを配置する構成とすれば、外部接続端子６３２と各スイッチモジュール５３２Ａとの間における相互インダクタンスに起因する誤動作等を抑制できる。 If each switch module 532A is arranged at the position farthest from the external connection terminal 632, that is, on the opposite side of the rotating shaft 501, the mutual inductance between the external connection terminal 632 and each switch module 532A. It is possible to suppress malfunctions caused by the above.
　次に、回転角度センサとして設けられるレゾルバ６６０に関する構成を説明する。 Next, the configuration of the resolver 660 provided as the rotation angle sensor will be described.
　図４９～図５１に示すように、インバータハウジング５３１には、回転電機５００の電気角θを検出するレゾルバ６６０が設けられている。レゾルバ６６０は、電磁誘導式センサであり、回転軸５０１に固定されたレゾルバロータ６６１と、そのレゾルバロータ６６１の径方向外側に対向配置されたレゾルバステータ６６２とを備えている。レゾルバロータ６６１は、円板リング状をなしており、回転軸５０１を挿通させた状態で、回転軸５０１に同軸で設けられている。レゾルバステータ６６２は、円環状をなすステータコア６６３と、ステータコア６６３に形成された複数のティースに巻回されたステータコイル６６４とを備えている。ステータコイル６６４には、１相の励磁コイルと２相の出力コイルとが含まれている。 As shown in FIGS. 49 to 51, the inverter housing 531 is provided with a resolver 660 for detecting the electric angle θ of the rotary electric machine 500. The resolver 660 is an electromagnetic induction type sensor, and includes a resolver rotor 661 fixed to a rotating shaft 501 and a resolver stator 662 arranged so as to face each other on the radial outer side of the resolver rotor 661. The resolver rotor 661 has a disk ring shape, and is provided coaxially with the rotating shaft 501 in a state where the rotating shaft 501 is inserted. The resolver stator 662 includes an annular stator core 663 and a stator coil 664 wound around a plurality of teeth formed on the stator core 663. The stator coil 664 includes a one-phase excitation coil and a two-phase output coil.
　ステータコイル６６４の励磁コイルは、正弦波状の励磁信号によって励磁され、励磁信号によって励磁コイルに生じた磁束は、一対の出力コイルを鎖交する。この際、励磁コイルと一対の出力コイルとの相対的な配置関係がレゾルバロータ６６１の回転角（すなわち回転軸５０１の回転角）に応じて周期的に変化するため、一対の出力コイルを鎖交する磁束数は周期的に変化する。本実施形態では、一対の出力コイルのそれぞれに生じる電圧の位相が互いにπ／２だけずれるように一対の出力コイルと励磁コイルとが配置されている。これにより、一対の出力コイルそれぞれの出力電圧は、励磁信号を変調波ｓｉｎθ、ｃｏｓθのそれぞれによって変調した被変調波となる。より具体的には、励磁信号を「ｓｉｎΩｔ」とすると、被変調波はそれぞれ「ｓｉｎθ×ｓｉｎΩｔ」，「ｃｏｓθ×ｓｉｎΩｔ」となる。 The exciting coil of the stator coil 664 is excited by a sinusoidal exciting signal, and the magnetic flux generated in the exciting coil by the exciting signal interlinks the pair of output coils. At this time, since the relative arrangement relationship between the exciting coil and the pair of output coils changes periodically according to the rotation angle of the resolver rotor 661 (that is, the rotation angle of the rotation shaft 501), the pair of output coils are interlocked. The number of magnetic fluxes to be applied changes periodically. In the present embodiment, the pair of output coils and the exciting coil are arranged so that the phases of the voltages generated in the pair of output coils are shifted by π / 2 from each other. 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 the modulated waves sinθ and cosθ, respectively. More specifically, when the excitation signal is "sinΩt", the modulated waves are "sinθ × sinΩt" and "cosθ × sinΩt", respectively.
　レゾルバ６６０はレゾルバデジタルコンバータを有している。レゾルバデジタルコンバータは、生成された被変調波及び励磁信号に基づく検波によって電気角θを算出する。例えばレゾルバ６６０は信号端子６３２Ｃに接続されており、レゾルバデジタルコンバータの算出結果は、信号端子６３２Ｃを介して外部装置に出力される。また、回転電機５００に制御装置が内蔵されている場合には、その制御装置にレゾルバデジタルコンバータの算出結果が入力される。 The resolver 660 has a resolver digital converter. The resolver digital converter calculates the electric angle θ by detecting the generated modulated wave and the excitation signal. For example, the resolver 660 is connected to the signal terminal 632C, and the calculation result of the resolver digital converter is output to an external device via the signal terminal 632C. When the rotary electric machine 500 has a built-in control device, the calculation result of the resolver digital converter is input to the control device.
　ここで、インバータハウジング５３１におけるレゾルバ６６０の組み付け構造について説明する。 Here, the assembly structure of the resolver 660 in the inverter housing 531 will be described.
　図４９及び図５１に示すように、インバータハウジング５３１を構成するボス形成部材５４３のボス部５４８は中空筒状をなしており、そのボス部５４８の内周側には、軸方向に直交する向きに延びる突出部５４８ａが形成されている。そして、この突出部５４８ａに軸方向に当接した状態で、ネジ等によりレゾルバステータ６６２が固定されている。ボス部５４８内には、突出部５４８ａを挟んで軸方向の一方側に軸受５６０が設けられるとともに、他方側にレゾルバ６６０が同軸で設けられている。 As shown in FIGS. 49 and 51, the boss portion 548 of the boss forming member 543 constituting the inverter housing 531 has a hollow tubular shape, and the inner peripheral side of the boss portion 548 is oriented orthogonal to the axial direction. A protrusion 548a extending to the surface is formed. Then, the resolver stator 662 is fixed by a screw or the like in a state of being in contact with the protruding portion 548a in the axial direction. In the boss portion 548, a bearing 560 is provided on one side in the axial direction with the protrusion 548a interposed therebetween, and a resolver 660 is coaxially provided on the other side.
　また、ボス部５４８の中空部には、軸方向においてレゾルバ６６０の一方の側に突出部５４８ａが設けられるとともに、他方の側に、レゾルバ６６０の収容空間を閉鎖する円板リング状のハウジングカバー６６６が取り付けられている。ハウジングカバー６６６は、炭素繊維強化プラスチック（ＣＦＲＰ）等の導電性材料により構成されている。ハウジングカバー６６６の中央部には、回転軸５０１を挿通させる孔６６６ａが形成されている。孔６６６ａ内には、回転軸５０１の外周面との間の空隙を封鎖するシール材６６７が設けられている。シール材６６７により、レゾルバ収容空間が密閉されている。シール材６６７は、例えば樹脂材料よりなる摺動シールであるとよい。 Further, in the hollow portion of the boss portion 548, a protruding portion 548a is provided on one side of the resolver 660 in the axial direction, and a disk ring-shaped housing cover 666 that closes the accommodating space of the resolver 660 is provided on the other side. Is installed. The housing cover 666 is made of a conductive material such as carbon fiber reinforced plastic (CFRP). A hole 666a through which the rotary shaft 501 is inserted is formed in the central portion of the housing cover 666. Inside the hole 666a, a sealing material 667 is provided to seal the gap between the rotating shaft 501 and the outer peripheral surface. The resolver accommodating space is sealed by the sealing material 667. The sealing material 667 may be, for example, a sliding seal made of a resin material.
　レゾルバ６６０が収容される空間は、ボス形成部材５４３において円環状をなすボス部５４８に囲まれ、かつ軸方向が軸受５６０とハウジングカバー６６６とにより挟まれた空間であり、レゾルバ６６０の周囲は導電材料により囲まれている。これにより、レゾルバ６６０に対する電磁ノイズの影響を抑制できるようになっている。 The space in which the resolver 660 is housed is a space surrounded by an annular boss portion 548 in the boss forming member 543 and sandwiched between the bearing 560 and the housing cover 666 in the axial direction, and the circumference of the resolver 660 is conductive. Surrounded by material. This makes it possible to suppress the influence of electromagnetic noise on the resolver 660.
　また、上述したとおりインバータハウジング５３１は、二重となる外側周壁ＷＡ１と内側周壁ＷＡ２とを有しており（図５７参照）、その二重となる周壁の外側（外側周壁ＷＡ１の外側）には固定子５２０が配置され、二重の周壁の間（ＷＡ１，ＷＡ２の間）には電気モジュール５３２が配置され、二重の周壁の内側（内側周壁ＷＡ２の内側）にはレゾルバ６６０が配置されている。インバータハウジング５３１は導電性部材であるため、固定子５２０とレゾルバ６６０とは、導電性の隔壁（本実施形態では特に二重の導電性隔壁）を隔てて配置されるようになっており、固定子５２０側（磁気回路側）とレゾルバ６６０とについて相互の磁気干渉の発生を好適に抑制できるものとなっている。 Further, as described above, the inverter housing 531 has a double outer peripheral wall WA1 and an inner peripheral wall WA2 (see FIG. 57), and is located outside the double peripheral wall (outside the outer peripheral wall WA1). The stator 520 is arranged, the electric module 532 is arranged between the double peripheral walls (between WA1 and WA2), and the resolver 660 is arranged inside the double peripheral wall (inside the inner peripheral wall WA2). There is. Since the inverter housing 531 is a conductive member, the stator 520 and the resolver 660 are arranged so as to be separated from each other by a conductive partition wall (particularly a double conductive partition wall in the present embodiment) and are fixed. The occurrence of mutual magnetic interference between the child 520 side (magnetic circuit side) and the resolver 660 can be suitably suppressed.
　次に、回転子キャリア５１１の開放端部の側に設けられる回転子カバー６７０について説明する。 Next, the rotor cover 670 provided on the open end side of the rotor carrier 511 will be described.
　図４９及び図５１に示すように、回転子キャリア５１１は軸方向の一方側が開放されており、その開放端部に、略円板リング状の回転子カバー６７０が取り付けられている。回転子カバー６７０は、溶接や接着、ビス止め等の任意の接合手法により回転子キャリア５１１に対して固定されているとよい。回転子カバー６７０が、磁石ユニット５１２の軸方向への移動を抑制できるように回転子キャリア５１１の内周よりも小さめに寸法設定されている部位を持つとなおよい。回転子カバー６７０は、その外径寸法が、回転子キャリア５１１の外径寸法に一致し、内径寸法が、インバータハウジング５３１の外径寸法よりも僅かに大きい寸法となっている。なお、インバータハウジング５３１の外径寸法と固定子５２０の内径寸法とは同じである。 As shown in FIGS. 49 and 51, one side of the rotor carrier 511 in the axial direction is open, and a substantially disk ring-shaped rotor cover 670 is attached to the open end. The rotor cover 670 may be fixed to the rotor carrier 511 by any joining method such as welding, bonding, or screwing. It is more preferable that the rotor cover 670 has a portion whose dimensions are set smaller than the inner circumference of the rotor carrier 511 so that the movement of the magnet unit 512 in the axial direction can be suppressed. The outer diameter of the rotor cover 670 matches the outer diameter of the rotor carrier 511, and the inner diameter of the rotor cover 670 is slightly larger than the outer diameter of the inverter housing 531. The outer diameter of the inverter housing 531 and the inner diameter of the stator 520 are the same.
　上述したとおりインバータハウジング５３１の径方向外側には固定子５２０が固定されており、それら固定子５２０及びインバータハウジング５３１が互いに接合されている接合部分では、固定子５２０に対してインバータハウジング５３１が軸方向に突出している。そして、インバータハウジング５３１の突出部分を囲むように回転子カバー６７０が取り付けられている。この場合、回転子カバー６７０の内周側の端面とインバータハウジング５３１の外周面との間には、それらの間の隙間を封鎖するシール材６７１が設けられている。シール材６７１により、磁石ユニット５１２及び固定子５２０の収容空間が密閉されている。シール材６７１は、例えば樹脂材料よりなる摺動シールであるとよい。 As described above, the stator 520 is fixed on the radial outer side of the inverter housing 531. At the joint where the stator 520 and the inverter housing 531 are joined to each other, the inverter housing 531 is shafted with respect to the stator 520. It protrudes in the direction. A rotor cover 670 is attached so as to surround the protruding portion of the inverter housing 531. In this case, a sealing material 671 for sealing the gap between the end surface of the rotor cover 670 on the inner peripheral side and the outer peripheral surface of the inverter housing 531 is provided. The accommodating space of the magnet unit 512 and the stator 520 is sealed by the sealing material 671. The sealing material 671 may be, for example, a sliding seal made of a resin material.
　以上詳述した本実施形態によれば、以下の優れた効果が得られる。 According to the present embodiment described in detail above, the following excellent effects can be obtained.
　回転電機５００において、磁石ユニット５１２及び固定子巻線５２１よりなる磁気回路部の径方向内側に、インバータハウジング５３１の外側周壁ＷＡ１を配置し、その外側周壁ＷＡ１に冷却水通路５４５を形成した。また、外側周壁ＷＡ１の径方向内側に、その外側周壁ＷＡ１に沿って周方向に複数の電気モジュール５３２を配置する構成とした。これにより、回転電機５００の径方向に積層されるようにして磁気回路部、冷却水通路５４５、電力変換器を配置でき、軸方向における寸法の縮小化を図りつつ、効率の良い部品配置が可能となる。また、電力変換器を構成する複数の電気モジュール５３２について効率良く冷却を行わせることができる。その結果、回転電機５００において、高効率かつ小型化が実現可能となる。 In the rotary electric machine 500, the outer peripheral wall WA1 of the inverter housing 531 was arranged inside the magnetic circuit portion including the magnet unit 512 and the stator winding 521 in the radial direction, and the cooling water passage 545 was formed on the outer peripheral wall WA1. Further, a plurality of electric modules 532 are arranged in the radial direction of the outer peripheral wall WA1 along the outer peripheral wall WA1 in the circumferential direction. As a result, the magnetic circuit unit, the cooling water passage 545, and the power converter can be arranged so as to be stacked in the radial direction of the rotary electric machine 500, and efficient component arrangement is possible while reducing the dimensions in the axial direction. It becomes. Further, the plurality of electric modules 532 constituting the power converter can be efficiently cooled. As a result, the rotary electric machine 500 can be realized with high efficiency and miniaturization.
　半導体スイッチング素子やコンデンサ等の発熱部品を有する電気モジュール５３２（スイッチモジュール５３２Ａ、コンデンサモジュール５３２Ｂ）を、外側周壁ＷＡ１の内周面に接した状態で設ける構成とした。これにより、各電気モジュール５３２における熱が外側周壁ＷＡ１に伝達され、その外側周壁ＷＡ１での熱交換により電気モジュール５３２が好適に冷却される。 An electric module 532 (switch module 532A, capacitor module 532B) having heat generating parts such as a semiconductor switching element and a capacitor is provided in a state of being in contact with the inner peripheral surface of the outer peripheral wall WA1. As a result, the heat in each electric module 532 is transferred to the outer peripheral wall WA1, and the electric module 532 is suitably cooled by the heat exchange in the outer peripheral wall WA1.
　スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に冷却器６２３をそれぞれ配置するとともに、スイッチ６０１，６０２の両側の冷却器６２３のうち少なくとも一方の冷却器においてスイッチ６０１，６０２とは逆側にコンデンサ６０４を配置する構成とした。これにより、スイッチ６０１，６０２に対する冷却性能を高めることができるとともに、コンデンサ６０４の冷却性能も高めることができる。 In the switch module 532A, coolers 623 are arranged on both sides of the switches 601, 602, respectively, and at least one of the coolers 623 on both sides of the switches 601, 602 is on the opposite side of the switches 601,602. The configuration is such that the capacitor 604 is arranged. As a result, the cooling performance of the switches 601, 602 can be improved, and the cooling performance of the capacitor 604 can also be improved.
　スイッチモジュール５３２Ａにおいて、スイッチ６０１，６０２を挟んで両側に冷却器６２３をそれぞれ配置するとともに、スイッチ６０１，６０２の両側の冷却器６２３のうち一方の冷却器においてスイッチ６０１，６０２とは逆側に駆動回路６０３を配置し、他方の冷却器６２３においてスイッチ６０１，６０２とは逆側にコンデンサ６０４を配置する構成とした。これにより、スイッチ６０１，６０２に対する冷却性能を高めることができるとともに、駆動回路６０３とコンデンサ６０４についても冷却性能も高めることができる。 In the switch module 532A, coolers 623 are arranged on both sides of the switches 601, 602, respectively, and one of the coolers 623 on both sides of the switches 601, 602 is driven to the opposite side of the switches 601,602. The circuit 603 is arranged, and the capacitor 604 is arranged on the opposite side of the switches 601, 602 in the other cooler 623. As a result, the cooling performance of the switches 601, 602 can be improved, and the cooling performance of the drive circuit 603 and the capacitor 604 can also be improved.
　例えばスイッチモジュール５３２Ａにおいて、冷却水通路５４５からモジュール内部に冷却水を流入させ、その冷却水により半導体スイッチング素子等を冷却する構成とした。この場合、スイッチモジュール５３２Ａは、外側周壁ＷＡ１での冷却水による熱交換に加えて、モジュール内部での冷却水による熱交換により冷却される。これにより、スイッチモジュール５３２Ａの冷却効果を高めることができる。 For example, in the switch module 532A, cooling water is made to flow into the module from the cooling water passage 545, and the semiconductor switching element or the like is cooled by the cooling water. In this case, the switch module 532A is cooled by heat exchange by the cooling water inside the module in addition to heat exchange by the cooling water on the outer peripheral wall WA1. Thereby, the cooling effect of the switch module 532A can be enhanced.
　冷却水通路５４５に対して外部の循環経路５７５から冷却水を流入させる冷却システムにおいて、スイッチモジュール５３２Ａを冷却水通路５４５の入口通路５７１に近い上流側に配置するとともに、コンデンサモジュール５３２Ｂをスイッチモジュール５３２Ａよりも下流側に配置する構成とした。この場合、冷却水通路５４５を流れる冷却水が上流側ほど低温であることを想定すれば、スイッチモジュール５３２Ａを優先的に冷却する構成を実現することが可能になる。 In the cooling system in which the cooling water flows into the cooling water passage 545 from the external circulation path 575, the switch module 532A is arranged on the upstream side near the inlet passage 571 of the cooling water passage 545, and the condenser module 532B is placed on the switch module 532A. It is configured to be placed on the downstream side of the. In this case, assuming that the cooling water flowing through the cooling water passage 545 is lower in temperature toward the upstream side, it is possible to realize a configuration in which the switch module 532A is preferentially cooled.
　周方向に隣り合う電気モジュール同士の間隔を一部で拡げ、その拡げた間隔（第２間隔ＩＮＴ２）となる部分に、入口通路５７１及び出口通路５７２を有する突出部５７３を設ける構成とした。これにより、外側周壁ＷＡ１の径方向内側となる部分に、冷却水通路５４５の入口通路５７１及び出口通路５７２を好適に形成することができる。つまり、冷却性能を高めるには冷媒の流通量を確保する必要があり、そのためには入口通路５７１及び出口通路５７２の開口面積を大きくすることが考えられる。この点、上記のとおり電気モジュール同士の間隔を一部で拡げて突出部５７３を設けることにより、所望とする大きさの入口通路５７１及び出口通路５７２を好適に形成することができる。 The distance between the electric modules adjacent to each other in the circumferential direction was partially widened, and a protruding portion 573 having an inlet passage 571 and an outlet passage 57 2 was provided in the portion where the distance was widened (second interval INT2). As a result, the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 can be suitably formed in the portion on the outer peripheral wall WA1 in the radial direction. That is, in order to improve the cooling performance, it is necessary to secure the flow amount of the refrigerant, and for that purpose, it is conceivable to increase the opening areas of the inlet passage 571 and the outlet passage 572. In this regard, as described above, by partially widening the distance between the electric modules and providing the protruding portion 573, the inlet passage 571 and the outlet passage 572 having a desired size can be suitably formed.
　バスバーモジュール５３３の外部接続端子６３２を、外側周壁ＷＡ１の径方向内側において突出部５７３に径方向に並ぶ位置に配置するようにした。つまり、外部接続端子６３２を、周方向に隣り合う電気モジュール同士の間隔が拡げられた部分（第２間隔ＩＮＴ２に相当する部分）に突出部５７３と共に配置するようにした。これにより、各電気モジュール５３２との干渉を避けつつ、外部接続端子６３２を好適に配置することができる。 The external connection terminal 632 of the bus bar module 533 is arranged at a position radially aligned with the protrusion 573 on the radial inside of the outer peripheral wall WA1. That is, the external connection terminal 632 is arranged together with the protrusion 573 in the portion where the distance between the electric modules adjacent to each other in the circumferential direction is widened (the part corresponding to the second distance INT2). As a result, the external connection terminal 632 can be preferably arranged while avoiding interference with each electric module 532.
　アウタロータ式の回転電機５００において、外側周壁ＷＡ１の径方向外側に固定子５２０を固定し、かつ径方向内側に複数の電気モジュール５３２を配置する構成とした。これにより、外側周壁ＷＡ１に対して、その径方向外側から固定子５２０の熱が伝わるとともに、径方向内側から電気モジュール５３２の熱が伝わることになる。この場合、固定子５２０と電気モジュール５３２とを，冷却水通路５４５を流れる冷却水により同時に冷やすことが可能となり、回転電機５００における発熱部材の熱を効率良く放出することができる。 In the outer rotor type rotary electric machine 500, the stator 520 is fixed on the radial outside of the outer peripheral wall WA1, and a plurality of electric modules 532 are arranged on the radial inside. As a result, the heat of the stator 520 is transferred to the outer peripheral wall WA1 from the radial outer side, and the heat of the electric module 532 is transferred from the radial inner side. 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 rotary electric machine 500 can be efficiently released.
　外側周壁ＷＡ１を挟んで径方向内側の電気モジュール５３２と径方向外側の固定子巻線５２１とを、バスバーモジュール５３３の巻線接続端子６３３により電気的に接続する構成とした。またこの場合、巻線接続端子６３３を、冷却水通路５４５に対して軸方向に離れた位置に設ける構成とした。これにより、外側周壁ＷＡ１において環状に冷却水通路５４５が形成される構成、すなわち外側周壁ＷＡ１の内外が冷却水通路５４５により分断されている構成であっても、電気モジュール５３２と固定子巻線５２１とを好適に接続することができる。 The electric module 532 on the inner side in the radial direction and the stator winding 521 on the outer side in the radial direction are electrically connected by the winding connection terminal 633 of the bus bar module 533 with the outer peripheral wall WA1 interposed therebetween. Further, in this case, the winding connection terminal 633 is provided at a position axially separated from the cooling water passage 545. As a result, even if the cooling water passage 545 is formed in an annular shape on the outer peripheral wall WA1, that is, the inside and outside of the outer peripheral wall WA1 are separated by the cooling water passage 545, the electric module 532 and the stator winding 521 Can be suitably connected to.
　本実施形態の回転電機５００では、固定子５２０において周方向に並ぶ各導線５２３の間のティース（鉄心）を小さくする又は無くすことで、それら各導線５２３の間で生じる磁気飽和に起因するトルク制限を抑制するとともに、導線５２３を扁平薄型にすることでトルク低下を抑制するものとしている。この場合、仮に回転電機５００の外径寸法が同じであっても、固定子５２０の薄型化により磁気回路部の径方向内側の領域を拡張することが可能となり、その内側領域を用いて、冷却水通路５４５を有する外側周壁ＷＡ１や、外側周壁ＷＡ１の径方向内側に設けられた複数の電気モジュール５３２を好適に配置することができる。 In the rotary electric machine 500 of the present embodiment, by reducing or eliminating the teeth (iron cores) between the conductors 523 arranged in the circumferential direction in the stator 520, the torque is limited due to the magnetic saturation generated between the conductors 523. The torque drop is suppressed by making the conductor 523 flat and thin. In this case, even if the outer diameter of the rotary electric machine 500 is the same, the area inside the magnetic circuit portion in the radial direction can be expanded by reducing the thickness of the stator 520, and the inner area is used for cooling. An outer peripheral wall WA1 having a water passage 545 and a plurality of electric modules 532 provided radially inside the outer peripheral wall WA1 can be preferably arranged.
　本実施形態の回転電機５００では、磁石ユニット５１２において磁石磁束がｄ軸側に集まることでｄ軸での磁石磁束が強化され、それに伴うトルク増強が可能となっている。この場合、磁石ユニット５１２において径方向の厚さ寸法の縮小化（薄型化）が可能になることに伴い、磁気回路部の径方向内側の領域を拡張することが可能となり、その内側領域を用いて、冷却水通路５４５を有する外側周壁ＷＡ１や、外側周壁ＷＡ１の径方向内側に設けられた複数の電気モジュール５３２を好適に配置することができる。 In the rotary electric machine 500 of the present embodiment, the magnetic flux on the d-axis is strengthened by collecting the magnetic flux on the d-axis side in the magnet unit 512, and the torque can be increased accordingly. In this case, as the thickness dimension in the radial direction can be reduced (thinned) in the magnet unit 512, the area inside the magnetic circuit portion in the radial direction can be expanded, and the inner area is used. Therefore, the outer peripheral wall WA1 having the cooling water passage 545 and a plurality of electric modules 532 provided on the inner side in the radial direction of the outer peripheral wall WA1 can be preferably arranged.
　また、磁気回路部、外側周壁ＷＡ１、複数の電気モジュール５３２だけでなく、軸受５６０やレゾルバ６６０についても同様に、径方向に好適に配置することができる。 Further, not only the magnetic circuit unit, the outer peripheral wall WA1, and the plurality of electric modules 532, but also the bearing 560 and the resolver 660 can be preferably arranged in the radial direction.
　回転電機５００をインホイールモータとして用いた車輪４００は、インバータハウジング５３１に固定されたベースプレート４０５と、サスペンション装置等の装着機構とを介して車体に装着される。ここで、回転電機５００では小型化が実現されていることから、車体への組み付けを想定しても省スペース化が可能となる。そのため、車両においてバッテリ等の電源装置の設置領域を拡大したり、車室スペースを拡張したりする上で有利な構成を実現できる。 The wheel 400 using the rotary electric machine 500 as an in-wheel motor is mounted on the vehicle body via a base plate 405 fixed to the inverter housing 531 and a mounting mechanism such as a suspension device. Here, since the rotary electric machine 500 has been miniaturized, it is possible to save space even if it is assumed to be assembled to the vehicle body. Therefore, it is possible to realize an advantageous configuration in expanding the installation area of the power supply device such as a battery in the vehicle and expanding the vehicle interior space.
　以下に、インホイールモータに関する変形例を説明する。 Below, a modified example of the in-wheel motor will be described.
　（インホイールモータにおける変形例１）
　回転電機５００では、インバータユニット５３０の外側周壁ＷＡ１の径方向内側に、電気モジュール５３２及びバスバーモジュール５３３が配置されるとともに、外側周壁ＷＡ１を隔てて径方向の内側及び外側に、電気モジュール５３２及びバスバーモジュール５３３と、固定子５２０とがそれぞれ配置されている。かかる構成において、電気モジュール５３２に対するバスバーモジュール５３３の位置は任意に設定可能である。また、外側周壁ＷＡ１を径方向に横切って固定子巻線５２１の各相巻線とバスバーモジュール５３３とを接続する場合において、その接続に用いられる巻線接続線（例えば巻線接続端子６３３）を案内する位置は任意に設定可能である。 (Modification example 1 in an in-wheel motor)
In the rotary electric machine 500, the electric module 532 and the bus bar module 533 are arranged radially inside the outer peripheral wall WA1 of the inverter unit 530, and the electric module 532 and the bus bar are arranged radially inside and outside across the outer peripheral wall WA1. The module 533 and the stator 520 are arranged respectively. In such a configuration, the position of the bus bar module 533 with respect to the electric module 532 can be arbitrarily set. Further, when connecting each phase winding of the stator winding 521 and the bus bar module 533 across the outer peripheral wall WA1 in the radial direction, the winding connection line (for example, winding connection terminal 633) used for the connection is connected. The guide position can be set arbitrarily.
　すなわち、電気モジュール５３２に対するバスバーモジュール５３３の位置としては、（α１）バスバーモジュール５３３を、軸方向において電気モジュール５３２よりも車両外側、すなわち回転子キャリア５１１側の奥側とする構成と、
（α２）バスバーモジュール５３３を、軸方向において電気モジュール５３２よりも車両内側、すなわち回転子キャリア５１１側の手前側とする構成と、
が考えられる。 That is, the position of the bus bar module 533 with respect to the electric module 532 is such that the (α1) bus bar module 533 is located outside the vehicle in the axial direction, that is, behind the rotor carrier 511 side.
(Α2) The bus bar module 533 is located inside the vehicle in the axial direction from the electric module 532, that is, on the front side of the rotor carrier 511 side.
Can be considered.
　また、巻線接続線を案内する位置としては、
（β１）巻線接続線を、軸方向において車両外側、すなわち回転子キャリア５１１側の奥側で案内する構成と、
（β２）巻線接続線を、軸方向において車両内側、すなわち回転子キャリア５１１側の手前側で案内する構成と、
が考えられる。 Also, as a position to guide the winding connection line,
(Β1) A configuration in which the winding connection wire is guided in the axial direction on the outside of the vehicle, that is, on the back side of the rotor carrier 511.
(Β2) A configuration in which the winding connection wire is guided inside the vehicle in the axial direction, that is, on the front side of the rotor carrier 511 side.
Can be considered.
　以下には、電気モジュール５３２、バスバーモジュール５３３及び巻線接続線の配置に関する４つの構成例を、図７２（ａ）～（ｄ）を用いて説明する。図７２（ａ）～（ｄ）は、回転電機５００の構成を簡略化して示す縦断面図であり、同図には、既に説明した構成に同じ符号が付されている。巻線接続線６３７は、固定子巻線５２１の各相巻線とバスバーモジュール５３３とを接続する電気配線であり、例えば既述の巻線接続端子６３３がこれに相当する。 Hereinafter, four configuration examples relating to the arrangement of the electric module 532, the bus bar module 533, and the winding connection line will be described with reference to FIGS. 72 (a) to 72 (d). 72 (a) to 72 (d) are vertical cross-sectional views showing the configuration of the rotary electric machine 500 in a simplified manner, and the same reference numerals are given to the configurations already described in the drawings. The winding connection line 637 is an electric wiring that connects each phase winding of the stator winding 521 and the bus bar module 533, and for example, the winding connection terminal 633 described above corresponds to this.
　図７２（ａ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α１）を採用するとともに、巻線接続線６３７を案内する位置として上記（β１）を採用している。つまり、電気モジュール５３２及びバスバーモジュール５３３、固定子巻線５２１及びバスバーモジュール５３３がいずれも車両外側（回転子キャリア５１１の奥側）で接続される構成となっている。なおこれは、図４９に示す構成に相当する。 In the configuration of FIG. 72 (a), the above (α1) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (β1) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532, the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected on the outside of the vehicle (the back side of the rotor carrier 511). This corresponds to the configuration shown in FIG. 49.
　本構成によれば、外側周壁ＷＡ１において、巻線接続線６３７との干渉を懸念することなく冷却水通路５４５を設けることができる。また、固定子巻線５２１とバスバーモジュール５３３とを接続する巻線接続線６３７を簡易に実現できる。 According to this configuration, the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637. Further, the winding connection line 637 that connects the stator winding 521 and the bus bar module 533 can be easily realized.
　図７２（ｂ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α１）を採用するとともに、巻線接続線６３７を案内する位置として上記（β２）を採用している。つまり、電気モジュール５３２とバスバーモジュール５３３とが車両外側（回転子キャリア５１１の奥側）で接続されるとともに、固定子巻線５２１とバスバーモジュール５３３とが車両内側（回転子キャリア５１１の手前側）で接続される構成となっている。 In the configuration of FIG. 72 (b), the above (α1) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (β2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected on the outside of the vehicle (the back side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected on the inside of the vehicle (the front side of the rotor carrier 511). It is configured to be connected with.
　本構成によれば、外側周壁ＷＡ１において、巻線接続線６３７との干渉を懸念することなく冷却水通路５４５を設けることができる。 According to this configuration, the cooling water passage 545 can be provided on the outer peripheral wall WA1 without fear of interference with the winding connection line 637.
　図７２（ｃ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α２）を採用するとともに、巻線接続線６３７を案内する位置として上記（β１）を採用している。つまり、電気モジュール５３２とバスバーモジュール５３３とが車両内側（回転子キャリア５１１の手前側）で接続されるとともに、固定子巻線５２１とバスバーモジュール５３３とが車両外側（回転子キャリア５１１の奥側）で接続される構成となっている。 In the configuration of FIG. 72 (c), the above (α2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (β1) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532 and the bus bar module 533 are connected inside the vehicle (front side of the rotor carrier 511), and the stator winding 521 and the bus bar module 533 are connected outside the vehicle (back side of the rotor carrier 511). It is configured to be connected with.
　図７２（ｄ）の構成では、電気モジュール５３２に対するバスバーモジュール５３３の位置として上記（α２）を採用するとともに、巻線接続線６３７を案内する位置として上記（β２）を採用している。つまり、電気モジュール５３２及びバスバーモジュール５３３、固定子巻線５２１及びバスバーモジュール５３３がいずれも車両内側（回転子キャリア５１１の手前側）で接続される構成となっている。 In the configuration of FIG. 72 (d), the above (α2) is adopted as the position of the bus bar module 533 with respect to the electric module 532, and the above (β2) is adopted as the position for guiding the winding connection line 637. That is, the electric module 532, the bus bar module 533, the stator winding 521, and the bus bar module 533 are all connected inside the vehicle (on the front side of the rotor carrier 511).
　図７２（ｃ）、図７２（ｄ）の構成によれば、バスバーモジュール５３３が車両内側（回転子キャリア５１１の手前側）に配置されることで、仮にファンモータなどの電気部品を追加しようとする場合に、その配線が容易となることが考えられる。また、軸受よりも車両内側に配置されるレゾルバ６６０に対してバスバーモジュール５３３を近づけることが可能になり、レゾルバ６６０に対する配線が容易になることも考えられる。 According to the configurations of FIGS. 72 (c) and 72 (d), the bus bar module 533 is arranged inside the vehicle (on the front side of the rotor carrier 511) to temporarily add an electric component such as a fan motor. In that case, it is considered that the wiring becomes easy. Further, it is possible that the bus bar module 533 can be brought closer to the resolver 660 arranged inside the vehicle than the bearing, and it is considered that the wiring to the resolver 660 becomes easier.
　（インホイールモータにおける変形例２）
　以下に、レゾルバロータ６６１の取付構造の変形例を説明する。すなわち、回転軸５０１、回転子キャリア５１１及び軸受５６０の内輪５６１は一体的に回転する回転体であり、その回転体に対するレゾルバロータ６６１の取付構造の変形例について以下に説明する。 (Modification example 2 in an in-wheel motor)
A modified example of the mounting structure of the resolver rotor 661 will be described below. That is, the rotating shaft 501, the rotor carrier 511, and the inner ring 561 of the bearing 560 are rotating bodies that rotate integrally, and a modified example of the mounting structure of the resolver rotor 661 with respect to the rotating body will be described below.
　図７３（ａ）～（ｃ）は、上記回転体に対するレゾルバロータ６６１の取付構造例を示す構成図である。いずれの構成においても、レゾルバ６６０は、回転子キャリア５１１及びインバータハウジング５３１等により囲まれ、外部からの被水や被泥等から防護された密閉空間に設けられている。図７３（ａ）～（ｃ）のうち図７３（ａ）では、軸受５６０を、図４９と同じ構成としている。また、図７３（ｂ）、図７３（ｃ）では、軸受５６０を、図４９とは異なる構成とし、かつ回転子キャリア５１１の端板５１４から離れた位置に配置している。これら各図には、レゾルバロータ６６１の取付場所としてそれぞれ２カ所を例示している。なお、レゾルバステータ６６２については図示されていないが、例えばボス形成部材５４３のボス部５４８をレゾルバロータ６６１の外周側又はその付近まで延ばし、そのボス部５４８にレゾルバステータ６６２が固定されていればよい。 FIGS. 73 (a) to 73 (c) are block diagrams showing an example of a mounting structure of the resolver rotor 661 to the rotating body. In either configuration, the resolver 660 is provided in a closed space surrounded by a rotor carrier 511, an inverter housing 531 and the like, and protected from external water and mud. Of FIGS. 73 (a) to 73 (c), in FIG. 73 (a), the bearing 560 has the same configuration as that in FIG. 49. Further, in FIGS. 73 (b) and 73 (c), the bearing 560 has a configuration different from that of FIG. 49, and is arranged at a position away from the end plate 514 of the rotor carrier 511. In each of these figures, two locations are illustrated as mounting locations for the resolver rotor 661. Although the resolver stator 662 is not shown, for example, the boss portion 548 of the boss forming member 543 may be extended to the outer peripheral side of the resolver rotor 661 or its vicinity, and the resolver stator 662 may be fixed to the boss portion 548. ..
　図７３（ａ）の構成では、軸受５６０の内輪５６１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、内輪５６１のフランジ５６１ｂの軸方向端面に設けられているか、又は内輪５６１の筒部５６１ａの軸方向端面に設けられている。 In the configuration of FIG. 73A, the resolver rotor 661 is attached to the inner ring 561 of the bearing 560. Specifically, the resolver rotor 661 is provided on the axial end face of the flange 561b of the inner ring 561, or is provided on the axial end face of the tubular portion 561a of the inner ring 561.
　図７３（ｂ）の構成では、回転子キャリア５１１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、回転子キャリア５１１において端板５１４の内面に設けられている。又は、回転子キャリア５１１が、端板５１４の内周縁部から回転軸５０１に沿って延びる筒部５１５を有する構成において、レゾルバロータ６６１が、回転子キャリア５１１の筒部５１５の外周面に設けられている。後者の場合、レゾルバロータ６６１は、回転子キャリア５１１の端板５１４と軸受５６０との間に配置されている。 In the configuration of FIG. 73 (b), the resolver rotor 661 is attached to the rotor carrier 511. Specifically, the resolver rotor 661 is provided on the inner surface of the end plate 514 in the rotor carrier 511. Alternatively, in a configuration in which the rotor carrier 511 has a tubular portion 515 extending from the inner peripheral edge portion of the end plate 514 along the rotation shaft 501, the resolver rotor 661 is provided on the outer peripheral surface of the tubular portion 515 of the rotor carrier 511. ing. In the latter case, the resolver rotor 661 is arranged between the end plate 514 of the rotor carrier 511 and the bearing 560.
　図７３（ｃ）の構成では、回転軸５０１にレゾルバロータ６６１が取り付けられている。具体的には、レゾルバロータ６６１が、回転軸５０１において回転子キャリア５１１の端板５１４と軸受５６０との間に設けられているか、又は回転軸５０１において軸受５６０を挟んで回転子キャリア５１１の反対側に配置されている。 In the configuration of FIG. 73 (c), the resolver rotor 661 is attached to the rotating shaft 501. Specifically, the resolver rotor 661 is provided between the end plate 514 of the rotor carrier 511 and the bearing 560 on the rotating shaft 501, or is opposite to the rotor carrier 511 with the bearing 560 sandwiched on the rotating shaft 501. It is located on the side.
　（インホイールモータにおける変形例３）
　以下に、インバータハウジング５３１及び回転子カバー６７０の変形例を図７４を用いて説明する。図７４（ａ）、図７４（ｂ）は、回転電機５００の構成を簡略化して示す縦断面図であり、同図には、既に説明した構成に同じ符号が付されている。なお、図７４（ａ）に示す構成は、実質的に図４９等で説明した構成に相当し、図７４（ｂ）に示す構成は、図７４（ａ）の構成の一部を変更した構成に相当する。 (Modification example 3 in an in-wheel motor)
A modification of the inverter housing 531 and the rotor cover 670 will be described below with reference to FIG. 74. 74 (a) and 74 (b) are vertical cross-sectional views showing a simplified configuration of the rotary electric machine 500, in which the same reference numerals are given to the configurations already described. The configuration shown in FIG. 74 (a) substantially corresponds to the configuration described in FIG. 49 and the like, and the configuration shown in FIG. 74 (b) is a configuration in which a part of the configuration of FIG. 74 (a) is modified. Corresponds to.
　図７４（ａ）に示す構成では、回転子キャリア５１１の開放端部に固定された回転子カバー６７０が、インバータハウジング５３１の外側周壁ＷＡ１を囲むように設けられている。つまり、回転子カバー６７０の内径側の端面が外側周壁ＷＡ１の外周面に対向しており、それら両者の間にシール材６７１が設けられている。また、インバータハウジング５３１のボス部５４８の中空部にはハウジングカバー６６６が取り付けられ、そのハウジングカバー６６６と回転軸５０１との間にシール材６６７が設けられている。バスバーモジュール５３３を構成する外部接続端子６３２は、インバータハウジング５３１を貫通して車両内側（図の下側）に延びている。 In the configuration shown in FIG. 74A, a rotor cover 670 fixed to the open end of the rotor carrier 511 is provided so as to surround the outer peripheral wall WA1 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the outer peripheral wall WA1, and a sealing material 671 is provided between them. A housing cover 666 is attached to the hollow portion of the boss portion 548 of the inverter housing 531, and a sealing material 667 is provided between the housing cover 666 and the rotating shaft 501. The external connection terminal 632 constituting the bus bar module 533 penetrates the inverter housing 531 and extends to the inside of the vehicle (lower side in the figure).
　また、インバータハウジング５３１には、冷却水通路５４５に連通する入口通路５７１及び出口通路５７２が形成されるとともに、それら入口通路５７１及び出口通路５７２の通路端部を含む水路ポート５７４が形成されている。 Further, the inverter housing 531 is formed with an inlet passage 571 and an outlet passage 57 2 communicating with the cooling water passage 545, and a water channel port 574 including the passage ends of the inlet passage 571 and the outlet passage 572. ..
　これに対して、図７４（ｂ）に示す構成では、インバータハウジング５３１（詳しくはボス形成部材５４３）に、回転軸５０１の突出側（車両内側）に延びる環状の凸部６８１が形成されており、回転子カバー６７０が、インバータハウジング５３１の凸部６８１を囲むように設けられている。つまり、回転子カバー６７０の内径側の端面が凸部６８１の外周面に対向しており、それら両者の間にシール材６７１が設けられている。また、バスバーモジュール５３３を構成する外部接続端子６３２は、インバータハウジング５３１のボス部５４８を貫通してボス部５４８の中空領域に延びるとともに、ハウジングカバー６６６を貫通して車両内側（図の下側）に延びている。 On the other hand, in the configuration shown in FIG. 74 (b), the inverter housing 531 (specifically, the boss forming member 543) is formed with an annular convex portion 681 extending toward the protruding side (inside the vehicle) of the rotating shaft 501. , The rotor cover 670 is provided so as to surround the convex portion 681 of the inverter housing 531. That is, the end surface on the inner diameter side of the rotor cover 670 faces the outer peripheral surface of the convex portion 681, and the sealing material 671 is provided between them. Further, the external connection terminal 632 constituting the bus bar module 533 penetrates the boss portion 548 of the inverter housing 531 and extends into the hollow region of the boss portion 548, and also penetrates the housing cover 666 and penetrates the inside of the vehicle (lower side of the figure). Extends to.
　また、インバータハウジング５３１には、冷却水通路５４５に連通する入口通路５７１及び出口通路５７２が形成されており、それら入口通路５７１及び出口通路５７２は、ボス部５４８の中空領域に延び、かつ中継配管６８２を介してハウジングカバー６６６よりも車両内側（図の下側）に延びている。本構成では、ハウジングカバー６６６から車両内側に延びる配管部分が水路ポート５７４となっている。 Further, the inverter housing 531 is formed with an inlet passage 571 and an outlet passage 572 communicating with the cooling water passage 545, and the inlet passage 571 and the outlet passage 572 extend into the hollow region of the boss portion 548 and are a relay pipe. It extends to the inside of the vehicle (lower side of the figure) from the housing cover 666 via 682. In this configuration, the piping portion extending from the housing cover 666 to the inside of the vehicle is the water channel port 574.
　図７４（ａ）、図７４（ｂ）の各構成によれば、回転子キャリア５１１及び回転子カバー６７０の内部空間の密閉性を保持しつつ、これら回転子キャリア５１１及び回転子カバー６７０をインバータハウジング５３１に対して好適に回転させることができる。 According to the configurations of FIGS. 74 (a) and 74 (b), the rotor carrier 511 and the rotor cover 670 are integrated with the rotor carrier 511 and the rotor cover 670 while maintaining the airtightness of the internal space of the rotor carrier 511 and the rotor cover 670. It can be suitably rotated with respect to the housing 531.
　また特に、図７４（ｂ）の構成によれば、図７４（ａ）の構成に比べて、回転子カバー６７０の内径が小さくなっている。そのため、電気モジュール５３２よりも車両内側となる位置に、インバータハウジング５３１と回転子カバー６７０とが軸方向に二重に設けられるようになり、電気モジュール５３２にて懸念される電磁ノイズによる不都合を抑制することができる。また、回転子カバー６７０の内径を小さくすることによりシール材６７１の摺動径が小さくなり、回転摺動部分における機械的ロスを抑制することができる。 In particular, according to the configuration of FIG. 74 (b), the inner diameter of the rotor cover 670 is smaller than that of the configuration of FIG. 74 (a). Therefore, the inverter housing 531 and the rotor cover 670 are provided twice in the axial direction at a position inside the vehicle from the electric module 532, and the inconvenience caused by electromagnetic noise, which is a concern in the electric module 532, is suppressed. can do. Further, by reducing the inner diameter of the rotor cover 670, the sliding diameter of the sealing material 671 can be reduced, and mechanical loss in the rotating sliding portion can be suppressed.
　（インホイールモータにおける変形例４）
　以下に、固定子巻線５２１の変形例を説明する。図７５に、固定子巻線５２１に関する変形例を示す。 (Modification example 4 in an in-wheel motor)
A modified example of the stator winding 521 will be described below. FIG. 75 shows a modified example of the stator winding 521.
　図７５に示すように、固定子巻線５２１は、横断面が矩形状をなす導線材を用い、その導線材の長辺が周方向に延びる向きにして波巻により巻回されている。この場合、固定子巻線５２１においてコイルサイドとなる各相の導線５２３は、相ごとに所定ピッチ間隔で配置されるとともに、コイルエンドで互いに接続されている。コイルサイドにおいて周方向に隣り合う各導線５２３は、周方向の端面同士が互いに当接するか、又は微小な間隔を隔てて近接配置されている。 As shown in FIG. 75, the stator winding 521 uses a conducting wire having a rectangular cross section, and is wound by a wave winding with the long side of the conducting wire extending in the circumferential direction. In this case, the lead wires 523 of each phase on the coil side of the stator winding 521 are arranged at predetermined pitch intervals for each phase and are connected to each other at the coil ends. The conductive wires 523 adjacent to each other in the circumferential direction on the coil side are in contact with each other at the end faces in the circumferential direction, or are arranged close to each other at a minute interval.
　また、固定子巻線５２１では、コイルエンドにおいて相ごとに導線材が径方向に折り曲げられている。より詳しくは、固定子巻線５２１（導線材）は、軸方向において相ごとに異なる位置にて径方向内側に折り曲げられており、これにより、Ｕ相、Ｖ相及びＷ相の各相巻線における互いの干渉が回避されている。図示の構成では、各相巻線で導線材の厚み分だけ異ならせて、相ごとに導線材が径方向内側に直角に折り曲げられている。周方向に並ぶ各導線５２３において軸方向の両端間の長さ寸法は各導線５２３で同じであるとよい。 Further, in the stator winding 521, the conducting wire material is bent in the radial direction for each phase at the coil end. More specifically, the stator winding 521 (conductor) is bent inward in the radial direction at different positions for each phase in the axial direction, whereby the U-phase, V-phase, and W-phase windings are formed. Interference with each other is avoided. In the illustrated configuration, the conductors are bent at right angles inward in the radial direction for each phase, with each phase winding being different by the thickness of the conductor. In each of the conductors 523 arranged in the circumferential direction, the length dimension between both ends in the axial direction may be the same for each of the conductors 523.
　なお、固定子巻線５２１に固定子コア５２２を組み付けて固定子５２０を製作する際には、固定子巻線５２１において円環状の一部を非接続として切り離しておき（すなわち、固定子巻線５２１を略Ｃ字状にしておき）、固定子巻線５２１の内周側に固定子コア５２２を組み付けた後に、切り離し部分を互いに接続させて固定子巻線５２１を円環状にするとよい。 When the stator core 522 is assembled to the stator winding 521 to manufacture the stator 520, a part of the annular shape of the stator winding 521 is disconnected as a non-connection (that is, the stator winding). 521 may be substantially C-shaped), and after assembling the stator core 522 on the inner peripheral side of the stator winding 521, the disconnecting portions may be connected to each other to form the stator winding 521 in an annular shape.
　上記以外に、固定子コア５２２を周方向にて複数（例えば３つ以上）に分割しておき、円環状に形成された固定子巻線５２１の内周側に、複数に分割されたコア片を組み付けるようにすることも可能である。 In addition to the above, the stator core 522 is divided into a plurality of parts (for example, three or more) in the circumferential direction, and the core pieces divided into a plurality of pieces are formed on the inner peripheral side of the stator winding 521 formed in an annular shape. It is also possible to assemble.
　（他の変形例）
　・例えば図５０に示すように、回転電機５００では、冷却水通路５４５の入口通路５７１と出口通路５７２とが一カ所にまとめて設けられているが、この構成を変更し、入口通路５７１と出口通路５７２とが周方向に異なる位置にそれぞれ設けられていてもよい。例えば、入口通路５７１と出口通路５７２とを周方向に１８０度異なる位置に設ける構成や、入口通路５７１及び出口通路５７２の少なくともいずれかを複数設ける構成であってもよい。 (Other variants)
-For example, as shown in FIG. 50, in the rotary electric machine 500, the inlet passage 571 and the outlet passage 572 of the cooling water passage 545 are provided together in one place. However, this configuration has been changed to change the configuration so that the inlet passage 571 and the outlet are provided. The passages 572 may be provided at different positions in the circumferential direction. For example, the inlet passage 571 and the exit passage 57 2 may be provided at positions different from each other by 180 degrees in the circumferential direction, or at least one of the inlet passage 571 and the exit passage 572 may be provided in a plurality of positions.
　・上記実施形態の車輪４００では、回転電機５００の軸方向の片側に回転軸５０１を突出させる構成としたが、これを変更し、軸方向の両方に回転軸５０１を突出させる構成としてもよい。これにより、例えば車両前後の少なくとも一方が１輪となる車両において好適な構成を実現できる。 -The wheel 400 of the above embodiment has a configuration in which the rotary shaft 501 protrudes on one side in the axial direction of the rotary electric machine 500, but this may be changed to a configuration in which the rotary shaft 501 protrudes in both axial directions. Thereby, for example, a suitable configuration can be realized in a vehicle in which at least one of the front and rear of the vehicle is one wheel.
　・車輪４００に用いられる回転電機５００として、インナロータ式の回転電機を用いることも可能である。 -It is also possible to use an inner rotor type rotary electric machine as the rotary electric machine 500 used for the wheel 400.
　（変形例１５）
　次に、本変形例における回転電機７００について説明する。回転電機７００は、車両の駆動用ユニットとして用いられる。回転電機７００の概要を図７６～図７８に示す。図７６は、回転電機７００の全体を示す斜視図であり、図７７は、回転電機７００の縦断面図であり、図７８は、回転電機７００の構成要素を分解した分解断面図である。 (Modification 15)
Next, the rotary electric machine 700 in this modification will be described. The rotary electric machine 700 is used as a vehicle driving unit. The outline of the rotary electric machine 700 is shown in FIGS. 76 to 78. FIG. 76 is a perspective view showing the entire rotary electric machine 700, FIG. 77 is a vertical sectional view of the rotary electric machine 700, and FIG. 78 is an exploded sectional view of components of the rotary electric machine 700.
　回転電機７００は、アウタロータ式の表面磁石型回転電機である。回転電機７００は、大別して、回転子７１０、固定子７３０、インナユニット７７０及びバスバーモジュール８１０を有する回転電機本体と、その回転電機本体を囲むように設けられるハウジング８３１及びカバー８３２とを備えている。これら各部材はいずれも、回転子７１０に一体に設けられた回転軸７０１に対して同軸に配置されており、所定順序で軸方向に組み付けられることで回転電機７００が構成されている。回転子７１０は、インナユニット７７０の径方向内側に設けられた一対の軸受７９１，７９２に片持ち支持され、その状態で回転可能となっている。回転軸７０１には、車両の車軸や車輪等に固定される連結軸７０５が一体に設けられている。 The rotary electric machine 700 is an outer rotor type surface magnet type rotary electric machine. The rotary electric machine 700 is roughly classified into a rotary electric machine main body having a rotor 710, a stator 730, an inner unit 770 and a bus bar module 810, and a housing 831 and a cover 832 provided so as to surround the rotary electric machine main body. .. Each of these members is arranged coaxially with respect to the rotating shaft 701 integrally provided on the rotor 710, and is assembled in the axial direction in a predetermined order to form the rotating electric machine 700. The rotor 710 is cantilevered by a pair of bearings 791 and 792 provided inside the inner unit 770 in the radial direction, and can rotate in that state. The rotating shaft 701 is integrally provided with a connecting shaft 705 fixed to the axle, wheels, or the like of the vehicle.
　回転電機７００において、回転子７１０及び固定子７３０はそれぞれ円筒状をなしており、エアギャップを挟んで径方向に対向配置されている。回転子７１０が回転軸７０１と共に一体回転することにより、固定子７３０の径方向外側にて回転子７１０が回転する。回転子７１０が「界磁子」に相当し、固定子７３０が「電機子」に相当する。 In the rotary electric machine 700, the rotor 710 and the stator 730 each have a cylindrical shape, and are arranged so as to face each other in the radial direction with an air gap in between. As the rotor 710 rotates integrally with the rotation shaft 701, the rotor 710 rotates on the radial outer side of the stator 730. The rotor 710 corresponds to the "field magnet" and the stator 730 corresponds to the "armature".
　図７９に示すように、回転子７１０は、略円筒状の回転子キャリア７１１と、その回転子キャリア７１１に固定された環状の磁石ユニット７１２とを有している。回転子キャリア７１１は、端板部７１３と、その端板部７１３の外周部から軸方向に延びる筒部７１４とを有している。端板部７１３には貫通孔７１３ａが形成されており、その貫通孔７１３ａに挿通された状態で、ボルト等の締結具７１５により端板部７１３に回転軸７０１が固定されている。回転軸７０１は、回転子キャリア７１１が固定される部分に、軸方向に交差（直交）する向きに延びるフランジ７０２を有しており、そのフランジ７０２と端板部７１３とが面接合されている状態で、回転軸７０１に対して回転子キャリア７１１が固定されている。 As shown in FIG. 79, the rotor 710 has a substantially cylindrical rotor carrier 711 and an annular magnet unit 712 fixed to the rotor carrier 711. The rotor carrier 711 has an end plate portion 713 and a tubular portion 714 extending in the axial direction from the outer peripheral portion of the end plate portion 713. A through hole 713a is formed in the end plate portion 713, and the rotating shaft 701 is fixed to the end plate portion 713 by a fastener 715 such as a bolt in a state of being inserted into the through hole 713a. The rotating shaft 701 has a flange 702 extending in a direction intersecting (orthogonal) in the axial direction at a portion where the rotor carrier 711 is fixed, and the flange 702 and the end plate portion 713 are surface-joined. In this state, the rotor carrier 711 is fixed to the rotating shaft 701.
　磁石ユニット７１２は、円筒状の磁石ホルダ７２１と、その磁石ホルダ７２１の内周面に固定された磁石７２２と、磁石７２２の軸方向両側において回転子キャリア７１１とは逆側に固定されたエンドプレート７２３とを有している。磁石ホルダ７２１は、軸方向において磁石７２２と同じ長さ寸法を有している。磁石７２２は、磁石ホルダ７２１に径方向外側から包囲された状態で設けられている。また、磁石ホルダ７２１及び磁石７２２は、軸方向両端のうち一端側が回転子キャリア７１１に当接した状態で固定され、他端側がエンドプレート７２３に当接した状態で固定されている。 The magnet unit 712 includes a cylindrical magnet holder 721, a magnet 722 fixed to the inner peripheral surface of the magnet holder 721, and an end plate fixed on both sides of the magnet 722 in the axial direction opposite to the rotor carrier 711. It has 723 and. The magnet holder 721 has the same length dimension as the magnet 722 in the axial direction. The magnet 722 is provided in the magnet holder 721 in a state of being surrounded from the outside in the radial direction. Further, the magnet holder 721 and the magnet 722 are fixed in a state where one end side of both ends in the axial direction is in contact with the rotor carrier 711, and the other end side is fixed in a state of being in contact with the end plate 723.
　回転子キャリア７１１、磁石ホルダ７２１及びエンドプレート７２３はいずれも非磁性体であるアルミニウム又は非磁性ステンレス（例えばＳＵＳ３０４）により構成されている。これら各部材は、アルミニウム等の軽金属により構成されることが望ましいが、これに代えて、合成樹脂により構成されることも可能である。これら各部材は、接着又は溶接により接合されているとよい。 The rotor carrier 711, the magnet holder 721, and the end plate 723 are all made of non-magnetic aluminum or non-magnetic stainless steel (for example, SUS304). Each of these members is preferably made of a light metal such as aluminum, but can be made of a synthetic resin instead. Each of these members may be joined by adhesion or welding.
　図８０は、磁石ユニット７１２の断面構造を示す部分断面図である。図８０には、磁石７２２の磁化容易軸を矢印にて示している。 FIG. 80 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 712. In FIG. 80, the easy magnetization axis of the magnet 722 is indicated by an arrow.
　磁石ユニット７１２において、磁石７２２は、回転子７１０の周方向に沿って極性が交互に変わるように並べて設けられている。これにより、磁石７２２は、周方向に複数の磁極を有する。磁石７２２は、極異方性の永久磁石であり、固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結ネオジム磁石を用いて構成されている。 In the magnet unit 712, the magnets 722 are arranged side by side so that the polarities alternate along the circumferential direction of the rotor 710. As a result, the magnet 722 has a plurality of magnetic poles in the circumferential direction. The magnet 722 is a polar anisotropy permanent magnet, and uses a sintered neodymium magnet having an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more. It is configured.
　磁石７２２は、周方向に隣り合う２磁極において各磁極の中心であるｄ軸間を１磁石として設けられている。つまり、磁石７２２は、１磁極分を１磁石とし、その周方向の中心がｑ軸となっている。磁石７２２において径方向内側の周面が、磁束の授受が行われる磁束授受面７２４である。磁石７２２では、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違しており、ｄ軸側では磁化容易軸の向きがｄ軸に平行する向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する向きとなっている。この場合、磁化容易軸の向きに沿って円弧状の磁石磁路が形成されている。要するに、磁石７２２は、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。 The magnet 722 is provided as one magnet between the d-axis, which is the center of each magnetic pole, in two magnetic poles adjacent to each other in the circumferential direction. That is, the magnet 722 has one magnetic pole as one magnet, and the center in the circumferential direction thereof is the q-axis. The peripheral surface on the inner side of the magnet 722 in the radial direction is the magnetic flux transfer surface 724 on which magnetic flux is transferred. In the magnet 722, the direction of the easy magnetization axis is different between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis), and the direction of the easy magnetization axis is the d-axis on the d-axis side. On the q-axis side, the direction of the easy magnetization axis is orthogonal to the q-axis. In this case, an arcuate magnet magnetic path is formed along the direction of the easy magnetization axis. In short, the magnet 722 is oriented so that the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the q-axis side, which is the magnetic pole boundary.
　周方向に並べられた各磁石７２２によれば、ｄ軸での磁石磁束が強化され、かつｑ軸付近での磁束変化が抑えられる。これにより、各磁極においてｑ軸からｄ軸にかけての表面磁束変化がなだらかになる磁石７２２を好適に実現できるものとなっている。磁石７２２は、周方向の中心をｑ軸とする構成に代えて、周方向の中心をｄ軸とする構成であってもよい。また、磁石７２２として、磁極数と同じ数の磁石を用いる構成に代えて、円環状に繋がった磁石を用いる構成としてもよい。 According to each magnet 722 arranged in the circumferential direction, the magnet magnetic flux on the d-axis is strengthened and the change in magnetic flux near the q-axis is suppressed. As a result, it is possible to preferably realize a magnet 722 in which the change in surface magnetic flux from the q-axis to the d-axis is gentle at each magnetic pole. The magnet 722 may have a configuration in which the center in the circumferential direction is the d-axis instead of the configuration in which the center in the circumferential direction is the q-axis. Further, the magnet 722 may be configured to use magnets connected in an annular shape instead of using the same number of magnets as the number of magnetic poles.
　磁石７２２は以下の構成であることが望ましい。磁石７２２において、ｄ－ｑ軸間の磁束授受面７２４の円弧長さは、磁石７２２の径方向の厚みよりも長くなっている。また、図８１に示すように、磁石７２２においてｑ軸と磁束授受面７２４との交点を中心点ＣＰとし、かつ磁石７２２の径方向の厚み寸法を半径とする円を、磁石７２２の磁化容易軸を定める配向円Ｘとする場合に、磁石７２２が配向円Ｘの四半円分を包括する構成となっている。つまり、磁石７２２では、ｑ軸を横切るように円弧状の磁化容易軸が設けられており、その磁化容易軸のうち、径方向において磁束授受面７２４とは反対側の周面とｑ軸との交点を通る磁化容易軸、すなわち配向円Ｘを通る磁化容易軸により最も強い磁石磁束が生じる。この場合、磁石７２２が配向円Ｘの四半円分を包括する構成であることにより、ｄ軸を通る磁石磁路の長さを、配向円Ｘで規定される長さとして確保した上で磁石磁束を生じさせることが可能となっている。 It is desirable that the magnet 722 has the following configuration. In the magnet 722, the arc length of the magnetic flux transfer surface 724 between the dq axes is longer than the radial thickness of the magnet 722. Further, as shown in FIG. 81, in the magnet 722, a circle whose center point CP is the intersection of the q-axis and the magnetic flux transfer surface 724 and whose radius is the radial thickness dimension of the magnet 722 is the easily magnetized axis of the magnet 722. The magnet 722 is configured to include a quarter circle of the orientation circle X when the orientation circle X is used. That is, the magnet 722 is provided with an arc-shaped easy-to-magnetize axis that crosses the q-axis, and among the easy-to-magnetize axes, the peripheral surface on the side opposite to the magnetic flux transfer surface 724 in the radial direction and the q-axis. The strongest magnet magnetic flux is generated by the easily magnetized axis passing through the intersection, that is, the easily magnetized axis passing through the alignment circle X. In this case, since the magnet 722 includes the quarter circle of the orientation circle X, the length of the magnet magnetic path passing through the d-axis is secured as the length defined by the orientation circle X, and then the magnet magnetic flux. It is possible to generate.
　ここで、磁石７２２においてｄ－ｑ軸間の磁束授受面７２４の円弧長さが磁石７２２の径方向の厚みよりも長くなっていると、磁石７２２よりも径方向外側、すなわち反固定子側への磁束漏れの懸念が生じる。しかしながら、本例の構成では、磁石ホルダ７２１を非磁性体にて構成していることにより、磁束漏れの影響を軽減できるものとなっている。 Here, if the arc length of the magnetic flux transfer surface 724 between the d and q axes of the magnet 722 is longer than the radial thickness of the magnet 722, the magnet 722 is radially outside, that is, toward the anti-stator side. There is a concern about magnetic flux leakage. However, in the configuration of this example, since the magnet holder 721 is made of a non-magnetic material, the influence of magnetic flux leakage can be reduced.
　また、磁石７２２には、径方向外側の外周面に、ｄ軸を含む所定範囲で凹部７２５が形成されているとともに、径方向内側の内周面に、ｑ軸を含む所定範囲で凹部７２６が形成されている。この場合、磁石７２２の磁化容易軸の向きによれば、磁石７２２の外周面においてｄ軸付近で磁石磁路が短くなるとともに、磁石７２２の内周面においてｑ軸付近で磁石磁路が短くなる。そこで、磁石７２２において磁石磁路長が短い場所で十分な磁石磁束を生じさせることが困難になることを考慮して、その磁石磁束の弱い場所で磁石が削除されている。 Further, the magnet 722 is formed with a recess 725 in a predetermined range including the d-axis on the outer peripheral surface in the radial direction, and a recess 726 is formed in a predetermined range including the q-axis on the inner peripheral surface in the radial direction. It is formed. In this case, according to the orientation of the easy-to-magnetize axis of the magnet 722, the magnetic path is shortened near the d-axis on the outer peripheral surface of the magnet 722, and the magnetic path is shortened near the q-axis on the inner peripheral surface of the magnet 722. .. Therefore, in consideration of the fact that it becomes difficult to generate a sufficient magnet magnetic flux in the place where the magnet magnetic path length is short in the magnet 722, the magnet is deleted in the place where the magnet magnetic flux is weak.
　磁石ホルダ７２１は、周方向に並ぶ各磁石７２２の径方向外側に設けられている。また、周方向における各磁石７２２の間と各磁石７２２の径方向内側とを含む範囲で磁石ホルダ７２１が設けられていてもよい。つまり、磁石７２２を囲むようにして磁石ホルダ７２１が設けられていてもよい。磁石ホルダ７２１において各磁石７２２の径方向外側の部分と径方向内側の部分とを有している場合、径方向外側の部分が径方向内側の部分よりも高強度であるとよい。 The magnet holder 721 is provided on the outer side in the radial direction of each magnet 722 arranged in the circumferential direction. Further, the magnet holder 721 may be provided in a range including between each magnet 722 in the circumferential direction and the inside in the radial direction of each magnet 722. That is, the magnet holder 721 may be provided so as to surround the magnet 722. When the magnet holder 721 has a radial outer portion and a radial inner portion of each magnet 722, it is preferable that the radial outer portion has a higher strength than the radial inner portion.
　磁石ホルダ７２１は、磁石７２２の凹部７２５内に入り込む凸部７２７を有している。この場合、磁石７２２の凹部７２５と磁石ホルダ７２１の凸部７２７との係合により、磁石７２２の周方向の位置ずれが抑制されるようになっている。つまり、磁石ホルダ７２１の凸部７２７は、磁石７２２の回り止め部として機能する。また、磁石ホルダ７２１が、磁石７２２よりも径方向内側（固定子７３０側）となる部分を有している場合には、当該部分に、磁石７２２の凹部７２６内に入り込む凸部が設けられていてもよい。 The magnet holder 721 has a convex portion 727 that penetrates into the concave portion 725 of the magnet 722. In this case, the displacement of the magnet 722 in the circumferential direction is suppressed by the engagement between the concave portion 725 of the magnet 722 and the convex portion 727 of the magnet holder 721. That is, the convex portion 727 of the magnet holder 721 functions as a detent portion of the magnet 722. Further, when the magnet holder 721 has a portion that is radially inside (the stator 730 side) of the magnet 722, the portion is provided with a convex portion that enters the recess 726 of the magnet 722. You may.
　次に、固定子７３０の構成を説明する。 Next, the configuration of the stator 730 will be described.
　固定子７３０は、固定子巻線７３１と固定子コア７３２とを有している。図８２は、固定子７３０の構成を示す斜視図であり、図８３は、固定子巻線７３１と固定子コア７３２とを分解して示す斜視図であり、図８４は、各相の相巻線のうちＵ相巻線に相当する構成のみを示す斜視図であり、図８５は、固定子７３０の縦断面図である。 The stator 730 has a stator winding 731 and a stator core 732. FIG. 82 is a perspective view showing the configuration of the stator 730, FIG. 83 is a perspective view showing the stator winding 731 and the stator core 732 in an exploded manner, and FIG. 84 is a phase winding of each phase. It is a perspective view which shows only the structure corresponding to the U-phase winding among lines, and FIG. 85 is a vertical sectional view of the stator 730.
　固定子コア７３２は、磁性体である電磁鋼板からなる複数のコアシート７３２ａを用いその複数のコアシート７３２ａが軸方向に積層されたコアシート積層体として構成されており、径方向に所定の厚さを有する円筒状をなしている。固定子コア７３２において回転子７１０側となる径方向外側には固定子巻線７３１が組み付けられている。固定子コア７３２の外周面は凹凸のない曲面状をなしている。固定子コア７３２は、スロットレス構造を有しており、バックヨークとして機能する。固定子コア７３２は、例えば円環板状に打ち抜き形成された複数枚のコアシート７３２ａが軸方向に積層されて構成されている。ただし、固定子コア７３２としてヘリカルコア構造を有するものを用いてもよい。ヘリカルコア構造の固定子コア７３２では、帯状のコアシートが用いられ、このコアシートが環状に巻回形成されるとともに軸方向に積層されることで、全体として円筒状の固定子コア７３２が構成されている。 The stator core 732 is configured as a core sheet laminate in which a plurality of core sheets 732a made of an electromagnetic steel plate which is a magnetic material are used and the plurality of core sheets 732a are laminated in the axial direction, and has a predetermined thickness in the radial direction. It has a cylindrical shape with a diameter. A stator winding 731 is assembled on the radial outer side of the stator core 732 on the rotor 710 side. The outer peripheral surface of the stator core 732 has a curved surface without unevenness. The stator core 732 has a slotless structure and functions as a back yoke. The stator core 732 is configured by, for example, a plurality of core sheets 732a punched out in an annular plate shape and laminated in the axial direction. However, a stator core 732 having a helical core structure may be used. A band-shaped core sheet is used in the stator core 732 having a helical core structure, and the core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 732 as a whole. Has been done.
　固定子コア７３２において、軸方向両側の端面にはエンドリング７３３が固定されている。エンドリング７３３は、固定子コア７３２に固定子巻線７３１を組み付けた状態で、その固定子巻線７３１を周方向の所定位置に保持する機能を有する位置決め部材である。固定子コア７３２及びエンドリング７３３がベース部材７３６である。 In the stator core 732, end rings 733 are fixed to the end faces on both sides in the axial direction. The end ring 733 is a positioning member having a function of holding the stator winding 731 at a predetermined position in the circumferential direction in a state where the stator winding 731 is assembled to the stator core 732. The stator core 732 and the end ring 733 are the base member 736.
　エンドリング７３３の外周面には、固定子コア７３２及びエンドリング７３３と同心となる同心円上の接線に対して傾斜する向きで係合面７３４が形成されている。係合面７３４は、エンドリング７３３の外周面を複数に等分して設けられている。本例では、固定子巻線７３１において周方向に並ぶコイルサイドの導線部（後述するコイルモジュール７４０の直線部７４４）と同数の係合面７３４が周方向に設けられている。また、本例では、当該接線に対する傾斜の向きが、周方向に隣り合う各係合面７３４で互いに逆向きとなっていることにより、エンドリング７３３の外周面にテーパ状の係合部が形成されている。この場合、テーパ状の凸部の間に凹部７３５が形成されている。 An engaging surface 734 is formed on the outer peripheral surface of the end ring 733 in a direction inclined with respect to a tangent line on a concentric circle concentric with the stator core 732 and the end ring 733. The engaging surface 734 is provided by dividing the outer peripheral surface of the end ring 733 into a plurality of equal parts. In this example, in the stator winding 731, the same number of engaging surfaces 734 as the coil side conducting wire portions (straight line portion 744 of the coil module 740 described later) arranged in the circumferential direction are provided in the circumferential direction. Further, in this example, the direction of inclination with respect to the tangent line is opposite to each other on the engaging surfaces 734 adjacent to each other in the circumferential direction, so that a tapered engaging portion is formed on the outer peripheral surface of the end ring 733. Has been done. In this case, a recess 735 is formed between the tapered protrusions.
　軸方向両側の各エンドリング７３３では、軸方向一端側及び他端側で周方向における凹凸の位置が一致している。つまり、軸方向一端側のエンドリング７３３及び軸方向他端側のエンドリング７３３は、係合面７３４による凸頂部の位置が周方向で一致するようにして固定子コア７３２に対して固定されている。 In each end ring 733 on both sides in the axial direction, the positions of the unevenness in the circumferential direction are the same on one end side and the other end side in the axial direction. That is, the end ring 733 on the one end side in the axial direction and the end ring 733 on the other end side in the axial direction are fixed to the stator core 732 so that the positions of the convex tops of the engaging surface 734 coincide with each other in the circumferential direction. There is.
　エンドリング７３３の内径は固定子コア７３２の内径と同じである。また、エンドリング７３３の外径は、最大径となる部分で固定子コア７３２の外径と同じであり、最小径となる部分で固定子コア７３２の外径よりも小さくなっている。 The inner diameter of the end ring 733 is the same as the inner diameter of the stator core 732. Further, the outer diameter of the end ring 733 is the same as the outer diameter of the stator core 732 at the portion where the maximum diameter is reached, and is smaller than the outer diameter of the stator core 732 at the portion where the minimum diameter is reached.
　エンドリング７３３は、例えばアルミニウムや銅等の非磁性材料により形成されている。エンドリング７３３は、固定子コア７３２に対して溶接により固定されている。これ以外に、エンドリング７３３が、ピン差しやキー圧入、ボルト締結により機械的に固定されていてもよい。こうした機械的な固定により、固定子コア７３２に対するエンドリング７３３の周方向の位置ずれが抑制されるものとなっている。 The end ring 733 is made of a non-magnetic material such as aluminum or copper. The end ring 733 is fixed to the stator core 732 by welding. Alternatively, the end ring 733 may be mechanically fixed by pin insertion, key press fitting, or bolt fastening. By such mechanical fixing, the displacement of the end ring 733 with respect to the stator core 732 in the circumferential direction is suppressed.
　図８５に示すように、固定子７３０は、軸方向において、回転子７１０における磁石７２２に径方向に対向するコイルサイドＣＳに相当する部分と、そのコイルサイドＣＳの軸方向外側であるコイルエンドＣＥ１，ＣＥ２に相当する部分とを有している。この場合、固定子コア７３２は、軸方向においてコイルサイドＣＳに対応する範囲で設けられ、エンドリング７３３は、軸方向一端側のコイルエンドＣＥ１及び他端側のコイルエンドＣＥ２にそれぞれ設けられている。コイルエンドＣＥ１が第１コイルエンドに相当し、コイルエンドＣＥ２が第２コイルエンドに相当する。なお、エンドリング７３３が固定子巻線７３１と係合した状態の構成については後述する。 As shown in FIG. 85, the stator 730 has a portion corresponding to the coil side CS that faces the magnet 722 in the rotor 710 in the axial direction in the axial direction, and a coil end CE1 that is outside the coil side CS in the axial direction. , It has a part corresponding to CE2. In this case, the stator core 732 is provided in the axial direction in a range corresponding to the coil side CS, and the end ring 733 is provided in the coil end CE1 on one end side in the axial direction and the coil end CE2 on the other end side, respectively. .. The coil end CE1 corresponds to the first coil end, and the coil end CE2 corresponds to the second coil end. The configuration in which the end ring 733 is engaged with the stator winding 731 will be described later.
　固定子巻線７３１は、複数の相巻線を有し、各相の相巻線が周方向に所定順序で配置されることで円筒状（環状）に形成されている。固定子巻線７３１の径方向内側に固定子コア７３２が組み付けられている。本例では、Ｕ相、Ｖ相及びＷ相の相巻線を用いることで、固定子巻線７３１が３相の相巻線を有する構成となっている。 The stator winding 731 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction to form a cylindrical shape (annular shape). A stator core 732 is assembled inside the stator winding 731 in the radial direction. In this example, by using U-phase, V-phase, and W-phase phase windings, the stator winding 731 has a configuration having three-phase phase windings.
　固定子巻線７３１において各相の相巻線は各々複数の部分巻線７４１を有しており（図８６参照）、その部分巻線７４１が個別にコイルモジュール７４０として設けられている。つまり、コイルモジュール７４０は、各相の相巻線における部分巻線７４１が一体に設けられたものとなっている。各相のコイルモジュール７４０が周方向に所定順序で並べて配置されることで、固定子巻線７３１のコイルサイドにおいて各相の導線部が所定順序に並べて配置されるものとなっている。図８２には、コイルサイドにおけるＵ相、Ｖ相及びＷ相の導線部の並び順が示されている。また、図８４には、３相の相巻線のうちＵ相巻線を構成するコイルモジュール７４０のみが抽出されて示されている。本例では、磁極数を２４としているが、その数は任意である。 In the stator winding 731, each phase winding of each phase has a plurality of partial windings 741 (see FIG. 86), and the partial windings 741 are individually provided as coil modules 740. That is, the coil module 740 is integrally provided with partial windings 741 in the phase windings of each phase. By arranging the coil modules 740 of each phase in a predetermined order in the circumferential direction, the conductor portions of each phase are arranged in a predetermined order on the coil side of the stator winding 731. FIG. 82 shows the arrangement order of the U-phase, V-phase, and W-phase conductors on the coil side. Further, in FIG. 84, only the coil module 740 constituting the U-phase winding is extracted and shown from the three-phase windings. In this example, the number of magnetic poles is 24, but the number is arbitrary.
　固定子巻線７３１では、相ごとに各コイルモジュール７４０の部分巻線７４１が並列又は直列に接続されることにより、各相の相巻線が構成されている。図８６は、３相の各相巻線における部分巻線７４１の接続状態を示す回路図である。図８６では、各相の相巻線における部分巻線７４１がそれぞれ並列に接続された状態が示されている。 In the stator winding 731, the phase windings of each phase are configured by connecting the partial windings 741 of each coil module 740 in parallel or in series for each phase. FIG. 86 is a circuit diagram showing a connection state of the partial winding 741 in each of the three-phase windings. FIG. 86 shows a state in which the partial windings 741 in the phase windings of each phase are connected in parallel.
　図８５に示すように、コイルモジュール７４０は固定子コア７３２の径方向外側に組み付けられている。固定子巻線７３１は、コイルサイドＣＳに相当する部分と、コイルエンドＣＥ１，ＣＥ２に相当する部分とを有している。この場合、コイルモジュール７４０は、その軸方向両端部分が固定子コア７３２よりも軸方向外側（すなわちコイルエンド側）に突出した状態で組み付けられている。 As shown in FIG. 85, the coil module 740 is assembled on the radial outer side of the stator core 732. The stator winding 731 has a portion corresponding to the coil side CS and a portion corresponding to the coil ends CE1 and CE2. In this case, the coil module 740 is assembled in a state in which both ends in the axial direction are projected outward in the axial direction (that is, the coil end side) from the stator core 732.
　コイルモジュール７４０は、軸方向両端のうち一方が径方向に折れ曲がることで略Ｌ字状に形成されており、その折れ曲がりにより、周方向に隣り合うコイルモジュール７４０の干渉が抑制されるものとなっている。本例では、コイルモジュール７４０として、軸方向一端側の部分が径方向外側に向くように配置されるコイルモジュール７４０Ａと、軸方向一端側の部分が径方向内側に向くように配置されるコイルモジュール７４０Ｂとを用いる構成としている。つまり、固定子巻線７３１は、２種類のコイルモジュール７４０Ａ，７４０Ｂを用いて構成されている。これらコイルモジュール７４０Ａ，７４０Ｂは、軸方向の向きを互いに逆向きにして固定子コア７３２に組み付けられている。 The coil module 740 is formed in a substantially L shape by bending one of both ends in the axial direction in the radial direction, and the bending suppresses interference between adjacent coil modules 740 in the circumferential direction. There is. In this example, as the coil module 740, the coil module 740A is arranged so that the portion on the one end side in the axial direction faces outward in the axial direction, and the coil module 740A is arranged so that the portion on one end side in the axial direction faces inward in the radial direction. It is configured to use 740B. That is, the stator winding 731 is configured by using two types of coil modules 740A and 740B. These coil modules 740A and 740B are assembled to the stator core 732 with their axial directions opposite to each other.
　図８２に示すように、固定子コア７３２に対して複数のコイルモジュール７４０が組み付けられた状態において、そのコイルモジュール７４０の径方向外側には軸方向の２箇所に拘束リング７６０が取り付けられている。拘束リング７６０は、各コイルモジュール７４０（固定子巻線７３１）を径方向に拘束する拘束部材である。拘束リング７６０は、例えば金属製の環状リングである。両端を自由端とするＣリング又は多重リングを拘束リング７６０として用い、その拘束リング７６０の端部どうしを溶接や接着等により連結する構成であってもよい。この場合、拘束リング７６０は、弾性を有し、自然状態で固定子巻線７３１よりも小径となっているものであるとよい。 As shown in FIG. 82, in a state where a plurality of coil modules 740 are assembled to the stator core 732, restraint rings 760 are attached at two positions in the axial direction on the radial outer side of the coil module 740. .. The restraint ring 760 is a restraint member that restrains each coil module 740 (stator winding 731) in the radial direction. The restraint ring 760 is, for example, a metal annular ring. A C ring or multiple rings having both ends as free ends may be used as the restraint ring 760, and the ends of the restraint ring 760 may be connected to each other by welding, adhesion, or the like. In this case, the restraint ring 760 is preferably elastic and has a diameter smaller than that of the stator winding 731 in a natural state.
　糸、紐、ワイヤ等の線状部材を拘束部材として用い、その拘束部材を、固定子巻線７３１の外周側に螺旋状に巻き付ける構成であってもよい。この場合、例えばワニスを染み込ませた紐を用い、ワニスにより紐固定の強化を図る構成としてもよい。 A linear member such as a thread, a string, or a wire may be used as a restraining member, and the restraining member may be spirally wound around the outer peripheral side of the stator winding 731. In this case, for example, a string impregnated with varnish may be used to strengthen the string fixing with the varnish.
　次に、コイルモジュール７４０の構成を詳しく説明する。 Next, the configuration of the coil module 740 will be described in detail.
　ここではまず、コイルモジュール７４０Ａとコイルモジュール７４０Ｂとのうちコイルモジュール７４０Ａについて説明する。なお、コイルモジュール７４０は、部分巻線７４１と巻線ホルダ７４２とを有するサブアセンブリである。以下の説明では、コイルモジュール７４０Ａの部分巻線７４１を「部分巻線７４１Ａ」、巻線ホルダ７４２を「巻線ホルダ７４２Ａ」とも称し、コイルモジュール７４０Ｂの部分巻線７４１を「部分巻線７４１Ｂ」、巻線ホルダ７４２を「巻線ホルダ７４２Ｂ」とも称する。部分巻線７４１Ａが第１部分巻線に相当し、部分巻線７４１Ｂが第２部分巻線に相当する。 Here, first, the coil module 740A among the coil module 740A and the coil module 740B will be described. The coil module 740 is a subassembly having a partial winding 741 and a winding holder 742. In the following description, the partial winding 741 of the coil module 740A is also referred to as "partial winding 741A", the winding holder 742 is also referred to as "winding holder 742A", and the partial winding 741 of the coil module 740B is referred to as "partial winding 741B". , The winding holder 742 is also referred to as "winding holder 742B". The partial winding 741A corresponds to the first partial winding, and the partial winding 741B corresponds to the second partial winding.
　図８７（ａ）は、コイルモジュール７４０Ａの斜視図であり、図８７（ｂ）は、コイルモジュール７４０Ａにおける部分巻線７４１Ａのみを示す斜視図であり、図８７（ｃ）は、コイルモジュール７４０Ａにおける巻線ホルダ７４２Ａのみを示す斜視図であり、図８７（ｄ）は、コイルモジュール７４０Ａの側面図である。また、図８８（ａ），（ｂ）は、コイルモジュール７４０Ａの横断面を示す断面図であり、図８８（ａ）は、図８７（ｄ）の８８Ａ－８８Ａ線断面図、図８８（ｂ）は、図８７（ｄ）の８８Ｂ－８８Ｂ線断面図である。なお、図８７（ｄ）では、コイルモジュール７４０Ａの左側が固定子コア７３２側であり、図８８（ａ），（ｂ）では、コイルモジュール７４０Ａの下側が固定子コア７３２側である。 87 (a) is a perspective view of the coil module 740A, FIG. 87 (b) is a perspective view showing only the partial winding 741A in the coil module 740A, and FIG. 87 (c) is a perspective view of the coil module 740A. It is a perspective view which shows only the winding holder 742A, and FIG. 87 (d) is a side view of the coil module 740A. 88 (a) and 88 (b) are cross-sectional views showing a cross section of the coil module 740A, and FIG. 88 (a) is a cross-sectional view taken along the line 88A-88A of FIG. 87 (d), FIG. 88 (b). ) Is a sectional view taken along line 88B-88B of FIG. 87 (d). In FIG. 87 (d), the left side of the coil module 740A is the stator core 732 side, and in FIGS. 88 (a) and 88 (b), the lower side of the coil module 740A is the stator core 732 side.
　コイルモジュール７４０Ａは、導線７４３を多重巻にして構成された部分巻線７４１Ａと、その部分巻線７４１Ａに一体に設けられた絶縁性の巻線ホルダ７４２Ａとを有している。巻線ホルダ７４２Ａは、部分巻線７４１Ａを周囲から絶縁するために設けられており、特に部分巻線７４１Ａと固定子コア７３２との間を絶縁すべく設けられている。コイルモジュール７４０Ａは、軸方向が長手となる長尺環状に形成されている。コイルモジュール７４０Ａは、軸方向に互いに平行に延びる一対の直線部７４４を有するとともに、軸方向両側の一端側に、軸方向に対して直交する向きに延びる曲がり部７４５を有している。これにより、コイルモジュール７４０Ａは、全体として略Ｌ字状に形成された構成となっている。 The coil module 740A has a partial winding 741A formed by multiple winding of the conducting wire 743, and an insulating winding holder 742A integrally provided with the partial winding 741A. The winding holder 742A is provided to insulate the partial winding 741A from the surroundings, and in particular, is provided to insulate between the partial winding 741A and the stator core 732. The coil module 740A is formed in an elongated annular shape having a longitudinal direction in the axial direction. The coil module 740A has a pair of straight portions 744 extending parallel to each other in the axial direction, and has bent portions 745 extending in a direction orthogonal to the axial direction at one ends on both sides in the axial direction. As a result, the coil module 740A has a structure formed in a substantially L shape as a whole.
　部分巻線７４１Ａは、互いに平行でかつ直線状に設けられる一対の中間導線部７４６と、一対の中間導線部７４６を軸方向一端側で接続する第１渡り部７４７と、一対の中間導線部７４６を軸方向他端側で接続する第２渡り部７４８を有しており、これら一対の中間導線部７４６、第１渡り部７４７及び第２渡り部７４８により環状に形成されている。一対の中間導線部７４６は、所定のコイルピッチ分を離して設けられており、周方向において一対の中間導線部７４６の間に、他相の部分巻線７４１の中間導線部７４６が配置可能となっている。本例では、一対の中間導線部７４６は２コイルピッチ分を離して設けられ、一対の中間導線部７４６の間に、他２相の部分巻線７４１における中間導線部７４６が１つずつ配置される構成となっている。 The partial winding 741A includes a pair of intermediate conductors 746 provided in parallel and linearly with each other, a first crossover 747 that connects the pair of intermediate conductors 746 on one end side in the axial direction, and a pair of intermediate conductors 746. Has a second crossover 748 that connects the two on the other end side in the axial direction, and is formed in an annular shape by the pair of intermediate conductors 746, the first crossover 747, and the second crossover 748. The pair of intermediate conductors 746 are provided so as to be separated by a predetermined coil pitch, and the intermediate conductors 746 of the partial winding 741 of the other phase can be arranged between the pair of intermediate conductors 746 in the circumferential direction. It has become. In this example, the pair of intermediate conductors 746 are provided so as to be separated by two coil pitches, and the intermediate conductors 746 of the other two-phase partial windings 741 are arranged one by one between the pair of intermediate conductors 746. It has a structure of
　第１渡り部７４７及び第２渡り部７４８は、それぞれコイルエンドＣＥ１，ＣＥ２（図８５参照）に相当する部分として設けられている。すなわち、これら各渡り部７４７，７４８は、コイルエンドＣＥ１，ＣＥ２において、周方向に異なる２位置の同相の中間導線部７４６どうしを接続するコイルエンド導線部として設けられている。部分巻線７４１Ａでは、第１渡り部７４７は、コイルモジュール７４０Ａにおける曲がり部７４５に対応する部分であり、中間導線部７４６に対して直交する向き、すなわち軸方向に対して直交する向きに折れ曲がるようにして設けられている。これに対して、第２渡り部７４８は、それよりも軸方向内側の中間導線部７４６と同じ向き、すなわち軸方向に直線状に延びるように設けられている。これにより、部分巻線７４１Ａは、全体として略Ｌ字状に形成された構成となっている。なお、図８７（ｄ）には、コイルサイドＣＳとコイルエンドＣＥ１，ＣＥ２との境界部ＢＤを破線にて示している。 The first crossover portion 747 and the second crossover portion 748 are provided as portions corresponding to the coil ends CE1 and CE2 (see FIG. 85), respectively. That is, these crossover portions 747 and 748 are provided as coil end conductor portions that connect the intermediate conductor portions 746 of the same phase at two positions different in the circumferential direction in the coil ends CE1 and CE2. In the partial winding 741A, the first crossover portion 747 is a portion corresponding to the bent portion 745 in the coil module 740A, and is bent in a direction orthogonal to the intermediate conductor portion 746, that is, in a direction orthogonal to the axial direction. It is provided as. On the other hand, the second crossover portion 748 is provided so as to extend in the same direction as the intermediate conductor portion 746 on the inner side in the axial direction, that is, linearly in the axial direction. As a result, the partial winding 741A has a structure formed in a substantially L shape as a whole. In FIG. 87 (d), the boundary portion BD between the coil side CS and the coil ends CE1 and CE2 is shown by a broken line.
　部分巻線７４１Ａでは、第１渡り部７４７（部分巻線７４１ＡにおいてコイルエンドＣＥ１側の第１渡り部７４７）に、径方向外側に曲がっている外曲がり部Ｙ１が設けられている。部分巻線７４１Ａは、コイルエンドＣＥ１側に外曲がり部Ｙ１が設けられ、かつコイルエンドＣＥ２側では径方向に曲げられていない構成となっている。 In the partial winding 741A, an outer bending portion Y1 that is bent outward in the radial direction is provided at the first crossing portion 747 (the first crossing portion 747 on the coil end CE1 side in the partial winding 741A). The partial winding 741A has a configuration in which an outer bent portion Y1 is provided on the coil end CE1 side and is not bent in the radial direction on the coil end CE2 side.
　図８８（ａ）に示すように、部分巻線７４１Ａは、横断面が四角形になるように導線７４３が多重に巻回されて形成されている。図８８（ａ）は、中間導線部７４６でのコイルモジュール７４０Ａの横断面を示しており、その中間導線部７４６において周方向及び径方向に並ぶように導線７４３が多重に巻回されている。部分巻線７４１Ａは、その横断面において、外径側における周方向長さと内径側における周方向長さとが同じである。なお、渡り部７４７，７４８において部分巻線７４１Ａが周方向に沿う向きとなる部分では、導線７４３が軸方向及び径方向に並ぶように多重に巻回されている。本例では、導線７４３を同心巻により巻回することで部分巻線７４１Ａが構成されている。ただし、導線７４３の巻き方は任意であり、同心巻に代えて、アルファ巻により導線７４３が多重に巻回されていてもよい。 As shown in FIG. 88 (a), the partial winding 741A is formed by winding the conducting wires 743 in multiple directions so that the cross section has a quadrangular shape. FIG. 88A shows a cross section of the coil module 740A at the intermediate conducting wire portion 746, and the conducting wires 743 are multiplely wound around the intermediate conducting wire portion 746 so as to be aligned in the circumferential direction and the radial direction. In the cross section of the partial winding 741A, the circumferential length on the outer diameter side and the circumferential length on the inner diameter side are the same. In the crossover portions 747 and 748 where the partial windings 741A are oriented along the circumferential direction, the conducting wires 743 are wound in multiple directions so as to be aligned in the axial direction and the radial direction. In this example, the partial winding 741A is formed by winding the conducting wire 743 by concentric winding. However, the winding method of the conductor 743 is arbitrary, and instead of the concentric winding, the conductor 743 may be wound multiple times by the alpha winding.
　部分巻線７４１Ａの横断面において、外径側における周方向長さが内径側における周方向長さよりも大きい略台形状をしていてもよい。これにより、外径側と内径側とで円周長さが異なることを考慮しつつ、周方向に並ぶ中間導線部７４６どうしの離間距離を均等にすることが可能となる。 The cross section of the partial winding 741A may have a substantially trapezoidal shape in which the circumferential length on the outer diameter side is larger than the circumferential length on the inner diameter side. As a result, it is possible to equalize the separation distance between the intermediate conducting wire portions 746 arranged in the circumferential direction while considering that the circumferential length differs between the outer diameter side and the inner diameter side.
　図８７（ａ）に示すように、部分巻線７４１Ａでは、第１渡り部７４７の側から、詳しくは曲がり部７４５の先端から、導線７４３の端部が軸方向に引き出されており、その端部が巻線端部７４３ａ，７４３ｂとなっている。巻線端部７４３ａ，７４３ｂは、それぞれ導線７４３の巻き始め及び巻き終わりである。このうち巻線端部７４３ａが電流入出力端子に接続され、巻線端部７４３ｂが中性点に接続されるようになっている。 As shown in FIG. 87 (a), in the partial winding 741A, the end of the conducting wire 743 is axially pulled out from the side of the first crossover 747, specifically from the tip of the bent portion 745, and the end thereof. The portions are winding end portions 743a and 743b. The winding end portions 743a and 743b are the winding start and winding end of the conducting wire 743, respectively. Of these, the winding end 743a is connected to the current input / output terminal, and the winding end 743b is connected to the neutral point.
　部分巻線７４１Ａでは、径方向外側ほど高い電位が印加される構成であるとよい。つまり、部分巻線７４１Ａにおいて、径方向外側と径方向内側とを比べると、径方向外側ほど一対の中間導線部７４６の間の距離が長くなるため、その点を考慮して、径方向外側ほど高い電位が印加される構成であることが望ましい。図９９には、部分巻線７４１Ａにおける導線７４３の巻回順序を示している。なお、図９９では、同一の部分巻線７４１Ａにおける中間導線部７４６を実線で示し、異なる部分巻線７４１Ｂ（すなわち異相の部分巻線７４１Ｂ）における中間導線部７４６を破線で示している。 The partial winding 741A is preferably configured so that a higher potential is applied toward the outer side in the radial direction. That is, in the partial winding 741A, when the radial outer side and the radial inner side are compared, the distance between the pair of intermediate lead wire portions 746 becomes longer as the radial outer side increases. It is desirable that the configuration is such that a high potential is applied. FIG. 99 shows the winding order of the conductor 743 in the partial winding 741A. In FIG. 99, the intermediate conductor portion 746 in the same partial winding 741A is shown by a solid line, and the intermediate conductor portion 746 in a different partial winding 741B (that is, the different phase partial winding 741B) is shown by a broken line.
　部分巻線７４１Ａでは、径方向外側から径方向内側に移行するようにして導線７４３が巻回されており、径方向外側の巻き始めが巻線端部７４３ａとなっている。また、径方向内側の巻き終わりが巻線端部７４３ｂとなっている。この場合、巻線端部７４３ａが電流入出力端子に接続され、巻線端部７４３ｂが中性点に接続されることで、径方向外側ほど高い電位が印加されるようになっている。なお、導線７４３の巻回順序自体は、径方向外側及び径方向内側において巻き始めと巻き終わりとが逆であってもよい。 In the partial winding 741A, the conducting wire 743 is wound so as to shift from the outer side in the radial direction to the inner side in the radial direction, and the winding start on the outer side in the radial direction is the winding end portion 743a. Further, the winding end on the inner side in the radial direction is the winding end portion 743b. In this case, the winding end portion 743a is connected to the current input / output terminal, and the winding end portion 743b is connected to the neutral point, so that a higher potential is applied toward the outer side in the radial direction. The winding order itself of the conducting wire 743 may be such that the winding start and the winding end are reversed on the radial outer side and the radial inner side.
　また、図９９では、周方向に隣り合う異相どうしの各中間導線部７４６の離間距離が、径方向外側と径方向内側とで異なっている。この場合、径方向外側での離間距離をＫ１、径方向内側の離間距離をＫ２とすると、Ｋ１＞Ｋ２となっている。つまり、径方向外側になるほど、周方向に隣り合う異相どうしの各中間導線部７４６の離間距離が大きくなっている。これにより、周方向に隣り合う中間導線部７４６どうしの離間距離に関して、電位差に応じた適切な離間距離がそれぞれ確保されるようになっている。 Further, in FIG. 99, the separation distance between the intermediate conducting wire portions 746 of the different phases adjacent to each other in the circumferential direction is different between the radial outer side and the radial inner side. In this case, assuming that the separation distance on the outer side in the radial direction is K1 and the separation distance on the inner side in the radial direction is K2, K1> K2. That is, the farther outward in the radial direction, the larger the separation distance between the intermediate conducting wire portions 746 of the different phases adjacent to each other in the circumferential direction. As a result, with respect to the separation distance between the intermediate conductor portions 746 adjacent to each other in the circumferential direction, an appropriate separation distance according to the potential difference is secured.
　巻線ホルダ７４２Ａは、ボビン状をなし、合成樹脂等の絶縁材料により構成されている。巻線ホルダ７４２Ａは、部分巻線７４１Ａと同様に、全体として略Ｌ字状に形成された構成となっており、部分巻線７４１Ａの中間導線部７４６に沿って設けられる部分と各渡り部７４７，７４８に沿って設けられる部分とを有している。 The winding holder 742A has a bobbin shape and is made of an insulating material such as synthetic resin. Like the partial winding 741A, the winding holder 742A has a structure formed in a substantially L shape as a whole, and a portion provided along the intermediate conductor portion 746 of the partial winding 741A and each crossover portion 747. , 748.
　図８８（ａ）に示すように、巻線ホルダ７４２Ａは、部分巻線７４１Ａの横断面において、部分巻線７４１Ａを三方から囲むように設けられており、固定子コア７３２側となる第１壁部７５１と、反固定子コア側となる第２壁部７５２と、それら第１壁部７５１及び第２壁部７５２を繋ぐ第３壁部７５３とを有している。第１壁部７５１がバックヨーク側絶縁壁に相当し、第２壁部７５２が反バックヨーク側絶縁壁に相当し、第３壁部７５３が周方向絶縁壁に相当する。第３壁部７５３は、周方向に並ぶ一対の直線部７４４において周方向内側に設けられている。第３壁部７５３は、固定子コア７３２の円中心に向かって延びる向きで設けられている。 As shown in FIG. 88 (a), the winding holder 742A is provided so as to surround the partial winding 741A from three sides in the cross section of the partial winding 741A, and is a first wall on the stator core 732 side. It has a portion 751, a second wall portion 752 on the anti-stator core side, and a third wall portion 753 connecting the first wall portion 751 and the second wall portion 752. The first wall portion 751 corresponds to the back yoke side insulating wall, the second wall portion 752 corresponds to the anti-back yoke side insulating wall, and the third wall portion 753 corresponds to the circumferential insulating wall. The third wall portion 753 is provided on the inner side in the circumferential direction in a pair of straight line portions 744 arranged in the circumferential direction. The third wall portion 753 is provided so as to extend toward the center of the circle of the stator core 732.
　巻線ホルダ７４２Ａは、第１～第３壁部７５１～７５３により形成された収容部７５４を有しており、その収容部７５４に収容された状態で部分巻線７４１Ａが設けられている。この場合、部分巻線７４１Ａは、固定子コア７３２側、反固定子コア側及び周方向片側の三方において各壁部７５１～７５３による絶縁がなされている。つまり、第１壁部７５１により、中間導線部７４６において固定子コア７３２との絶縁が図られている。第２壁部７５２により、中間導線部７４６が回転子７１０側（エアギャップ側）に露出しないように被覆されている。第３壁部７５３により周方向における中間導線部７４６どうしの絶縁が図られている。 The winding holder 742A has an accommodating portion 754 formed by the first to third wall portions 751 to 753, and the partial winding 741A is provided in a state of being accommodating in the accommodating portion 754. In this case, the partial winding 741A is insulated by the wall portions 751 to 753 on the stator core 732 side, the anti-stator core side, and one side in the circumferential direction. That is, the first wall portion 751 insulates the intermediate conductor portion 746 from the stator core 732. The second wall portion 752 covers the intermediate conductor portion 746 so as not to be exposed to the rotor 710 side (air gap side). The third wall portion 753 insulates the intermediate conductor portions 746 from each other in the circumferential direction.
　巻線ホルダ７４２Ａにおいて、第１壁部７５１の壁厚さ方向（径方向）の厚さ寸法をＴ１１、第２壁部７５２の壁厚さ方向（径方向）の厚さ寸法をＴ１２、第３壁部７５３の壁厚さ方向（周方向）の厚さ寸法をＴ１３とする場合、第２壁部７５２の厚さ寸法Ｔ１２が第１壁部７５１の厚さ寸法Ｔ１１よりも小さいことが望ましい（Ｔ１１＞Ｔ１２）。つまり、第２壁部７５２は磁石７２２側（エアギャップ側）の絶縁壁であり、その絶縁壁が薄いことにより磁石７２２と部分巻線７４１との距離、詳しくは磁気回路上の距離を縮めることができ、性能向上を期待できる。また、磁石７２２と部分巻線７４１との距離が同じものどうしで比べると、第２壁部７５２の厚さ寸法Ｔ１２を小さくした分、コイルモジュール７４０（ホルダ表面）と磁石７２２との間のエアギャップ（空隙の間隔）を大きくすることができ、回転子７１０の回転時における接触を抑制できる。なお、図１００には、図８８（ａ）の構成に比べて第１壁部７５１の厚さ寸法Ｔ１１を厚くし、かつ第２壁部７５２の厚さ寸法Ｔ１２を薄くすることでＴ１１＞Ｔ１２とした構成が示されている。 In the winding holder 742A, the thickness dimension of the first wall portion 751 in the wall thickness direction (radial direction) is T11, and the thickness dimension of the second wall portion 752 in the wall thickness direction (radial direction) is T12, the third. When the thickness dimension of the wall portion 753 in the wall thickness direction (circumferential direction) is T13, it is desirable that the thickness dimension T12 of the second wall portion 752 is smaller than the thickness dimension T11 of the first wall portion 751 ( T11> T12). That is, the second wall portion 752 is an insulating wall on the magnet 722 side (air gap side), and the thin insulating wall reduces the distance between the magnet 722 and the partial winding 741, specifically, the distance on the magnetic circuit. Can be expected, and performance improvement can be expected. Further, when the distance between the magnet 722 and the partial winding 741 is the same, the air between the coil module 740 (holder surface) and the magnet 722 is increased by the amount that the thickness dimension T12 of the second wall portion 752 is reduced. The gap (interval between gaps) can be increased, and the contact of the rotor 710 during rotation can be suppressed. In addition, in FIG. 100, T11> T12 by making the thickness dimension T11 of the first wall portion 751 thicker and thinning the thickness dimension T12 of the second wall portion 752 as compared with the configuration of FIG. 88 (a). The configuration is shown.
　また、第１壁部７５１の厚さ寸法Ｔ１１が第２壁部７５２の厚さ寸法Ｔ１２よりも大きいことで、固定子コア７３２との間の絶縁距離が確保され、その絶縁性能を高めることができる。ただし、Ｔ１１＝Ｔ１２であってもよい。 Further, since the thickness dimension T11 of the first wall portion 751 is larger than the thickness dimension T12 of the second wall portion 752, the insulation distance between the first wall portion 751 and the stator core 732 can be secured, and the insulation performance thereof can be improved. it can. However, T11 = T12 may be used.
　第３壁部７５３の厚さ寸法Ｔ１３については、例えば第１壁部７５１の厚さ寸法Ｔ１１と同じであるとよい。ただし、Ｔ１３＞Ｔ１１であるか、又はＴ１３＜Ｔ１１であってもよい。 The thickness dimension T13 of the third wall portion 753 may be the same as, for example, the thickness dimension T11 of the first wall portion 751. However, T13> T11 or T13 <T11 may be satisfied.
　図１００に示すように、第３壁部７５３において、径方向内側と径方向外側との各位置で厚さ寸法Ｔ１３を異ならせ、径方向外側の方が、厚さ寸法Ｔ１３が大きくなるように構成してもよい。つまり、第３壁部７５３を、径方向外側ほど幅広のテーパ状断面とする。この場合、第３壁部７５３の厚さ寸法Ｔ１３を、径方向内側よりも径方向外側の方が大きくなるようにしたことにより、径方向内側と径方向外側とで円周長さが異なることを加味しつつ、周方向に並ぶ各中間導線部７４６を適正に配置することができる。つまり、第３壁部７５３の厚さ寸法Ｔ１３を径方向で均一にしておくと、部分巻線７４１Ａの横断面を四角形状にする場合において、周方向に隣り合う２つの中間導線部７４６が、第３壁部７５３の側では寄りすぎてしまい、その反対側では離れすぎてしまう。そのため、周方向において回転磁束が不均等になることが懸念される。これに対して本例の構成では、周方向において回転磁束の均等化が可能となる。また、周方向における絶縁性能の均一化も可能となる。さらに、径方向外側（外周側）において中間導線部７４６と第３壁部７５３との間に余剰な隙間が形成されることが抑制されるため、中間導線部７４６（部分巻線７４１Ａ）の位置決めや固定を行う上でも好適である。 As shown in FIG. 100, in the third wall portion 753, the thickness dimension T13 is made different at each position of the radial inner side and the radial outer side so that the thickness dimension T13 is larger on the radial outer side. It may be configured. That is, the third wall portion 753 has a tapered cross section that is wider toward the outer side in the radial direction. In this case, the thickness dimension T13 of the third wall portion 753 is set to be larger on the radial outer side than on the radial inner side, so that the circumferential length differs between the radial inner side and the radial outer side. It is possible to appropriately arrange each intermediate lead wire portion 746 arranged in the circumferential direction while taking into consideration the above. That is, if the thickness dimension T13 of the third wall portion 753 is made uniform in the radial direction, when the cross section of the partial winding 741A is made into a quadrangular shape, the two intermediate conductor portions 746 adjacent to each other in the circumferential direction are formed. The side of the third wall portion 753 is too close, and the opposite side is too far away. Therefore, there is a concern that the rotating magnetic flux becomes uneven in the circumferential direction. On the other hand, in the configuration of this example, the rotational magnetic flux can be equalized in the circumferential direction. In addition, it is possible to make the insulation performance uniform in the circumferential direction. Further, since it is suppressed that an excess gap is formed between the intermediate conductor portion 746 and the third wall portion 753 on the outer side (outer peripheral side) in the radial direction, the intermediate conductor portion 746 (partial winding 741A) is positioned. It is also suitable for fixing and fixing.
　コイルモジュール７４０Ａの曲がり部７４５との関係で言えば、一対の直線部７４４において、第１壁部７５１は、曲がり部７４５とは反対側の壁部（軸方向内側の壁部）であり、第２壁部７５２は、曲がり部７４５側の壁部（軸方向外側の壁部）である。 Speaking in relation to the bent portion 745 of the coil module 740A, in the pair of straight portions 744, the first wall portion 751 is the wall portion (the wall portion on the inner side in the axial direction) opposite to the bent portion 745, and is the first wall portion. The two wall portion 752 is a wall portion (a wall portion on the outer side in the axial direction) on the bent portion 745 side.
　部分巻線７４１Ａは、収容部７５４において三方の各壁部７５１～７５３に当接又は近接した状態で設けられ、かつ周方向において第３壁部７５３とは逆側で、第１壁部７５１及び第２壁部７５２の端部よりも内側となる領域に配置されている。つまり、巻線ホルダ７４２Ａにおいて、第１壁部７５１及び第２壁部７５２における中間導線部７４６の周方向両側のうち一方の側には第３壁部７５３が設けられ、他方の側には、中間導線部７４６よりも周方向にはみ出したはみ出し部７５１ａ，７５２ａが設けられている。このはみ出し部７５１ａ，７５２ａは、部分巻線７４１Ａに対して周方向に余剰となる余剰部分である。これにより、収容部７５４内には、周方向の片側に、部分巻線７４１Ａが収容されていない空き領域ＳＺが設けられている。この場合、空き領域ＳＺにより、収容部７５４内の部分巻線７４１Ａが巻線ホルダ７４２よりも外側にはみ出ることが抑制されるものとなっている。 The partial winding 741A is provided in the accommodating portion 754 in a state of being in contact with or close to each of the wall portions 751 to 753 on three sides, and is opposite to the third wall portion 753 in the circumferential direction, and the first wall portion 751 and It is arranged in an area inside the end of the second wall portion 752. That is, in the winding holder 742A, the third wall portion 753 is provided on one side of both sides of the intermediate conductor portion 746 in the first wall portion 751 and the second wall portion 752 in the circumferential direction, and the other side is provided with the third wall portion 753. Protruding portions 751a and 752a protruding in the circumferential direction from the intermediate conductor portion 746 are provided. The protruding portions 751a and 752a are surplus portions that are surplus in the circumferential direction with respect to the partial winding 741A. As a result, an empty area SZ in which the partial winding 741A is not accommodated is provided on one side in the circumferential direction in the accommodating portion 754. In this case, the free area SZ prevents the partial winding 741A in the accommodating portion 754 from protruding outside the winding holder 742.
　要するに、第１壁部７５１及び第２壁部７５２は、部分巻線７４１Ａの中間導線部７４６の周方向両側に、その中間導線部７４６よりも周方向に延びる延長部を有しており、その周方向両側の延長部のうち一方の側に、第１壁部７５１及び第２壁部７５２から径方向に延びる第３壁部７５３が設けられている。また、周方向両側の延長部のうち一方の側に、はみ出し部７５１ａ，７５２ａが設けられている。 In short, the first wall portion 751 and the second wall portion 752 have extension portions extending in the circumferential direction from the intermediate conductor portion 746 on both sides of the intermediate conductor portion 746 of the partial winding 741A in the circumferential direction. A third wall portion 753 extending in the radial direction from the first wall portion 751 and the second wall portion 752 is provided on one side of the extension portions on both sides in the circumferential direction. Further, protruding portions 751a and 752a are provided on one side of the extension portions on both sides in the circumferential direction.
　収容部７５４内には、絶縁材料として樹脂材料が充填されており、その樹脂材料によりモールドされた状態で部分巻線７４１Ａが収容されている。これにより、収容部７５４において中間導線部７４６を挟んで第３壁部７５３の逆側には樹脂層７５５が形成されている。この場合、部分巻線７４１Ａの導線７４３間の隙間にも樹脂材料が入り込むことで、部分巻線７４１Ａにおいて、多重に巻回された導線７４３の近接するものどうしが、モールド樹脂を接合材として互いに接合されている。本構成では、部分巻線７４１Ａにおいて多重に巻回された導線７４３の近接するものどうしが接合材により互いに接合されていることにより、部分巻線７４１Ａにおける導線７４３どうしを所望の近接状態で維持できる。つまり、部分巻線７４１Ａにおける多重巻の状態を所望の状態で維持することができる。樹脂層７５５は、第３壁部７５３と同様に、径方向内側と径方向外側との各位置で厚さ寸法（周方向寸法）を異ならせ、径方向外側の方が、周方向寸法が大きくなるように構成されているとよい（図１００参照）。つまり、周方向に隣り合う異相どうしの各中間導線部７４６の離間距離が、径方向外側と径方向内側とで異なっている構成であるとよい。これにより、径方向内側と径方向外側とで円周長さが異なることを加味しつつ、周方向に並ぶ各中間導線部７４６を適正に配置することができる。なお、図１００において、第３壁部７５３及び樹脂層７５５が周方向の絶縁部に相当する。 A resin material is filled in the accommodating portion 754 as an insulating material, and the partial winding 741A is accommodated in a state of being molded by the resin material. As a result, the resin layer 755 is formed on the opposite side of the third wall portion 753 with the intermediate conductor portion 746 sandwiched in the accommodating portion 754. In this case, the resin material also enters the gap between the conductors 743 of the partial winding 741A, so that in the partial winding 741A, the multiplely wound conductors 743 are close to each other using the mold resin as a bonding material. It is joined. In this configuration, the conductors 743 in the partial winding 741A can be maintained in a desired proximity state because the adjacent conductors 743 that are wound multiple times in the partial winding 741A are joined to each other by a joining material. .. That is, the state of multiple windings in the partial winding 741A can be maintained in a desired state. Similar to the third wall portion 753, the resin layer 755 has different thickness dimensions (circumferential dimensions) at each position of the radial inner side and the radial outer side, and the radial outer side has a larger circumferential dimension. It is preferable that the configuration is as follows (see FIG. 100). That is, it is preferable that the distance between the intermediate conductors 746 of the different phases adjacent to each other in the circumferential direction is different between the outer side in the radial direction and the inner side in the radial direction. As a result, it is possible to appropriately arrange the intermediate conductor portions 746 that are lined up in the circumferential direction, taking into consideration that the circumferential length is different between the inner side in the radial direction and the outer side in the radial direction. In FIG. 100, the third wall portion 753 and the resin layer 755 correspond to the insulating portion in the circumferential direction.
　樹脂モールドに代えて、収容部７５４内においてワニスを含む接着剤が含浸されることで部分巻線７４１Ａが固められていてもよい。また、樹脂モールドとワニスの含浸との両方が行われていてもよい。また、導線７４３が、絶縁被膜により導体が覆われた被覆導線である場合に、その絶縁被膜の自己溶着により導線７４３どうしを互いに固着（接合）させる構成としてもよい。ただし、収容部７５４内に樹脂材料等が充填されていない構成、すなわち空き領域ＳＺが空間領域として設けられている構成であってもよい。 Instead of the resin mold, the partial winding 741A may be hardened by impregnating the housing portion 754 with an adhesive containing varnish. Further, both the resin mold and the impregnation of the varnish may be performed. Further, when the conducting wire 743 is a coated conducting wire whose conductor is covered with an insulating coating, the conducting wires 743 may be fixed (bonded) to each other by self-welding of the insulating coating. However, the accommodating portion 754 may not be filled with a resin material or the like, that is, an empty area SZ may be provided as a space area.
　コイルモジュール７４０Ａは、筒状の固定子コア７３２に対して径方向外側から組み付けられるものであり、固定子コア７３２側である第１壁部７５１は、固定子コア７３２の外周面と同じ曲率で円弧面に形成されている。これにより、固定子コア７３２に対するコイルモジュール７４０Ａの密着性が高められている。反固定子コア側である第２壁部７５２については、直線状、円弧状のいずれにすることも任意であるが、本例では、第１壁部７５１と同心の円弧状に形成されている。 The coil module 740A is assembled to the tubular stator core 732 from the outside in the radial direction, and the first wall portion 751 on the stator core 732 side has the same curvature as the outer peripheral surface of the stator core 732. It is formed on an arcuate surface. As a result, the adhesion of the coil module 740A to the stator core 732 is enhanced. The second wall portion 752 on the anti-stator core side may be linear or arcuate, but in this example, it is formed in an arc shape concentric with the first wall portion 751. ..
　また、コイルモジュール７４０Ａは、曲がり部７４５を径方向外側にして固定子コア７３２に組み付けられるものであり、第２壁部７５２の側（すなわち第１壁部７５１の反対側）に曲がり部７４５を有している。またこの場合、一対の直線部７４４において２つの第２壁部７５２を含む周方向距離は、２つの第１壁部７５１を含む周方向距離よりも長くなっており、その長い方の周方向距離と同じ寸法で、径方向外側となる曲がり部７４５が設けられている。 Further, the coil module 740A is assembled to the stator core 732 with the bent portion 745 radially outward, and the bent portion 745 is provided on the side of the second wall portion 752 (that is, the opposite side of the first wall portion 751). Have. Further, in this case, the circumferential distance including the two second wall portions 752 in the pair of straight portions 744 is longer than the circumferential distance including the two first wall portions 751, and the longer circumferential distance thereof. A bent portion 745 having the same dimensions as the above and which is outward in the radial direction is provided.
　また、図８７（ｄ）に示すように、コイルモジュール７４０Ａの一対の直線部７４４において、コイルサイドＣＳとコイルエンドＣＥ１，ＣＥ２との境界部ＢＤ付近には、曲がり部７４５とは逆側、すなわち径方向内側（固定子コア７３２側）に突出する突出部７５６が上下２箇所に設けられている。巻線ホルダ７４２Ａでは、第１渡り部７４７側のコイルエンドＣＥ１であって、かつ境界部ＢＤの軸方向外側となる位置に突出部７５６が設けられるとともに、第２渡り部７４８側のコイルエンドＣＥ２であって、かつ境界部ＢＤの軸方向外側となる位置に突出部７５６が設けられている。 Further, as shown in FIG. 87 (d), in the pair of straight portions 744 of the coil module 740A, in the vicinity of the boundary portion BD between the coil side CS and the coil ends CE1 and CE2, the side opposite to the bent portion 745, that is, Protruding portions 756 projecting inward in the radial direction (on the stator core 732 side) are provided at two upper and lower positions. In the winding holder 742A, the coil end CE1 on the first crossover 747 side and the protruding portion 756 are provided at a position outside the boundary portion BD in the axial direction, and the coil end CE2 on the second crossover 748 side. Moreover, the protruding portion 756 is provided at a position outside the boundary portion BD in the axial direction.
　換言すれば、コイルモジュール７４０Ａにおいて、第１壁部７５１は、固定子コア７３２の軸方向端面よりも軸方向外側に延びる部分（ヨーク外部分）を有しており、その部分に、固定子コア７３２との周方向の対向面よりも固定子コア７３２側に突出する突出部７５６が一体成形されている。突出部７５６は、例えば樹脂材料の射出成形により第１壁部７５１と同時に成形される。 In other words, in the coil module 740A, the first wall portion 751 has a portion (yoke outer portion) extending axially outward from the axial end face of the stator core 732, and the stator core is in that portion. A protruding portion 756 projecting toward the stator core 732 side from the surface facing the 732 in the circumferential direction is integrally molded. The protrusion 756 is formed at the same time as the first wall portion 751 by, for example, injection molding of a resin material.
　コイルモジュール７４０Ａの横断面で見ると、図８８（ｂ）に示すように、固定子コア７３２側である第１壁部７５１から突出するようにして突出部７５６が設けられている。突出部７５６は、第１壁部７５１の周方向一端から周方向他端までの範囲で片側に傾斜する傾斜面７５６ａを有する構成となっている。本例では、左右一対の直線部７４４において第１壁部７５１の内側端部（周方向内側）が高くなるようにして突出部７５６が形成されている。ただし、図８８（ｂ）に示す構成とは異なり、左右一対の直線部７４４において第１壁部７５１の外側端部（周方向外側）が高くなるようにして突出部７５６が形成されていてもよい。 Looking at the cross section of the coil module 740A, as shown in FIG. 88 (b), the protruding portion 756 is provided so as to protrude from the first wall portion 751 on the stator core 732 side. The protruding portion 756 is configured to have an inclined surface 756a that is inclined to one side in the range from one end in the circumferential direction to the other end in the circumferential direction of the first wall portion 751. In this example, the protruding portion 756 is formed so that the inner end portion (inside in the circumferential direction) of the first wall portion 751 becomes higher in the pair of left and right straight portions 744. However, unlike the configuration shown in FIG. 88 (b), even if the protruding portion 756 is formed so that the outer end portion (outside in the circumferential direction) of the first wall portion 751 is raised in the pair of left and right straight portions 744. Good.
　次に、コイルモジュール７４０Ｂについて説明する。 Next, the coil module 740B will be described.
　コイルモジュール７４０Ｂは、曲がり部７４５の延びる径方向の向きがコイルモジュール７４０Ａとは異なっており、それによる構成の違いがあるものの、基本構成はコイルモジュール７４０Ａと同じであるため、ここでは、コイルモジュール７４０Ａとの相違点を中心に説明する。 In the coil module 740B, the direction in which the bent portion 745 extends in the radial direction is different from that of the coil module 740A, and although there is a difference in the configuration due to this, the basic configuration is the same as that of the coil module 740A. The differences from the 740A will be mainly described.
　図８９（ａ）は、コイルモジュール７４０Ｂの斜視図であり、図８９（ｂ）は、コイルモジュール７４０Ｂの側面図である。また、図９０（ａ），（ｂ）は、コイルモジュール７４０Ｂの横断面を示す断面図であり、図９０（ａ）は、図８９（ｂ）の９０Ａ－９０Ａ線断面図、図９０（ｂ）は、図８９（ｂ）の９０Ｂ－９０Ｂ線断面図である。なお、図８９（ｂ）では、コイルモジュール７４０Ｂの左側が固定子コア７３２側であり、図９０（ａ），（ｂ）では、コイルモジュール７４０Ｂの下側が固定子コア７３２側である。 FIG. 89A is a perspective view of the coil module 740B, and FIG. 89B is a side view of the coil module 740B. 90 (a) and 90 (b) are cross-sectional views showing a cross section of the coil module 740B, and FIG. 90 (a) is a cross-sectional view taken along the line 90A-90A of FIG. 89 (b) and FIG. 90 (b). ) Is a cross-sectional view taken along the line 90B-90B of FIG. 89 (b). In FIG. 89 (b), the left side of the coil module 740B is the stator core 732 side, and in FIGS. 90 (a) and 90 (b), the lower side of the coil module 740B is the stator core 732 side.
　コイルモジュール７４０Ｂは、導線７４３を多重巻にして構成された部分巻線７４１Ｂと、その部分巻線７４１Ｂに一体に設けられた絶縁性の巻線ホルダ７４２Ｂとを有している。また、コイルモジュール７４０Ｂは、軸方向に互いに平行に延びる一対の直線部７４４を有するとともに、軸方向両側の一端側に、軸方向に対して直交する向きに延びる曲がり部７４５を有し、全体として略Ｌ字状に形成された構成となっている。 The coil module 740B has a partial winding 741B formed by multiple winding of the conducting wire 743, and an insulating winding holder 742B integrally provided with the partial winding 741B. Further, the coil module 740B has a pair of straight portions 744 extending parallel to each other in the axial direction, and has bent portions 745 extending in a direction orthogonal to the axial direction on one end side on both sides in the axial direction as a whole. It has a structure formed in a substantially L shape.
　部分巻線７４１Ｂの構成は、基本的に部分巻線７４１Ａと同じである。すなわち、部分巻線７４１Ｂは、部分巻線７４１Ａと同様に、互いに平行でかつ直線状に設けられる一対の中間導線部７４６と、一対の中間導線部７４６を軸方向一端側で接続する第１渡り部７４７と、一対の中間導線部７４６を軸方向他端側で接続する第２渡り部７４８を有しており、これら一対の中間導線部７４６、第１渡り部７４７及び第２渡り部７４８により環状に形成されている。 The configuration of the partial winding 741B is basically the same as that of the partial winding 741A. That is, the partial winding 741B is the same as the partial winding 741A, and has a first crossover that connects a pair of intermediate conductors 746 provided in parallel and linearly with each other and a pair of intermediate conductors 746 on one end side in the axial direction. It has a second crossing portion 748 that connects the portion 747 and the pair of intermediate conductor portions 746 on the other end side in the axial direction, and the pair of intermediate conductor portions 746, the first crossing portion 747, and the second crossing portion 748. It is formed in a ring shape.
　ただし、コイルモジュール７４０Ａとコイルモジュール７４０Ｂとでは、固定子コア７３２に組み付けられた状態での曲がり部７４５の延びる向きが異なり、かつ軸方向の向きが互いに逆向きとなっている。これにより、コイルモジュール７４０Ａ，７４０Ｂでは構成の相違が生じている。 However, the coil module 740A and the coil module 740B have different extending directions of the bent portion 745 when assembled to the stator core 732, and the axial directions are opposite to each other. As a result, the coil modules 740A and 740B have different configurations.
　部分巻線７４１Ｂでは、第１渡り部７４７（部分巻線７４１ＢにおいてコイルエンドＣＥ２側の第１渡り部７４７）に、径方向内側に曲がっている内曲がり部Ｙ２が設けられている。部分巻線７４１Ｂは、コイルエンドＣＥ２側に内曲がり部Ｙ２が設けられ、かつコイルエンドＣＥ１側では径方向に曲げられていない構成となっている。 In the partial winding 741B, the first crossover 747 (the first crossover 747 on the coil end CE2 side in the partial winding 741B) is provided with an inwardly bent portion Y2 that is bent inward in the radial direction. The partial winding 741B has an inwardly bent portion Y2 provided on the coil end CE2 side and is not bent in the radial direction on the coil end CE1 side.
　部分巻線７４１Ｂでは、第２渡り部７４８の側から、詳しくは曲がり部７４５とは逆側の先端から巻線端部７４３ａ，７４３ｂが引き出されている。これにより、コイルモジュール７４０Ａ，７４０Ｂが固定子コア７３２に組み付けられた状態において、軸方向の同じ側（コイルエンドＣＥ１側）に巻線端部７４３ａ，７４３ｂが引き出されるようになっている。 In the partial winding 741B, the winding end portions 743a and 743b are pulled out from the side of the second crossover portion 748, specifically from the tip opposite to the bending portion 745. As a result, when the coil modules 740A and 740B are assembled to the stator core 732, the winding end portions 743a and 743b are pulled out on the same side in the axial direction (coil end CE1 side).
　また、図９０（ａ）に示すように、巻線ホルダ７４２Ｂは、巻線ホルダ７４２Ａの構成と同様に、固定子コア７３２側となる第１壁部７５１と、反固定子コア側となる第２壁部７５２と、それら第１壁部７５１及び第２壁部７５２を繋ぐ第３壁部７５３とを有している。また、巻線ホルダ７４２Ｂでは、巻線ホルダ７４２Ａの構成とは異なり、一対の直線部７４４において、第１壁部７５１が曲がり部７４５側の壁部（軸方向内側の壁部）となり、第２壁部７５２が曲がり部７４５とは反対側の壁部（軸方向外側の壁部）となっている。 Further, as shown in FIG. 90A, the winding holder 742B has a first wall portion 751 on the stator core 732 side and a first wall portion 751 on the anti-stator core side, similarly to the configuration of the winding holder 742A. It has two wall portions 752 and a third wall portion 753 connecting the first wall portion 751 and the second wall portion 752. Further, in the winding holder 742B, unlike the configuration of the winding holder 742A, in the pair of straight portions 744, the first wall portion 751 becomes the wall portion on the bent portion 745 side (the wall portion on the inner side in the axial direction), and the second wall portion 751 becomes a wall portion on the inner side in the axial direction. The wall portion 752 is a wall portion (a wall portion on the outer side in the axial direction) on the opposite side of the bent portion 745.
　コイルモジュール７４０Ｂは、曲がり部７４５を径方向内側にして固定子コア７３２に組み付けられるものであり、第１壁部７５１の側に曲がり部７４５を有している。この場合、一対の直線部７４４において２つの第１壁部７５１を含む周方向距離は、２つの第２壁部７５２を含む周方向距離よりも短くなっており、その短い方の周方向距離と同じ寸法で、径方向内側となる曲がり部７４５が設けられている。 The coil module 740B is assembled to the stator core 732 with the bent portion 745 inside in the radial direction, and has the bent portion 745 on the side of the first wall portion 751. In this case, the circumferential distance including the two first wall portions 751 in the pair of straight portions 744 is shorter than the circumferential distance including the two second wall portions 752, and the shorter circumferential distance and the circumferential distance. A bent portion 745 having the same dimensions and being inward in the radial direction is provided.
　また、図８９（ｂ）に示すように、コイルモジュール７４０Ｂの一対の直線部７４４において、コイルサイドＣＳとコイルエンドＣＥ１，ＣＥ２との境界部ＢＤ付近には、曲がり部７４５側、すなわち径方向内側（固定子コア７３２側）に突出する突出部７５６が上下２箇所に設けられている。巻線ホルダ７４２では、突出部７５６が、第１渡り部７４７側のコイルエンドＣＥ２であって、かつ境界部ＢＤの軸方向外側となる位置に設けられるとともに、第２渡り部７４８側のコイルエンドＣＥ１であって、かつ境界部ＢＤの軸方向外側となる位置に設けられている。突出部７５６の構成も、巻線ホルダ７４２Ａと同様である（図９０（ｂ）参照）。 Further, as shown in FIG. 89B, in the pair of straight portions 744 of the coil module 740B, the bent portion 745 side, that is, the inside in the radial direction is located near the boundary portion BD between the coil side CS and the coil ends CE1 and CE2. Protruding portions 756 protruding toward (the stator core 732 side) are provided at two upper and lower positions. In the winding holder 742, the protruding portion 756 is provided at the coil end CE2 on the first crossover portion 747 side and at a position outside the boundary portion BD in the axial direction, and the coil end on the second crossover portion 748 side. It is CE1 and is provided at a position outside the boundary portion BD in the axial direction. The configuration of the protrusion 756 is also the same as that of the winding holder 742A (see FIG. 90B).
　コイルモジュール７４０の製造方法を説明する。ここではコイルモジュール７４０Ａの製造方法を説明するが、コイルモジュール７４０Ｂについても同様である。まず、部分巻線７４１Ａを空芯巻コイルとして作製する。具体的には、治具を用いて導線７４３を多重に巻回させ、空芯巻コイルとして、図８７（ｂ）に示す形状の部分巻線７４１Ａを作製する。そして、部分巻線７４１Ａの作製後、部分巻線７４１Ａに対して巻線ホルダ７４２Ａを組み付ける。このとき、巻線ホルダ７４２Ａは、複数に分割された状態で個々に部分巻線７４１Ａに対して組み付けられるとよい。巻線ホルダ７４２Ａは、径方向又は軸方向に２つ又は３つに分割可能になっているとよい。 The manufacturing method of the coil module 740 will be described. Here, the method of manufacturing the coil module 740A will be described, but the same applies to the coil module 740B. First, the partial winding 741A is manufactured as an air-core winding coil. Specifically, the conducting wire 743 is wound in multiple directions using a jig to produce a partial winding 741A having the shape shown in FIG. 87 (b) as an air-core winding coil. Then, after the partial winding 741A is manufactured, the winding holder 742A is assembled to the partial winding 741A. At this time, the winding holder 742A may be individually assembled to the partial winding 741A in a state of being divided into a plurality of parts. It is preferable that the winding holder 742A can be divided into two or three in the radial direction or the axial direction.
　なお、巻線ホルダ７４２Ａに対して導線７４３を多重に巻回することで、コイルモジュール７４０Ａを作製することも可能である。巻線ホルダ７４２Ａにおいて、部分巻線７４１Ａを収容する収容部７５４の内周面に、導線７４３を案内する突起又は溝を設けてもよい。部分巻線７４１Ａがほどけないように外側の導線７４３で縛る構成であってもよい。 It is also possible to manufacture the coil module 740A by winding the lead wire 743 multiple times around the winding holder 742A. In the winding holder 742A, a protrusion or a groove for guiding the conducting wire 743 may be provided on the inner peripheral surface of the accommodating portion 754 accommodating the partial winding 741A. It may be configured to be tied with the outer conductor 743 so that the partial winding 741A is not unwound.
　そして、部分巻線７４１Ａを一体化した巻線ホルダ７４２Ａにおいて、収容部７５４内に樹脂を充填する。これにより、収容部７５４内に樹脂層７５５が形成される。 Then, in the winding holder 742A in which the partial winding 741A is integrated, the accommodating portion 754 is filled with resin. As a result, the resin layer 755 is formed in the accommodating portion 754.
　次に、固定子コア７３２に対してコイルモジュール７４０Ａ，７４０Ｂを組み付けた状態について説明する。 Next, the state in which the coil modules 740A and 740B are assembled to the stator core 732 will be described.
　図９１は、固定子７３０の縦断面を示す断面図であり、図９２は、固定子７３０の横断面を示す断面図であり、図９３は、固定子コア７３２及びエンドリング７３３とコイルモジュール７４０Ａとを互いに分離して示す断面図である。なお、図９２は、図９１の９２－９２線断面図である。 91 is a cross-sectional view showing a vertical cross section of the stator 730, FIG. 92 is a cross-sectional view showing a cross section of the stator 730, and FIG. 93 is a stator core 732 and an end ring 733 and a coil module 740A. It is sectional drawing which shows and separated from each other. Note that FIG. 92 is a cross-sectional view taken along the line 92-92 of FIG. 91.
　図９１に示すように、コイルモジュール７４０Ａ，７４０Ｂは、それぞれの曲がり部７４５が軸方向に互いに逆となり、かつ曲がりの向きが径方向に互いに逆となるようにして、固定子コア７３２に組み付けられている。この場合、各コイルモジュール７４０Ａ，７４０Ｂにおける曲がり部７４５の位置及び向きにより、周方向に隣り合うコイルモジュール７４０Ａ，７４０Ｂどうしの干渉が回避されるようになっている。部分巻線７４１Ａ，７４１Ｂで言えば、部分巻線７４１Ａに外曲がり部Ｙ１が設けられるとともに、部分巻線７４１Ｂに内曲がり部Ｙ２が設けられていることにより、周方向に隣り合う部分巻線７４１Ａ，７４１Ｂどうしの干渉が回避されるようになっている。外曲がり部Ｙ１及び内曲がり部Ｙ２が干渉回避部に相当する。 As shown in FIG. 91, the coil modules 740A and 740B are assembled to the stator core 732 so that the bending portions 745 are opposite to each other in the axial direction and the bending directions are opposite to each other in the radial direction. ing. In this case, interference between the coil modules 740A and 740B adjacent to each other in the circumferential direction is avoided depending on the position and orientation of the bent portion 745 in each coil module 740A and 740B. Speaking of the partial windings 741A and 741B, the partial winding 741A is provided with the outer bending portion Y1 and the partial winding 741B is provided with the inner bending portion Y2, so that the partial windings 741A are adjacent to each other in the circumferential direction. , 741B are designed to avoid interference with each other. The outer bent portion Y1 and the inner bent portion Y2 correspond to the interference avoiding portion.
　図８５を併せ用いて補足すると、コイルエンドＣＥ１側では、コイルモジュール７４０Ａ（部分巻線７４１Ａの第１渡り部７４７）の軸方向外側に、コイルモジュール７４０Ｂ（部分巻線７４１Ｂの第２渡り部７４８）が位置する。また、コイルエンドＣＥ２側では、コイルモジュール７４０Ｂ（部分巻線７４１Ｂの第１渡り部７４７）の軸方向外側に、コイルモジュール７４０Ａ（部分巻線７４１Ａの第２渡り部７４８）が位置するようにしつつ、各部分巻線７４１Ａ，７４１Ｂが周方向に並べて配置されている。これにより、各部分巻線７４１Ａ，７４１Ｂが、互いの干渉を回避しつつ周方向に適正に配置され、体格の小型化が可能となっている。 Supplementing with reference to FIG. 85, on the coil end CE1 side, the coil module 740B (the second crossover portion 748 of the partial winding 741B) is located outside the coil module 740A (the first crossover portion 747 of the partial winding 741A) in the axial direction. ) Is located. Further, on the coil end CE2 side, the coil module 740A (second crossing portion 748 of the partial winding 741A) is located outside the coil module 740B (first crossing portion 747 of the partial winding 741B) in the axial direction. , The partial windings 741A and 741B are arranged side by side in the circumferential direction. As a result, the partial windings 741A and 741B are appropriately arranged in the circumferential direction while avoiding mutual interference, and the physique can be reduced.
　また、図９１に示すように、固定子コア７３２の軸方向両端にはエンドリング７３３が設けられており、そのエンドリング７３３に対して上下２箇所の突出部７５６がそれぞれ係合した状態で、固定子コア７３２にコイルモジュール７４０Ａ，７４０Ｂが組み付けられている。ここで、コイルモジュール７４０Ａ，７４０Ｂの突出部７５６は、固定子コア７３２の軸方向端面（図の上側端面、下側端面）に軸方向に重なる状態で突出している。これにより、固定子コア７３２は、各コイルモジュール７４０Ａ，７４０Ｂにおける一対の突出部７５６により軸方向に挟まれた状態（すなわち軸方向に押圧された状態）となっている。この場合、固定子コア７３２は複数のコアシート７３２ａが軸方向に積層されて構成されており、そのコアシート７３２ａの積層方向で、一対の突出部７５６により固定子コア７３２が挟まれた状態となっている。これにより、コアシート７３２ａどうしの間の隙間が拡がってしまい、固定子コア７３２の軸長寸法が意図せず大きくなるといった不都合が抑制されるようになっている。一対の突出部７５６は、固定子コア７３２の軸方向端面を軸方向外側から軸方向に押圧する押圧部として機能する。 Further, as shown in FIG. 91, end rings 733 are provided at both ends in the axial direction of the stator core 732, and the end rings 733 are engaged with the upper and lower protruding portions 756, respectively. Coil modules 740A and 740B are assembled to the stator core 732. Here, the protruding portions 756 of the coil modules 740A and 740B project in a state of overlapping in the axial direction with the axial end faces (upper end face and lower end face in the figure) of the stator core 732. As a result, the stator core 732 is in a state of being sandwiched in the axial direction by a pair of protruding portions 756 in the coil modules 740A and 740B (that is, in a state of being pressed in the axial direction). In this case, the stator core 732 is configured by laminating a plurality of core sheets 732a in the axial direction, and the stator core 732 is sandwiched by a pair of protrusions 756 in the laminating direction of the core sheets 732a. It has become. As a result, the gap between the core sheets 732a is widened, and the inconvenience that the axial length of the stator core 732 is unintentionally increased is suppressed. The pair of projecting portions 756 function as pressing portions that press the axial end faces of the stator core 732 in the axial direction from the outside in the axial direction.
　なお、固定子コア７３２には、径方向内側（すなわち径方向内外のうちコイルモジュール７４０Ａ，７４０Ｂとは逆側）に、突出部７５６とは別に、複数のコアシート７３２ａの積層状態を保持するための積層保持構造が設けられているとよい。図９１では、太破線で示すＱ位置に積層保持構造が設けられている。積層保持構造としては、コアシート７３２ａの溶接による接合、コアシート７３２ａのカシメによる接合、接着剤（ワニスを含む）による接合、固定子コア７３２の径方向内側に圧入により組み付けられる外筒部材７７２（筒状部材）の摩擦力による積層保持などが考えられる。径方向内側に積層保持構造が設けられることにより、固定子コア７３２の軸長寸法の縮小化をより一層適正に実現できる。 In addition, in order to hold the laminated state of a plurality of core sheets 732a on the stator core 732 in the radial direction (that is, on the side opposite to the coil modules 740A and 740B in the radial direction) apart from the protruding portion 756. It is preferable that the laminated holding structure of the above is provided. In FIG. 91, the laminated holding structure is provided at the Q position indicated by the thick broken line. As the laminated holding structure, the core sheet 732a is joined by welding, the core sheet 732a is joined by caulking, the adhesive (including varnish) is used, and the outer cylinder member 772 (which is press-fitted inside the stator core 732 in the radial direction) is assembled. Stacking and holding due to the frictional force of the tubular member) can be considered. By providing the laminated holding structure on the inner side in the radial direction, it is possible to more appropriately reduce the axial length of the stator core 732.
　コイルモジュール７４０Ａ，７４０Ｂの外周側には拘束リング７６０が取り付けられている。この拘束リング７６０の拘束により、突出部７５６がエンドリング７３３に係合する向きにコイルモジュール７４０Ａ，７４０Ｂが押圧された状態となっている。特に、エンドリング７３３及び突出部７５６の係合部分に対して軸方向に重複する位置に拘束リング７６０が設けられていることで、エンドリング７３３及び突出部７５６の係合状態がより確実に保持されるものとなっている。 A restraint ring 760 is attached to the outer peripheral side of the coil modules 740A and 740B. Due to the restraint of the restraint ring 760, the coil modules 740A and 740B are pressed in the direction in which the protrusion 756 engages with the end ring 733. In particular, since the restraint ring 760 is provided at a position where the end ring 733 and the protruding portion 756 overlap in the axial direction with respect to the engaging portion, the engaged state of the end ring 733 and the protruding portion 756 can be more reliably maintained. It is supposed to be done.
　拘束リング７６０は、コイルモジュール７４０Ａ，７４０Ｂの径方向外側、すなわち回転子７１０の磁石７２２との対向面側に設けられている。そのため、回転子７１０側との干渉を避けるには、拘束リング７６０は径方向の厚さが極力薄くなっていることが望ましい。また、軸方向においてコイルサイドＣＳとなる領域には設けず、コイルエンドＣＥ１，ＣＥ２となる領域に設ける構成としてもよい。この場合、コイルエンドＣＥ１，ＣＥ２となる範囲であり、かつコイルモジュール７４０Ａ，７４０Ｂの径方向外側となる位置に拘束リング７６０が設けられるとよい。ただし、拘束リング７６０が設けられる位置及び拘束リング７６０の数は任意である。 The restraint ring 760 is provided on the radial outside of the coil modules 740A and 740B, that is, on the side of the rotor 710 facing the magnet 722. Therefore, in order to avoid interference with the rotor 710 side, it is desirable that the restraint ring 760 is as thin as possible in the radial direction. Further, the coil side CS may not be provided in the axial direction, but may be provided in the coil end CE1 and CE2 regions. In this case, it is preferable that the restraint ring 760 is provided at a position within the range of the coil ends CE1 and CE2 and at a position outside the coil modules 740A and 740B in the radial direction. However, the position where the restraint ring 760 is provided and the number of restraint rings 760 are arbitrary.
　拘束リング７６０は、巻線ホルダ７４２の第２壁部７５２の外側に取り付けられている。つまり、拘束リング７６０は、巻線ホルダ７４２には接触するが、部分巻線７４１には接触しない構成となっている。これにより、例えば固定強度を高めるべく金属製の拘束リング７６０を用いた構成にあっても、部分巻線７４１の絶縁性の低下を抑制できるものとなっている。 The restraint ring 760 is attached to the outside of the second wall portion 752 of the winding holder 742. That is, the restraint ring 760 is configured to contact the winding holder 742 but not the partial winding 741. As a result, for example, even in a configuration in which a metal restraint ring 760 is used to increase the fixing strength, it is possible to suppress a decrease in the insulating property of the partial winding 741.
　また、図９２及び図９３に示すように、エンドリング７３３の係合面７３４には、突出部７５６の傾斜面７５６ａが当接している。なお、エンドリング７３３の係合面７３４が第１係合部に相当し、コイルモジュール７４０Ａ，７４０Ｂの突出部７５６が第２係合部に相当する。また、傾斜面７５６ａが被係合面に相当する。この場合、エンドリング７３３には、傾斜方向が互い違いとなるようにして複数の係合面７３４が周方向に連続して設けられており、周方向に隣り合う２つの係合面７３４により凹部７３５が形成されている（図９３参照）。そして、この凹部７３５に、２つのコイルモジュール７４０Ａ，７４０Ｂの１つずつの突出部７５６が入り込むようになっている。１つの凹部７３５に入り込む２つの突出部７５６は、それぞれ突出部７５６の頂部が凹部７３５の底に到達している。これにより、各コイルモジュール７４０Ａ，７４０Ｂにおける第３壁部７５３どうしが周方向に当接した状態となっている。また、周方向に隣り合う２つの係合面７３４により形成された頂部では、各コイルモジュール７４０Ａ，７４０Ｂの第１壁部７５１どうし及び第２壁部７５２どうしがそれぞれ周方向に当接又は近接した状態となっている。 Further, as shown in FIGS. 92 and 93, the inclined surface 756a of the protruding portion 756 is in contact with the engaging surface 734 of the end ring 733. The engaging surface 734 of the end ring 733 corresponds to the first engaging portion, and the protruding portions 756 of the coil modules 740A and 740B correspond to the second engaging portion. Further, the inclined surface 756a corresponds to the engaged surface. In this case, the end ring 733 is provided with a plurality of engaging surfaces 734 continuously in the circumferential direction so that the inclination directions are staggered, and the recess 735 is provided by the two engaging surfaces 734 adjacent to each other in the circumferential direction. Is formed (see FIG. 93). Then, one protrusion 756 of each of the two coil modules 740A and 740B is inserted into the recess 735. In each of the two protrusions 756 that enter one recess 735, the top of the protrusion 756 reaches the bottom of the recess 735. As a result, the third wall portions 753 of the coil modules 740A and 740B are in contact with each other in the circumferential direction. Further, at the top formed by two engaging surfaces 734 adjacent to each other in the circumferential direction, the first wall portions 751 and the second wall portions 752 of the coil modules 740A and 740B are in contact with each other or close to each other in the circumferential direction. It is in a state.
　上記構成では、２つのコイルモジュール７４０Ａ，７４０Ｂの各突出部７５６は、凹部７３５を形成する２つの係合面７３４により周方向に互いに近づく方向に案内される。これにより、周方向に隣り合う２つの部分巻線７４１についてがたつきを抑制し、ひいては振動や電磁力による固定子巻線７３１の位置ずれを好適に抑制できる。また、中間導線部７４６どうしの隙間を縮小化することが可能となるため、占積率の向上を期待できる。 In the above configuration, the protruding portions 756 of the two coil modules 740A and 740B are guided in the circumferential direction toward each other by the two engaging surfaces 734 forming the recess 735. As a result, rattling of the two partial windings 741 adjacent to each other in the circumferential direction can be suppressed, and the displacement of the stator winding 731 due to vibration or electromagnetic force can be suitably suppressed. Further, since the gap between the intermediate conductors 746 can be reduced, an improvement in the space factor can be expected.
　また、各コイルモジュール７４０Ａ，７４０Ｂは、周方向に離れた２箇所の第１壁部７５１にそれぞれ突出部７５６を有し、その２箇所の突出部７５６は、エンドリング７３３において傾斜の向きが互いに逆となる２つの係合面７３４にそれぞれ当接している。この場合、各コイルモジュール７４０Ａ，７４０Ｂにおいて、各々２つの突出部７５６がエンドリング７３３の係合面７３４側に係合することで、各コイルモジュール７４０Ａ，７４０Ｂの周方向の位置ずれを一層生じにくくすることができる。 Further, each of the coil modules 740A and 740B has protrusions 756 on two first wall portions 751 separated from each other in the circumferential direction, and the two protrusions 756 are inclined at the end ring 733 with respect to each other. It is in contact with two opposite engaging surfaces 734, respectively. In this case, in each of the coil modules 740A and 740B, the two protrusions 756 engage with the engaging surface 734 side of the end ring 733, so that the misalignment of the coil modules 740A and 740B in the circumferential direction is less likely to occur. can do.
　また、コイルモジュール７４０Ａ，７４０Ｂの径方向外側に拘束リング７６０が取り付けられた構成では、エンドリング７３３の係合面７３４に対して、突出部７５６の傾斜面７５６ａが押圧状態で当接することになる。これにより、固定子コア７３２に対してコイルモジュール７４０Ａ，７４０Ｂをより強固に固定できる。 Further, in the configuration in which the restraint ring 760 is attached to the radial outer side of the coil modules 740A and 740B, the inclined surface 756a of the protruding portion 756 comes into contact with the engaging surface 734 of the end ring 733 in a pressed state. .. As a result, the coil modules 740A and 740B can be more firmly fixed to the stator core 732.
　各コイルモジュール７４０Ａ，７４０Ｂが周方向に並べて配置された状態では、各コイルモジュール７４０Ａ，７４０Ｂの直線部７４４において、収容部７５４に収容された部分巻線７４１が周方向に互いに所定間隔ずつ離れた位置に配置されている。より詳しくは、周方向に隣り合う各部分巻線７４１は、巻線ホルダ７４２の第３壁部７５３により互いに隔離されているか、又は巻線ホルダ７４２の収容部７５４内の空き領域ＳＺにより互いに隔離されている。これにより、周方向に隣り合う異相の部分巻線７４１どうしの絶縁性が確保されている。 In a state where the coil modules 740A and 740B are arranged side by side in the circumferential direction, in the straight portion 744 of each coil module 740A and 740B, the partial windings 741 housed in the accommodating portion 754 are separated from each other by a predetermined interval in the circumferential direction. It is placed in position. More specifically, the peripherally adjacent partial windings 741 are isolated from each other by the third wall portion 753 of the winding holder 742, or by the free space SZ in the accommodating portion 754 of the winding holder 742. Has been done. As a result, the insulation between the partial windings 741 having different phases adjacent to each other in the circumferential direction is ensured.
　周方向に隣り合う異相の部分巻線７４１の間には、２つの第３壁部７５３が介在している。この場合、第３壁部７５３を２枚重ねとすることで、固定子巻線７３１での絶縁性が一層高められている。又は、周方向に隣り合う異相の部分巻線７４１の間には、２つの空き領域ＳＺが介在している。この場合、収容部７５４内の空き領域ＳＺが周方向に連続していること、さらに言えばそれら空き領域ＳＺが樹脂モールドされていることで、固定子巻線７３１での絶縁性が一層高められている。つまり、図示の構成では、周方向に隣り合う中間導線部７４６どうしの間に、異なる巻線ホルダ７４２の第３壁部７５３が周方向に連続して設けられるか、異なる巻線ホルダ７４２のはみ出し部７５１ａ，７５２ａが周方向に連続して設けられている。 Two third wall portions 753 are interposed between the partial windings 741 of different phases adjacent to each other in the circumferential direction. In this case, by stacking two third wall portions 753, the insulating property of the stator winding 731 is further enhanced. Alternatively, two free areas SZ are interposed between the partial windings 741 of different phases adjacent to each other in the circumferential direction. In this case, the free areas SZ in the accommodating portion 754 are continuous in the circumferential direction, and moreover, the free areas SZ are resin-molded, so that the insulation property of the stator winding 731 is further enhanced. ing. That is, in the illustrated configuration, the third wall portion 753 of the different winding holder 742 is continuously provided in the circumferential direction between the intermediate conductor portions 746 adjacent to each other in the circumferential direction, or the different winding holder 742 protrudes. The portions 751a and 752a are continuously provided in the circumferential direction.
　第３壁部７５３の厚さ寸法Ｔ１３（図８８（ａ）参照）に関して、第３壁部７５３の２枚分の厚さ寸法Ｔ１３（すなわち、２×Ｔ１３）が第１壁部７５１の厚さ寸法Ｔ１１よりも大きいとよい。すなわち、２×Ｔ１３＞Ｔ１１であるとよい。この場合、周方向に並ぶ中間導線部７４６どうしの間において、固定子コア７３２と中間導線部７４６との間よりも大きい電位差が生じても、適切な相間絶縁が実施となっている。 Regarding the thickness dimension T13 of the third wall portion 753 (see FIG. 88 (a)), the thickness dimension T13 (that is, 2 × T13) of two pieces of the third wall portion 753 is the thickness of the first wall portion 751. It should be larger than the dimension T11. That is, it is preferable that 2 × T13> T11. In this case, even if a larger potential difference occurs between the intermediate conductors 746s arranged in the circumferential direction than between the stator core 732 and the intermediate conductors 746, appropriate interphase insulation is performed.
　各コイルモジュール７４０Ａ，７４０Ｂにおける径方向及び周方向の絶縁構造について補足する。コイルモジュール７４０Ａ，７４０Ｂにおいて、第１壁部７５１及び第２壁部７５２は、部分巻線７４１Ａ，７４１Ｂの中間導線部７４６の周方向両側のうち一方側に第３壁部７５３を有するとともに、他方側にはみ出し部７５１ａ，７５２ａを有している。また、第１壁部７５１及び第２壁部７５２において、第３壁部７５３が接続される部分及びはみ出し部７５１ａ，７５２ａは、それぞれ中間導線部７４６よりも周方向に延びる延長部に相当し、周方向に隣り合う中間導線部７４６どうしの間において、異なるコイルモジュール７４０Ａ，７４０Ｂの延長部が周方向に対向して設けられている。この場合、周方向に隣り合う中間導線部７４６は、各コイルモジュール７４０Ａ，７４０Ｂにおける第１壁部７５１の延長部により互いに離間されることで、相互の絶縁性が確保される。これにより、中間導線部７４６において径方向の固定子コア７３２との絶縁に加え、周方向の相間絶縁も好適に実現できる。 Supplementary information on the radial and circumferential insulation structures of each coil module 740A and 740B. In the coil modules 740A and 740B, the first wall portion 751 and the second wall portion 752 have the third wall portion 753 on one of the circumferential directions of the intermediate conductor portions 746 of the partial windings 741A and 741B, and the other. The protruding portions 751a and 752a are provided on the side. Further, in the first wall portion 751 and the second wall portion 752, the portion to which the third wall portion 753 is connected and the protruding portions 751a and 752a correspond to extension portions extending in the circumferential direction from the intermediate conductor portion 746, respectively. Extensions of different coil modules 740A and 740B are provided so as to face each other in the circumferential direction between the intermediate conductors 746 that are adjacent to each other in the circumferential direction. In this case, the intermediate conductor portions 746 adjacent to each other in the circumferential direction are separated from each other by the extension portion of the first wall portion 751 in the coil modules 740A and 740B, so that mutual insulation is ensured. As a result, in addition to the insulation of the intermediate conductor portion 746 with the stator core 732 in the radial direction, interphase insulation in the circumferential direction can be suitably realized.
　本例では特に、周方向に並ぶ各中間導線部７４６の周方向一方側において、異なるコイルモジュール７４０Ａ，７４０Ｂの第３壁部７５３が周方向に互いに対向させた状態で設けられるとともに、周方向に並ぶ各中間導線部７４６の周方向他方側において、第３壁部７５３が無くはみ出し部７５１ａ，７５２ａによる離間がなされている。この場合、径方向に並ぶ固定子コア７３２と中間導線部７４６との間には、１つの第１壁部７５１が設けられる一方、周方向に並ぶ中間導線部７４６の間には、２つの第３壁部７５３が設けられているため、周方向に並ぶ中間導線部７４６どうしの間に、固定子コア７３２と中間導線部７４６との間よりも大きい電位差が生じることを考慮しつつ適切な相間絶縁を実施できる。 In this example, in particular, the third wall portions 753 of the different coil modules 740A and 740B are provided in a state of facing each other in the circumferential direction on one side in the circumferential direction of each of the intermediate conductor portions 746 arranged in the circumferential direction, and in the circumferential direction. On the other side in the circumferential direction of each of the intermediate conducting wire portions 746 that are lined up, the third wall portion 753 is absent and separated by the protruding portions 751a and 752a. In this case, one first wall portion 751 is provided between the stator cores 732 arranged in the radial direction and the intermediate conductor portion 746, while the two first wall portions 746 are provided between the intermediate conductor portions 746 arranged in the circumferential direction. Since the three wall portions 753 are provided, an appropriate phase spacing is taken into consideration that a larger potential difference is generated between the intermediate conductor portions 746 arranged in the circumferential direction than between the stator core 732 and the intermediate conductor portion 746. Insulation can be performed.
　なお、固定子コア７３２に対してコイルモジュール７４０Ａ，７４０Ｂを組み付けた状態において、コイルモジュール７４０Ａ，７４０Ｂの突出部７５６とエンドリング７３３とはワニス等の接着剤により互いに固定されているとよい。また、コイルモジュール７４０Ａ，７４０Ｂの突出部７５６とエンドリング７３３との間に合成樹脂やワニスを充填することで、がたつきを抑制するようにしてもよい。 In the state where the coil modules 740A and 740B are assembled to the stator core 732, the protruding portions 756 and the end ring 733 of the coil modules 740A and 740B may be fixed to each other by an adhesive such as varnish. Further, rattling may be suppressed by filling a synthetic resin or varnish between the protruding portion 756 of the coil modules 740A and 740B and the end ring 733.
　複数の部分巻線７４１Ａ，７４１Ｂは、多重巻された状態の導体断面積と多重巻の巻回数が同じであるとよい。この場合、各相の相巻線において、並列回路を構成する各部分巻線７４１Ａ，７４１Ｂの鎖交磁束を均一化することができる。これにより、各部分巻線７４１Ａ，７４１Ｂにおける相互の電位差を無くすことができ、並列回路内での循環電流の発生を抑制できる。また、循環電流の発生に伴うモータ効率の低下や熱定格性能の低下を抑制できる。 It is preferable that the plurality of partial windings 741A and 741B have the same conductor cross-sectional area in the state of multiple winding and the number of multiple windings. In this case, in the phase winding of each phase, the interlinkage magnetic flux of each of the partial windings 741A and 741B constituting the parallel circuit can be made uniform. As a result, the mutual potential difference between the partial windings 741A and 741B can be eliminated, and the generation of circulating current in the parallel circuit can be suppressed. In addition, it is possible to suppress a decrease in motor efficiency and a decrease in thermal rating performance due to the generation of circulating current.
　また、複数の部分巻線７４１Ａ，７４１Ｂは、渡り部７４７，７４８を含めて同一の形状であるため、コイルエンドＣＥ１，ＣＥ２での漏れ磁束まで含めて鎖交磁束を均一化することができる。これにより、やはり各部分巻線７４１Ａ，７４１Ｂでの電位差を無くし、並列回路内の循環電流を抑制できる。 Further, since the plurality of partial windings 741A and 741B have the same shape including the crossovers 747 and 748, the interlinkage magnetic flux can be made uniform including the leakage flux at the coil ends CE1 and CE2. As a result, the potential difference between the partial windings 741A and 741B can be eliminated, and the circulating current in the parallel circuit can be suppressed.
　固定子７３０は、以下の（Ａ）～（Ｃ）のいずれかを用いたものであるとよい。
（Ａ）固定子７３０において、周方向における各導線部（中間導線部７４６）の間に導線間部材を設け、かつその導線間部材として、１磁極における導線間部材の周方向の幅寸法をＷｔ、導線間部材の飽和磁束密度をＢｓ、１磁極における磁石７２２の周方向の幅寸法をＷｍ、磁石７２２の残留磁束密度をＢｒとした場合に、Ｗｔ×Ｂｓ≦Ｗｍ×Ｂｒの関係となる磁性材料を用いている。
（Ｂ）固定子７３０において、周方向における各導線部（中間導線部７４６）の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
（Ｃ）固定子７３０において、周方向における各導線部（中間導線部７４６）の間に導線間部材を設けていない構成となっている。 The stator 730 may use any of the following (A) to (C).
(A) In the stator 730, a conductor-to-conductor member is provided between each conductor portion (intermediate conductor portion 746) in the circumferential direction, and as the conductor-to-conductor member, the width dimension of the conductor-to-conductor member at one magnetic pole in the circumferential direction is Wt. When the saturation magnetic flux density of the conductor-to-conductor member is Bs, the width dimension of the magnet 722 at one magnetic pole in the circumferential direction is Wm, and the residual magnetic flux density of the magnet 722 is Br, the magnetic relationship is Wt × Bs ≦ Wm × Br. The material is used.
(B) In the stator 730, a conductor-to-conductor member is provided between each conductor portion (intermediate conductor portion 746) in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
(C) The stator 730 has a configuration in which no interconductor member is provided between each conductor portion (intermediate conductor portion 746) in the circumferential direction.
　次に、インナユニット７７０について説明する。 Next, the inner unit 770 will be described.
　図９４及び図９５は、インナユニット７７０の縦断面図である。なお、図９５には、インナユニット７７０に、回転軸７０１を支持する軸受７９１，７９２を組み付けた状態を示している。便宜上、以下の説明では、軸受７９１を第１軸受７９１、軸受７９２を第２軸受７９２とも称する。第１軸受７９１は、回転軸７０１の軸方向において基端側、すなわち連結軸７０５側に設けられた軸受であり、第２軸受７９２は、回転軸７０１の先端側に設けられた軸受である。 94 and 95 are vertical cross-sectional views of the inner unit 770. Note that FIG. 95 shows a state in which bearings 791 and 792 that support the rotating shaft 701 are assembled to the inner unit 770. For convenience, in the following description, the bearing 791 will also be referred to as a first bearing 791, and the bearing 792 will also be referred to as a second bearing 792. The first bearing 791 is a bearing provided on the base end side in the axial direction of the rotating shaft 701, that is, on the connecting shaft 705 side, and the second bearing 792 is a bearing provided on the tip end side of the rotating shaft 701.
　インナユニット７７０は、インナハウジング７７１を有している。インナハウジング７７１は、円筒状をなす外筒部材７７２と、外周径が外筒部材７７２よりも小径の円筒状をなし、外筒部材７７２の径方向内側に配置される内筒部材７７３と、これら外筒部材７７２及び内筒部材７７３の軸方向一端側に固定される略円板状の端板７７４とを有している。これら各部材７７２～７７４は、導電性材料により構成されているとよく、例えば炭素繊維強化プラスチック（ＣＦＲＰ）により構成されている。外筒部材７７２と端板７７４とは同一の外形寸法を有しており、これら外筒部材７７２及び端板７７４により形成された空間内に内筒部材７７３が設けられている。内筒部材７７３は、ボルト等の締結具７７５により外筒部材７７２及び端板７７４に対してそれぞれ固定されている。 The inner unit 770 has an inner housing 771. The inner housing 771 has a cylindrical outer cylinder member 772, and an inner cylinder member 773 having an outer peripheral diameter smaller than that of the outer cylinder member 772 and arranged inside the outer cylinder member 772 in the radial direction. It has a substantially disk-shaped end plate 774 fixed to one end side in the axial direction of the outer cylinder member 772 and the inner cylinder member 773. Each of these members 772 to 774 is preferably made of a conductive material, for example, made of carbon fiber reinforced plastic (CFRP). The outer cylinder member 772 and the end plate 774 have the same external dimensions, and the inner cylinder member 773 is provided in the space formed by the outer cylinder member 772 and the end plate 774. The inner cylinder member 773 is fixed to the outer cylinder member 772 and the end plate 774 by fasteners 775 such as bolts, respectively.
　インナハウジング７７１の外筒部材７７２の径方向外側には固定子コア７３２が固定される。これにより、固定子７３０とインナユニット７７０とが一体化されるようになっている。 The stator core 732 is fixed to the radial outer side of the outer cylinder member 772 of the inner housing 771. As a result, the stator 730 and the inner unit 770 are integrated.
　外筒部材７７２及び内筒部材７７３の間には、冷却水等の冷媒を流通させる冷媒通路７７７が形成されている。冷媒通路７７７は、インナハウジング７７１の周方向に環状に設けられている。図示は省略するが、冷媒通路７７７には冷媒配管が接続されており、その冷媒配管から流入する冷媒が冷媒通路７７７内で熱交換した後、再び冷媒配管に流出するようになっている。 A refrigerant passage 777 for circulating a refrigerant such as cooling water is formed between the outer cylinder member 772 and the inner cylinder member 773. The refrigerant passage 777 is provided in an annular shape in the circumferential direction of the inner housing 771. Although not shown, a refrigerant pipe is connected to the refrigerant passage 777, and the refrigerant flowing from the refrigerant pipe exchanges heat in the refrigerant passage 777 and then flows out to the refrigerant pipe again.
　内筒部材７７３の径方向内側には環状空間が形成されており、その環状空間に、例えば電力変換器としてのインバータを構成する電気部品が配置されるとよい。電気部品は、例えば半導体スイッチング素子やコンデンサをパッケージ化した電気モジュールである。内筒部材７７３に当接した状態で電気モジュールを配置することにより、冷媒通路７７７を流れる冷媒により電気モジュールが冷却されるようになっている。 An annular space is formed inside the inner cylinder member 773 in the radial direction, and it is preferable that, for example, an electric component constituting an inverter as a power converter is arranged in the annular space. The electric component is, for example, an electric module in which a semiconductor switching element or a capacitor is packaged. By arranging the electric module in contact with the inner cylinder member 773, the electric module is cooled by the refrigerant flowing through the refrigerant passage 777.
　外筒部材７７２は、内筒部材７７３よりも径方向内側に円筒状のボス部７８０を有している。ボス部７８０は、中空筒状に設けられており、その中空部に回転軸７０１が挿通されるようになっている。ボス部７８０は、軸受７９１，７９２を保持する軸受保持部となっており、その中空部に軸受７９１，７９２が固定されている（図９５参照）。軸受７９１，７９２は、例えば、筒状の内輪と、内輪の径方向外側に配置された筒状の外輪と、それら内輪及び外輪の間に配置された複数の玉とを有するラジアル玉軸受であり、外輪がボス部７８０に固定されることで、インナユニット７７０に組み付けられている。 The outer cylinder member 772 has a cylindrical boss portion 780 radially inside the inner cylinder member 773. The boss portion 780 is provided in a hollow tubular shape, and the rotating shaft 701 is inserted into the hollow portion. The boss portion 780 is a bearing holding portion that holds the bearings 791 and 792, and the bearings 791 and 792 are fixed to the hollow portion thereof (see FIG. 95). The bearings 791 and 792 are, for example, radial ball bearings having a tubular inner ring, a tubular outer ring arranged radially outside the inner ring, and a plurality of balls arranged between the inner ring and the outer ring. , The outer ring is fixed to the boss portion 780 and is assembled to the inner unit 770.
　ボス部７８０の中空部には、第１軸受７９１を固定する第１固定部７８１と、第２軸受７９２を固定する第２固定部７８２とが設けられている。第１軸受７９１及び第２軸受７９２は、回転子７１０の振動や遠心荷重を考慮して、回転軸７０１における支持位置に応じて体格が異なっており、回転軸７０１の基端側を支持する第１軸受７９１の方が大きいサイズの軸受、すなわち支持荷重の大きい軸受となっている。そのため、第１固定部７８１は、第２固定部７８２に比べて大径に形成されている。 The hollow portion of the boss portion 780 is provided with a first fixing portion 781 for fixing the first bearing 791 and a second fixing portion 782 for fixing the second bearing 792. The first bearing 791 and the second bearing 792 have different physiques depending on the support position on the rotary shaft 701 in consideration of the vibration and the centrifugal load of the rotor 710, and support the proximal end side of the rotary shaft 701. 1 Bearing 791 is a bearing having a larger size, that is, a bearing having a larger bearing load. Therefore, the first fixed portion 781 is formed to have a larger diameter than the second fixed portion 782.
　また、第１軸受７９１と第２軸受７９２とを比べると、第１軸受７９１は、第２軸受７９２に比べて径方向の内部隙間、すなわちラジアル隙間が大きいものとなっている。なお、ラジアル隙間は、軸受の内輪と外輪と玉との軸方向の遊び量である。ここで、第１軸受７９１は、第２軸受７９２に比べて回転子７１０の振動や遠心荷重を受けやすい軸受であり、その第１軸受７９１のラジアル隙間を大きくすることにより、荷重吸収の効果が高められる。これにより、回転軸７０１の基端部側においてボス部７８０に作用する荷重が低減され、回転軸７０１の先端側における振れが抑制されるようになっている。 Comparing the first bearing 791 and the second bearing 792, the first bearing 791 has a larger radial internal gap, that is, a radial gap than the second bearing 792. The radial gap is the amount of play in the axial direction between the inner ring, the outer ring, and the ball of the bearing. Here, the first bearing 791 is a bearing that is more susceptible to vibration and centrifugal load of the rotor 710 than the second bearing 792, and by increasing the radial gap of the first bearing 791, the effect of load absorption can be obtained. Can be enhanced. 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 end side of the rotating shaft 701 is suppressed.
　第１固定部７８１は、ボス部７８０において軸方向に平行な平行面７８１ａと、軸方向に直交する直交面７８１ｂとにより形成されており、これら各面に当接した状態で第１軸受７９１が固定されている。また、第２固定部７８２は、ボス部７８０において軸方向に平行な平行面７８２ａと、軸方向に直交する直交面７８２ｂとにより形成されており、これら各面に当接した状態で第２軸受７９２が固定されている。 The first fixed portion 781 is formed by a parallel surface 781a parallel to the axial direction and an orthogonal surface 781b orthogonal to the axial direction in the boss portion 780, and the first bearing 791 is in contact with each of these surfaces. It is fixed. Further, the second fixed portion 782 is formed by a parallel surface 782a parallel to the axial direction and an orthogonal surface 782b orthogonal to the axial direction in the boss portion 780, and the second bearing is in contact with each of these surfaces. 792 is fixed.
　また、ボス部７８０の中空部には、第１固定部７８１と第２固定部７８２とのうち第２固定部７８２の側に、回転センサとしてのレゾルバ８００を固定する第３固定部７８３が設けられている。第３固定部７８３は、第２固定部７８２を段差状に拡径させることで形成されている。 Further, in the hollow portion of the boss portion 780, a third fixing portion 783 for fixing the resolver 800 as a rotation sensor is provided on the side of the second fixing portion 782 of the first fixing portion 781 and the second fixing portion 782. Has been done. The third fixed portion 783 is formed by expanding the diameter of the second fixed portion 782 in a stepped shape.
　図７７に示すように、レゾルバ８００は、回転軸７０１に固定されるレゾルバロータ８０１と、そのレゾルバロータ８０１の径方向外側に対向配置されたレゾルバステータ８０２とを備えている。レゾルバロータ８０１は、円板リング状をなしており、回転軸７０１を挿通させた状態で、回転軸７０１に同軸に設けられている。レゾルバステータ８０２は、不図示のステータコアとステータコイルとを有し、ボス部７８０の第３固定部７８３に固定されている。 As shown in FIG. 77, the resolver 800 includes a resolver rotor 801 fixed to a rotating shaft 701 and a resolver stator 802 arranged so as to face each other on the radial outer side of the resolver rotor 801. The resolver rotor 801 has a disk ring shape, and is provided coaxially with the rotating shaft 701 in a state where the rotating shaft 701 is inserted. The resolver stator 802 has a stator core and a stator coil (not shown), and is fixed to a third fixing portion 783 of the boss portion 780.
　図９４に示すように、ボス部７８０の中空部には、軸方向において第１固定部７８１と第２固定部７８２との間となる位置に、これら各固定部７８１，７８２よりも小径の縮径部７８４，７８５が設けられている。縮径部７８４は第１固定部７８１よりも径の小さい孔であり、縮径部７８５は第２固定部７８２よりも径の小さい孔である。また、レゾルバ８００を固定する第３固定部７８３は、第２固定部７８２よりも軸方向外側となる位置、換言すれば回転軸７０１の先端側となる位置に、第２固定部７８２よりも拡径された部位として設けられている。第２固定部７８２と第３固定部７８３とは、軸方向に隣り合う位置に設けられている。 As shown in FIG. 94, the hollow portion of the boss portion 780 has a diameter smaller than that of each of the fixed portions 781 and 782 at a position between the first fixed portion 781 and the second fixed portion 782 in the axial direction. Diameter portions 784 and 785 are provided. The reduced diameter portion 784 is a hole having a smaller diameter than the first fixed portion 781, and the reduced diameter portion 785 is a hole having a smaller diameter than the second fixed portion 782. Further, the third fixing portion 783 for fixing the resolver 800 is wider than the second fixing portion 782 at a position outside the second fixing portion 782 in the axial direction, in other words, at a position at the tip end side of the rotating shaft 701. It is provided as a diameterd part. The second fixed portion 782 and the third fixed portion 783 are provided at positions adjacent to each other in the axial direction.
　この場合、外筒部材７７２において中ぐり加工等により孔加工を行う際に、第２固定部７８２と第３固定部７８３とを同一方向から同軸で連続加工することが可能となる。そのため、第２固定部７８２に固定される第２軸受７９２と第３固定部７８３に固定されるレゾルバステータ８０２との同軸度が高められ、ひいてはレゾルバロータ８０１とレゾルバステータ８０２との同軸度が高められることとなる。この場合、レゾルバロータ８０１に対するレゾルバステータ８０２の振れが低減され、ひいてはレゾルバ８００における角度検出誤差が低減される。 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 can be continuously machined coaxially from the same direction. Therefore, the coaxiality between the second bearing 792 fixed to the second fixed portion 782 and the resolver stator 802 fixed to the third fixed portion 783 is increased, and the coaxiality between the resolver rotor 801 and the resolver stator 802 is increased. Will be. In this case, the runout of the resolver stator 802 with respect to the resolver rotor 801 is reduced, and the angle detection error in the resolver 800 is reduced.
　次に、バスバーモジュール８１０について説明する。バスバーモジュール８１０は、固定子巻線７３１において各コイルモジュール７４０の部分巻線７４１に電気的に接続され、各相の部分巻線７４１の一端を相ごとに並列接続するとともに、それら各部分巻線７４１の他端を中性点で接続する巻線接続部材である。図９６は、バスバーモジュール８１０の斜視図であり、図９７は、バスバーモジュール８１０の縦断面の一部を示す断面図である。 Next, the bus bar module 810 will be described. The bus bar module 810 is electrically connected to the partial winding 741 of each coil module 740 in the stator winding 731, and one end of the partial winding 741 of each phase is connected in parallel for each phase, and each of these partial windings is connected in parallel. It is a winding connecting member that connects the other end of 741 at a neutral point. FIG. 96 is a perspective view of the bus bar module 810, and FIG. 97 is a cross-sectional view showing a part of a vertical cross section of the bus bar module 810.
　バスバーモジュール８１０は、円環状をなす環状部８１１と、その環状部８１１から延びる複数の接続端子８１２と、相巻線ごとに設けられる３つの入出力端子８１３と、各相の電流センサに接続される電流検出端子８１４とを有している。 The bus bar module 810 is connected to an annular portion 811 forming an annular shape, a plurality of connection terminals 812 extending from the annular portion 811, three input / output terminals 813 provided for each phase winding, and a current sensor for each phase. It has a current detection terminal 814.
　図９７に示すように、環状部８１１は、例えば樹脂等の絶縁部材により円環状に形成されており、その内部に埋設された状態で複数のバスバー８２１～８２４が設けられている。各バスバー８２１～８２４は、Ｕ相用のバスバー８２１と、Ｖ相用のバスバー８２２と、Ｗ相用のバスバー８２３と、中性点用のバスバー８２４とからなり、板面を対向させるようにして軸方向に並べて配置されている。そして、各バスバー８２１～８２４に、それぞれ環状部８１１から径方向外側に突出させるようにして接続端子８１２が接続されている。図９６に示すように、各接続端子８１２は、環状部８１１の周方向に並び、かつ径方向外側において軸方向に延びるように設けられている。 As shown in FIG. 97, the annular portion 811 is formed in an annular shape by, for example, an insulating member such as a resin, and a plurality of bus bars 821 to 824 are provided in a state of being embedded therein. Each bus bar 821 to 824 is composed of a U-phase bus bar 821, a V-phase bus bar 822, a W-phase bus bar 823, and a neutral point bus bar 824 so that the plate surfaces face each other. They are arranged side by side in the axial direction. Then, the connection terminals 812 are connected to the bus bars 821 to 824 so as to project radially outward from the annular portion 811. As shown in FIG. 96, the connection terminals 812 are provided so as to be arranged in the circumferential direction of the annular portion 811 and to extend in the axial direction on the outer side in the radial direction.
　図９８には、各バスバー８２１～８２４に対する接続端子８１２の接続位置を略図として示している。図９８において、左右方向が環状部８１１の周方向に相当する。また、図９８において、ＵはＵ相巻線に接続される接続端子８１２を示し、ＶはＶ相巻線に接続される接続端子８１２を示し、ＷはＷ相巻線に接続される接続端子８１２を示し、ＮＥは中性点に接続される接続端子８１２を示す。 FIG. 98 shows the connection positions of the connection terminals 812 for each bus bar 821 to 824 as a schematic diagram. In FIG. 98, the left-right direction corresponds to the circumferential direction of the annular portion 811. Further, in FIG. 98, U indicates a connection terminal 812 connected to the U-phase winding, V indicates a connection terminal 812 connected to the V-phase winding, and W indicates a connection terminal connected to the W-phase winding. 812 is indicated, NE indicates a connection terminal 812 connected to the neutral point.
　図９８に示すように、中性点に接続される接続端子８１２（ＮＥ）は周方向に１つ置きに配置され、その間に、Ｕ相巻線に接続される接続端子８１２（Ｕ）、Ｖ相巻線に接続される接続端子８１２（Ｖ）、Ｗ相巻線に接続される接続端子８１２（Ｗ）が１つずつ配置されている。これらの接続端子８１２は、コイルモジュール７４０における各部分巻線７４１の巻線端部７４３ａ，７４３ｂと同数で設けられており、接続端子８１２と巻線端部７４３ａ，７４３ｂとが１つずつ接続されるようになっている。なお、接続端子８１２と巻線端部７４３ａ，７４３ｂとの少なくともいずれかが、必要に応じて径方向に折り曲げられるか又は湾曲されて互いに接触され、その接触状態で、溶接や接着等による接合が行われるとよい。 As shown in FIG. 98, the connection terminals 812 (NE) connected to the neutral point are arranged every other in the circumferential direction, and the connection terminals 812 (U), V connected to the U-phase winding are in between. A connection terminal 812 (V) connected to the phase winding and a connection terminal 812 (W) connected to the W phase winding are arranged one by one. These connection terminals 812 are provided in the same number as the winding ends 743a and 743b of each partial winding 741 in the coil module 740, and the connection terminals 812 and the winding ends 743a and 743b are connected one by one. It has become so. It should be noted that at least one of the connection terminal 812 and the winding end portions 743a and 743b is bent or curved in the radial direction and is brought into contact with each other as necessary, and in the contact state, joining by welding, adhesion or the like is performed. It should be done.
　また、環状部８１１は、内周側に複数の被固定部８１５を有しており、その被固定部８１５にボルト等の締結具が組み付けられることで、インナハウジング７７１の端板７７４にバスバーモジュール８１０が固定されるようになっている。 Further, the annular portion 811 has a plurality of fixed portions 815 on the inner peripheral side, and by assembling fasteners such as bolts to the fixed portion 815, the bus bar module is attached to the end plate 774 of the inner housing 771. The 810 is fixed.
　入出力端子８１３は、Ｕ相用の入出力端子８１３Ｕ、Ｖ相用の入出力端子８１３Ｖ及びＷ相用の入出力端子８１３Ｗであり、これらは、環状部８１１内において相ごとにバスバー８２１～８２３にそれぞれ接続されている。これらの各入出力端子８１３を通じて、固定子巻線７３１の各相の相巻線に対して、不図示のインバータから電力の入出力が行われるようになっている。 The input / output terminals 813 are input / output terminals 813U for U phase, input / output terminals 813V for V phase, and input / output terminals 813W for W phase, and these are bus bars 821 to 823 for each phase in the annular portion 811. Are each connected to. Through each of these input / output terminals 813, power is input / output from an inverter (not shown) to the phase windings of each phase of the stator winding 731.
　また、環状部８１１には、相ごとに電流センサ８１６が設けられており、電流検出端子８１４を通じて、電流センサ８１６の検出結果が不図示の制御装置に対して出力されるようになっている。 Further, the annular portion 811 is provided with a current sensor 816 for each phase, and the detection result of the current sensor 816 is output to a control device (not shown) through the current detection terminal 814.
　上記構成の回転電機７００では、固定子７３０において、周方向に所定間隔で配置される導線部（中間導線部７４６）の間に導線間部材（いわゆるティース）が設けられていないか、又は導線間部材が設けられていても磁気的に脆弱な構成となっている。そのため、回転子７１０にて生じる磁石磁束が固定子巻線７３１の導線部に直接鎖交し、銅渦損の増加に伴うモータ効率の低下や熱定格性能の低下が懸念される。特に、上記のとおり配向による磁束密度の強化が図られている構成においては、銅渦損の影響がより顕著に生じることが懸念される。 In the rotary electric machine 700 having the above configuration, in the stator 730, no interconductor member (so-called teeth) is provided between the conductors (intermediate conductors 746) arranged at predetermined intervals in the circumferential direction, or between the conductors. Even if the members are provided, the configuration is magnetically fragile. Therefore, the magnetic flux generated by the rotor 710 is directly interlocked with the conducting wire portion of the stator winding 731, and there is a concern that the motor efficiency and the thermal rating performance may be lowered due to the increase in copper eddy loss. In particular, in the configuration in which the magnetic flux density is strengthened by orientation as described above, there is a concern that the effect of copper vortex loss will be more remarkable.
　この点、上記構成では、固定子巻線７３１において、部分巻線７４１を、周方向に離して設けられた同相の導線部間で導線７４３を多重に巻回して構成した。また、各相の相巻線を、複数の部分巻線７４１どうしを並列接続することで構成した。これにより、固定子巻線７３１において導線１本あたりの断面積の細分化が可能となり、銅渦損の発生を抑制でき、ひいては、モータ効率の向上や熱定格性能の向上を図ることができる。 In this respect, in the above configuration, in the stator winding 731, the partial winding 741 is configured by winding the conducting wire 743 multiple times between the conducting wires having the same phase provided apart from each other in the circumferential direction. Further, the phase windings of each phase are configured by connecting a plurality of partial windings 741 in parallel. As a result, the cross-sectional area of the stator winding 731 can be subdivided, the occurrence of copper vortex loss can be suppressed, and the motor efficiency and the thermal rating performance can be improved.
　また、磁極の極数をＰ、１相当たりの部分巻線７４１Ａの数及び部分巻線７４１Ｂの数を各々Ｎ個とした場合に、極数Ｐが４×Ｎであり、相巻線では、相ごとにＮ個の部分巻線７４１ＡとＮ個の部分巻線７４１Ｂとが全て並列接続されている。本例において具体的には、１相当たりの部分巻線７４１Ａ，７４１Ｂの数（Ｎ）は、それぞれ６であり、極数Ｐは２４である。例えば図８４には、３相のうち１相のコイルモジュール７４０が示されており、部分巻線７４１Ａを備えるコイルモジュール７４０Ａとして６個のコイルモジュール７４０Ａと、部分巻線７４１Ｂを備えるコイルモジュール７４０Ｂとして６個のコイルモジュール７４０Ｂとが示されている。各相巻線では、相ごとに６個の部分巻線７４１Ａと６個の部分巻線７４１Ｂとが全て並列接続されている。 Further, when the number of poles of the magnetic poles is P and the number of partial windings 741A and the number of partial windings 741B per phase are N, the number of poles P is 4 × N. N partial windings 741A and N partial windings 741B are all connected in parallel for each phase. Specifically, in this example, the number (N) of the partial windings 741A and 741B per phase is 6, and the number of poles P is 24, respectively. For example, FIG. 84 shows a coil module 740 of one of the three phases, as a coil module 740A having a partial winding 741A, as a coil module 740A having six coil modules 740A, and as a coil module 740B having a partial winding 741B. Six coil modules 740B are shown. In each phase winding, six partial windings 741A and six partial windings 741B are all connected in parallel for each phase.
　図８６で言えば、Ｕ、Ｖ、Ｗの各相の相巻線において、部分巻線７４１の並列数がいずれも１２となっている。この場合、相ごとに全ての部分巻線７４１Ａ，７４１Ｂを並列接続することにより、固定子巻線７３１での各導線の断面積の最小化が可能となり、銅渦損のより一層の低減を図ることができる。 In FIG. 86, in the phase windings of each of the U, V, and W phases, the number of parallel windings 741 is 12 in each case. In this case, by connecting all the partial windings 741A and 741B in parallel for each phase, it is possible to minimize the cross-sectional area of each conducting wire in the stator winding 731, and further reduce the copper vortex loss. be able to.
　（変形例１６）
　次に、本変形例における回転電機９００について説明する。回転電機９００は、例えば車両の駆動用ユニットとして用いられる。本例の回転電機９００では、変形例１５で説明した回転電機７００と同様に、固定子の固定子巻線として複数の部分巻線（コイルモジュール）を用いた構成としている。また、本例の回転電機９００では、変形例１５の回転電機７００との主な相違点として、インナロータ式とした構成、固定子コアをティース付き構造とした構成を有している。以下にその詳細を説明する。図１０１は、インナロータ式の回転電機９００の縦断面図であり、図１０２は、回転電機９００の横縦断面図であり、図１０３は、図１０２に示す構成の一部を拡大して示す横断面図である。 (Modification 16)
Next, the rotary electric machine 900 in this modification will be described. The rotary electric machine 900 is used, for example, as a vehicle driving unit. Similar to the rotary electric machine 700 described in the modified example 15, the rotary electric machine 900 of this example has a configuration in which a plurality of partial windings (coil modules) are used as the stator windings of the stator. Further, the rotary electric machine 900 of this example has an inner rotor type configuration and a stator core structure with teeth as the main differences from the rotary electric machine 700 of the modified example 15. The details will be described below. FIG. 101 is a vertical cross-sectional view of the inner rotor type rotary electric machine 900, FIG. 102 is a horizontal vertical cross-sectional view of the rotary electric machine 900, and FIG. 103 is a cross section showing a part of the configuration shown in FIG. 102 in an enlarged manner. It is a top view.
　回転電機９００は、回転軸９０１と一体回転可能に設けられた回転子９１０と、その回転子９１０の径方向外側に設けられた固定子９２０とを有している。径方向において回転子９１０と固定子９２０との間にはエアギャップが形成されている。なお、回転軸９０１は、既述の構成と同様、不図示の軸受により回転可能に支持されている。回転子９１０が「界磁子」に相当し、固定子９２０が「電機子」に相当する。 The rotary electric machine 900 has a rotor 910 provided so as to be rotatable integrally with the rotary shaft 901, and a stator 920 provided on the radial outer side of the rotor 910. An air gap is formed between the rotor 910 and the stator 920 in the radial direction. The rotary shaft 901 is rotatably supported by bearings (not shown) as in the above-described configuration. The rotor 910 corresponds to the "field magnet" and the stator 920 corresponds to the "armature".
　回転子９１０は、中空筒状に形成された回転子キャリア９１１と、その回転子キャリア９１１の径方向外側に固定された環状の磁石ユニット９１２とを有している。回転子キャリア９１１は回転軸９０１に固定されており、磁石保持部材としての機能を有する。磁石ユニット９１２は、回転子９１０の周方向に極性が交互となる複数の磁極を有している。磁石ユニット９１２が「磁石部」に相当する。 The rotor 910 has a rotor carrier 911 formed in a hollow tubular shape and an annular magnet unit 912 fixed to the outside in the radial direction of the rotor carrier 911. The rotor carrier 911 is fixed to the rotating shaft 901 and has a function as a magnet holding member. The magnet unit 912 has a plurality of magnetic poles having alternating polarities in the circumferential direction of the rotor 910. The magnet unit 912 corresponds to the "magnet portion".
　図１０３に示すように、磁石ユニット９１２は、周方向に並べて配置された複数の磁石９１３（永久磁石）を有しており、それら各磁石９１３により、周方向に極性が交互となる複数の磁極が形成されている。磁石９１３は、固有保磁力が４００［ｋＡ／ｍ］以上であり、かつ残留磁束密度Ｂｒが１．０［Ｔ］以上である焼結ネオジム磁石である。 As shown in FIG. 103, the magnet unit 912 has a plurality of magnets 913 (permanent magnets) arranged side by side in the circumferential direction, and a plurality of magnetic poles having polarities alternating in the circumferential direction due to each of the magnets 913. Is formed. The magnet 913 is a sintered neodymium magnet having an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more.
　各磁石９１３は、径方向両面のうち固定子９２０側（図の上側）が磁束作用面９１３ａとなっており、その磁束作用面９１３ａにおいて、磁極中心であるｄ軸付近の領域に集中的に磁束を生じさせるものとなっている。具体的には、各磁石９１３は、それぞれ極異方性磁石であり、磁極中心であるｄ軸の側において、磁極境界であるｑ軸の側に比べて磁化容易軸の向きがｄ軸に平行となるように配向がなされて構成されている。つまり、ｄ軸側（ｄ軸寄りの部分）とｑ軸側（ｑ軸寄りの部分）とで磁化容易軸の向きが相違し、ｄ軸側では磁化容易軸の向きがｄ軸に平行な方向に近い向きとなり、ｑ軸側では磁化容易軸の向きがｑ軸に直交する方向に近い向きとなっている。そして、この磁化容易軸の向きに応じた配向により円弧状の磁石磁路が形成されている。なお、各磁石９１３において、ｄ軸側では磁化容易軸をｄ軸に平行な向きとし、ｑ軸側では磁化容易軸をｑ軸に直交する向きとしてもよい。 In each magnet 913, the stator 920 side (upper side in the figure) of both sides in the radial direction is the magnetic flux acting surface 913a, and the magnetic flux is concentrated in the region near the d-axis which is the center of the magnetic pole on the magnetic flux acting surface 913a. Is to occur. Specifically, each magnet 913 is a polar anisotropy magnet, and the direction of the easy magnetization axis is parallel to the d-axis on the d-axis side, which is the center of the magnetic pole, as compared with the side of the q-axis, which is the magnetic pole boundary. It is configured so that it is oriented so as to be. That is, the direction of the easy-to-magnetize axis is different between the d-axis side (the part closer to the d-axis) and the q-axis side (the part closer to the q-axis), and the direction of the easy-to-magnetize axis is parallel to the d-axis on the d-axis side. On the q-axis side, the direction of the easy-to-magnetize axis is close to the direction orthogonal to the q-axis. Then, an arcuate magnet magnetic path is formed by the orientation according to the direction of the easily magnetized axis. In each magnet 913, the easy magnetization axis may be oriented parallel to the d-axis on the d-axis side, and the easy-magnetization axis may be oriented orthogonal to the q-axis on the q-axis side.
　磁石９１３は、径方向両側の磁束作用面の間において磁化容易軸の向きがｄ軸に対して斜めであり、周方向において固定子９２０側でｄ軸に近づき、かつ反固定子側でｄ軸から離れる向きとなるように直線的な配向がなされているものであってもよい。この構成であっても、磁石９１３の固定子９２０側の磁束作用面９１３ａにおいて、ｄ軸付近の領域に集中的に磁束を生じさせることができる。 In the magnet 913, the direction of the easy-magnetizing axis is oblique to the d-axis between the magnetic flux acting surfaces on both sides in the radial direction, the stator 920 side approaches the d-axis in the circumferential direction, and the d-axis is on the anti-stator side. It may be linearly oriented so as to be oriented away from. Even with this configuration, magnetic flux can be intensively generated in the region near the d-axis on the magnetic flux acting surface 913a on the stator 920 side of the magnet 913.
　なお、磁石９１３の構成を上記以外に変更することも可能であり、磁石９１３として、磁化方向が径方向となるラジアル異方性の永久磁石や、磁化方向が平行なパラレル異方性の永久磁石を用いることも可能である。また、回転子９１０は、表面磁石型の回転子構造である以外に、埋込磁石型の回転子構造であってもよい。 The configuration of the magnet 913 can be changed to other than the above. As the magnet 913, a radial anisotropy permanent magnet whose magnetization direction is the radial direction and a parallel anisotropy permanent magnet whose magnetization direction is parallel can be changed. It is also possible to use. Further, the rotor 910 may have an embedded magnet type rotor structure in addition to the surface magnet type rotor structure.
　また、固定子９２０は、多相の固定子巻線９２１と、その固定子巻線９２１に一体に設けられた固定子コア９２２とを有している。固定子コア９２２は、電磁鋼板からなる複数のコアシートが軸方向に積層されたコアシート積層体として構成されている。また、固定子コア９２２は、円筒状のヨーク９２３と、ヨーク９２３の径方向内側において周方向に所定間隔で設けられた複数のティース９２４とを有し、各ティース９２４どうしの間に、径方向に延びるスロット９２５が形成されている。スロット９２５は、径方向が長手となる略矩形状に形成され、それぞれが径方向内側に開口している。 Further, the stator 920 has a multi-phase stator winding 921 and a stator core 922 integrally provided with the stator winding 921. The stator core 922 is configured as a core sheet laminate in which a plurality of core sheets made of electrical steel sheets are laminated in the axial direction. Further, the stator core 922 has a cylindrical yoke 923 and a plurality of teeth 924 provided at predetermined intervals in the circumferential direction inside the yoke 923 in the radial direction, and is provided between the teeth 924 in the radial direction. A slot 925 extending into is formed. The slots 925 are formed in a substantially rectangular shape having a longitudinal direction in the radial direction, and each slot 925 opens inward in the radial direction.
　固定子巻線９２１は、複数の相巻線を有し、各相の相巻線が周方向に所定順序で配置されている。本例では、Ｕ相、Ｖ相及びＷ相の相巻線を用いることで、固定子巻線９２１が３相の相巻線を有する構成となっている。 The stator winding 921 has a plurality of phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction. In this example, by using U-phase, V-phase, and W-phase phase windings, the stator winding 921 has a configuration having three-phase phase windings.
　図１０１に示すように、固定子９２０は、軸方向において、回転子９１０における磁石ユニット９１２に径方向に対向するコイルサイドＣＳに相当する部分と、そのコイルサイドＣＳの軸方向外側であるコイルエンドＣＥに相当する部分とを有している。この場合、固定子コア９２２は、軸方向においてコイルサイドＣＳに相当する範囲で設けられている。なお、コイルエンドＣＥは、固定子コア９２２の軸方向端面よりも軸方向外側の部分である。 As shown in FIG. 101, the stator 920 has a portion corresponding to a coil side CS that faces the magnet unit 912 in the rotor 910 in the axial direction in the axial direction, and a coil end that is outside the coil side CS in the axial direction. It has a part corresponding to CE. In this case, the stator core 922 is provided in a range corresponding to the coil side CS in the axial direction. The coil end CE is a portion axially outside of the axial end face of the stator core 922.
　固定子巻線９２１において各相の相巻線は、コイルエンド形状の異なる２種類の部分巻線９３１を有している。部分巻線９３１は、導線材を多重に巻回してなる環状コイルであり、図１０４（ａ）は、一方の部分巻線９３１である第１部分巻線９３１Ａの構成を示す斜視図、図１０４（ｂ）は、他方の部分巻線９３１である第２部分巻線９３１Ｂの構成を示す斜視図である。また、図１０５は、各部分巻線９３１Ａ，９３１Ｂを横に並べて対比して示す側面図である。これら各図に示すように、各部分巻線９３１Ａ，９３１Ｂは、軸方向長さが互いに異なり、かつ軸方向両側の端部形状が互いに異なるものとなっている。第１部分巻線９３１Ａは、側面視において略Ｃ字状をなし、第２部分巻線９３１Ｂは、側面視において略Ｉ字状をなしている。 In the stator winding 921, the phase winding of each phase has two types of partial windings 931 having different coil end shapes. The partial winding 931 is an annular coil formed by winding a conducting wire material in multiple directions, and FIG. 104 (a) is a perspective view showing the configuration of a first partial winding 931A which is one partial winding 931, FIG. 104. (B) is a perspective view which shows the structure of the 2nd partial winding 931B which is the other partial winding 931. Further, FIG. 105 is a side view showing the partial windings 931A and 931B side by side for comparison. As shown in each of these figures, the partial windings 931A and 931B have different axial lengths and different end shapes on both sides in the axial direction. The first partial winding 931A has a substantially C shape in the side view, and the second partial winding 931B has a substantially I shape in the side view.
　図１０４（ａ）に示すように、第１部分巻線９３１Ａは、互いに平行でかつ直線状に設けられる一対の中間導線部９３２と、一対の中間導線部９３２を軸方向両端でそれぞれ接続する一対の渡り部９３３とを有しており、これら一対の中間導線部９３２と一対の渡り部９３３とにより環状に形成されている。各中間導線部９３２は、コイルサイドＣＳにおいて周方向に並ぶコイルサイド導線部として設けられている。また、各渡り部９３３は、コイルエンドＣＥにおいて、周方向に異なる２位置の同相の中間導線部９３２どうしを接続するコイルエンド導線部として設けられている。固定子コア９２２への部分巻線９３１の組み付け時には、各中間導線部９３２がそれぞれスロット９２５に収容される。 As shown in FIG. 104 (a), the first partial winding 931A is a pair of intermediate conductors 932 provided parallel to each other and linearly connected to each other and a pair of intermediate conductors 932 connected at both ends in the axial direction. It has a crossover portion 933, and is formed in an annular shape by the pair of intermediate conductor portions 932 and the pair of crossover portions 933. Each intermediate conductor portion 932 is provided as a coil side conductor portion arranged in the circumferential direction in the coil side CS. Further, each crossover portion 933 is provided as a coil end lead wire portion for connecting the intermediate lead wire portions 932 having two positions different in the circumferential direction in the coil end CE. When assembling the partial winding 931 to the stator core 922, each intermediate lead portion 932 is housed in the slot 925.
　一対の渡り部９３３は、軸方向両側でそれぞれ同じ形状となっており、いずれもコイルエンドＣＥに相当する部分として設けられている（図１０５参照）。各渡り部９３３は、中間導線部９３２に対して直交する向き、すなわち軸方向に直交する方向に折れ曲がるようにして設けられている。 The pair of crossovers 933 have the same shape on both sides in the axial direction, and both are provided as portions corresponding to the coil end CE (see FIG. 105). Each crossover 933 is provided so as to bend in a direction orthogonal to the intermediate conductor 932, that is, in a direction orthogonal to the axial direction.
　なお、第１部分巻線９３１Ａと、第２部分巻線９３１Ｂとでは、渡り部９３３の形状が異なっており、その区別を明確にすべく、第１部分巻線９３１Ａの渡り部９３３を「第１渡り部９３３Ａ」、第２部分巻線９３１Ｂの渡り部９３３を「第２渡り部９３３Ｂ」とも記載する。 The shape of the crossover 933 is different between the first partial winding 931A and the second partial winding 931B, and in order to clarify the distinction, the crossover 933 of the first partial winding 931A is referred to as "the first". 1 Crossover 933A ”and the crossover 933 of the second partial winding 931B are also referred to as“ second crossover 933B ”.
　図１０６は、図１０４（ａ）における１０６－１０６線断面図である。図１０６に示すように、一対の中間導線部９３２は、所定のスロットピッチ分を離して設けられており、本例では、周方向における互いの中心間距離Ｄが３スロットピッチに相当する距離、すなわち相数のスロットピッチに相当する距離となっている。図１０６には、一対の中間導線部９３２の間となるスロット位置を仮想線で示している。一対の中間導線部９３２間の各スロット９２５には、他相の部分巻線９３１の中間導線部９３２が収容される。この場合、部分巻線９３１は、固定子コア９２２における３つのティース９２４を跨ぐように配置されるものとなっている。部分巻線９３１は、全節集中巻コイルであり、１極対において相ごとに１つずつ設けられている。 FIG. 106 is a cross-sectional view taken along the line 106-106 in FIG. 104 (a). As shown in FIG. 106, the pair of intermediate lead wire portions 932 are provided so as to be separated by a predetermined slot pitch. In this example, the distance D between the centers in the circumferential direction corresponds to a three-slot pitch. That is, the distance corresponds to the slot pitch of the number of phases. In FIG. 106, the slot positions between the pair of intermediate conductors 932 are shown by virtual lines. Each slot 925 between the pair of intermediate conductors 932 accommodates the intermediate conductor 932 of the other phase partial winding 931. In this case, the partial winding 931 is arranged so as to straddle the three teeth 924 in the stator core 922. The partial winding 931 is a centralized winding coil for all nodes, and is provided one for each phase in a one-pole pair.
　また、第１部分巻線９３１Ａは、導線集合部分の横断面が四角形になるように導線材ＣＲが多重に巻回されて形成されている。図１０６に示す中間導線部９３２では、導体断面が矩形状をなす平角線からなる導線材ＣＲを周方向及び径方向に並ぶように多重に巻回することで、断面矩形状の導線集合体が構成されている。つまり、第１部分巻線９３１Ａは、角線を多重に巻回されることで構成されており、角線の集合体である導線集合部の横断面が四角形形状をなしている。一対の中間導線部９３２は、その横断面形状が、径方向（図の上下方向）が長手側となる長方形状をなしており、その長手方向において各中間導線部９３２の中心線Ｌ１，Ｌ２は互いに平行になっている。なお、第１渡り部９３３Ａの先端部では、径方向への折れ曲がりにより、導線材ＣＲが軸方向及び径方向に並ぶように多重に巻回される構成となっている。本例では、導線材ＣＲを同心巻により巻回することで第１部分巻線９３１Ａが構成されている。ただし、導線材ＣＲの巻き方は任意であり、同心巻に代えて、アルファ巻により導線材ＣＲが多重に巻回されていてもよい。 Further, the first partial winding 931A is formed by winding the conducting wire material CR multiple times so that the cross section of the conducting wire gathering portion becomes a quadrangle. In the intermediate conductor portion 932 shown in FIG. 106, a conductor assembly having a rectangular cross section is formed by winding a conductor CR composed of flat wires having a rectangular cross section in a plurality of directions so as to be arranged in the circumferential direction and the radial direction. It is configured. That is, the first partial winding 931A is configured by winding the square wires multiple times, and the cross section of the conducting wire collecting portion, which is an aggregate of the square wires, has a quadrangular shape. The pair of intermediate conductors 932 has a rectangular shape whose cross-sectional shape is the longitudinal side in the radial direction (vertical direction in the figure), and the center lines L1 and L2 of the intermediate conductors 932 are in the longitudinal direction. They are parallel to each other. The tip of the first crossover 933A is configured to be multiplely wound so that the conductor CRs are aligned in the axial direction and the radial direction due to the bending in the radial direction. In this example, the first partial winding 931A is configured by winding the conductor CR by concentric winding. However, the method of winding the conductor CR is arbitrary, and instead of concentric winding, the conductor CR may be wound multiple times by alpha winding.
　また、図１０４（ｂ）に示すように、第２部分巻線９３１Ｂは、互いに平行でかつ直線状に設けられる一対の中間導線部９３２と、一対の中間導線部９３２を軸方向両端でそれぞれ接続する一対の第２渡り部９３３Ｂとを有しており、これら一対の中間導線部９３２と一対の第２渡り部９３３Ｂとにより環状に形成されている。第２部分巻線９３１Ｂにおいて一対の中間導線部９３２は、第１部分巻線９３１Ａの中間導線部９３２と構成が同じである。これに対して、一対の第２渡り部９３３Ｂは、第１部分巻線９３１Ａの第１渡り部９３３Ａとは構成が異なっている。第２部分巻線９３１Ｂの第２渡り部９３３Ｂは、径方向に折り曲げられることなく、中間導線部９３２から直線状に軸方向に延びるようにして設けられている。第１部分巻線９３１Ａと第２部分巻線９３１Ｂとはコイルエンド形状が異なる以外は同一構成を有しており、図１０５には、部分巻線９３１Ａ，９３１Ｂの違いが対比して明示されている。 Further, as shown in FIG. 104 (b), the second partial winding 931B connects a pair of intermediate conductor portions 932 provided in parallel and linearly with each other and a pair of intermediate conductor portions 932 at both ends in the axial direction. It has a pair of second crossover portions 933B, and is formed in an annular shape by the pair of intermediate conductor portions 932 and the pair of second crossover portions 933B. The pair of intermediate conductors 932 in the second partial winding 931B has the same configuration as the intermediate conductor 932 of the first partial winding 931A. On the other hand, the pair of second crossover portions 933B has a different configuration from the first crossover portion 933A of the first partial winding 931A. The second crossover portion 933B of the second partial winding 931B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 932 without being bent in the radial direction. The first partial winding 931A and the second partial winding 931B have the same configuration except that the coil end shape is different, and in FIG. 105, the differences between the partial windings 931A and 931B are clearly shown in comparison. There is.
　各部分巻線９３１Ａ，９３１Ｂは、その一部又は全てが合成樹脂等の絶縁材料により被覆されて構成されていてもよい。又は、各部分巻線９３１Ａ，９３１Ｂは、例えば図８７に示すような絶縁性の巻線ホルダに一体化されたものであってもよい。 Each partial winding 931A, 931B may be configured by covering a part or all of the partial windings with an insulating material such as synthetic resin. Alternatively, the partial windings 931A and 931B may be integrated with an insulating winding holder as shown in FIG. 87, for example.
　各部分巻線９３１Ａ，９３１Ｂは、固定子コア９２２のスロット９２５に各中間導線部９３２が収容されることで、固定子コア９２２に対して組み付けられる。各部分巻線９３１Ａ，９３１Ｂは、２種類のコイルエンド形状を有していることから、周方向に隣り合う部分巻線９３１どうしの干渉が抑制されるものとなっている。具体的には、上述したとおり、第１部分巻線９３１Ａの第１渡り部９３３Ａは、中間導線部９３２に対して直交する向き（径方向）に折れ曲がるようにして設けられているのに対し、第２部分巻線９３１Ｂの第２渡り部９３３Ｂは、径方向に折り曲げられることなく中間導線部９３２から直線状に軸方向に延びるようにして設けられている。この場合、各部分巻線９３１Ａ，９３１Ｂは、周方向に一部が互いに重複した状態で固定子コア９２２に組み付けられるが、各渡り部９３３Ａ，９３３Ｂが軸方向に互いに離間していることで、渡り部９３３Ａ，９３３Ｂどうしの互いの干渉が回避されるようになっている。 The partial windings 931A and 931B are assembled to the stator core 922 by accommodating each intermediate conductor portion 932 in the slot 925 of the stator core 922. Since each of the partial windings 931A and 931B has two types of coil end shapes, interference between the partial windings 931 adjacent to each other in the circumferential direction is suppressed. Specifically, as described above, the first crossing portion 933A of the first partial winding 931A is provided so as to be bent in a direction (diameter direction) orthogonal to the intermediate conductor portion 932. The second crossing portion 933B of the second partial winding 931B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 932 without being bent in the radial direction. In this case, the partial windings 931A and 931B are assembled to the stator core 922 in a state where the partial windings 931A and 931B partially overlap each other in the circumferential direction, but the crossover portions 933A and 933B are separated from each other in the axial direction. Interference between the crossovers 933A and 933B is avoided.
　ところで、各部分巻線９３１Ａ，９３１Ｂはそれぞれ渡り部９３３を有しているため、固定子コア９２２に対して各部分巻線９３１Ａ，９３１Ｂを組み付ける際には、それら各部分巻線９３１Ａ，９３１Ｂが、軸方向でなく径方向内側からスロット９２５内に挿入される。また、各部分巻線９３１Ａ，９３１Ｂはそれぞれ一対の中間導線部９３２を有しており、それら各中間導線部９３２が、スロット９２５内に無駄なデッドスペースを生じさせることなく収容されることが望ましい。以下には、固定子コア９２２に対する各部分巻線９３１Ａ，９３１Ｂの組み付けに関する構成を説明する。図１０７は、固定子コア９２２に対して任意の部分巻線９３１Ｘを組み付ける構成を示す概略図である。 By the way, since each of the partial windings 931A and 931B has a crossover portion 933, when the partial windings 931A and 931B are assembled to the stator core 922, the partial windings 931A and 931B are used. , Is inserted into the slot 925 from the inside in the radial direction instead of the axial direction. Further, each of the partial windings 931A and 931B has a pair of intermediate conductor portions 932, and it is desirable that each of the intermediate conductor portions 932 is accommodated in the slot 925 without causing a wasteful dead space. .. The configuration for assembling the partial windings 931A and 931B to the stator core 922 will be described below. FIG. 107 is a schematic view showing a configuration in which an arbitrary partial winding 931X is assembled to the stator core 922.
　図１０７において、固定子コア９２２には、周方向に所定間隔で複数のスロット９２５が形成されており、そのうち２つのスロット９２５Ａ，９２５Ｂが、部分巻線９３１Ｘの組み付け位置となるスロットである。これら各スロット９２５Ａ，９２５Ｂは、部分巻線９３１Ｘの一対の中間導線部９３２を収容するスロット対ＳＰに相当するものであり、以下の記載ではスロット９２５Ａを「第１スロット９２５Ａ」、スロット９２５Ｂを「第２スロット９２５Ｂ」とする。スロット対ＳＰは、部分巻線９３１ごとにそれぞれ２つの他のスロット９２５を跨ぐようにして設けられている。 In FIG. 107, a plurality of slots 925 are formed in the stator core 922 at predetermined intervals in the circumferential direction, and two of the slots 925A and 925B are slots where the partial winding 931X is assembled. Each of these slots 925A and 925B corresponds to a slot pair SP accommodating a pair of intermediate lead portions 932 of the partial winding 931X. In the following description, the slot 925A is referred to as "first slot 925A" and the slot 925B is referred to as "first slot 925A". Second slot 925B ". The slot-to-SP is provided so as to straddle two other slots 925 for each partial winding 931.
　ここで、第１スロット９２５Ａ及び第２スロット９２５Ｂにおいて、周方向に互いに内側となるスロット壁を内側壁９４１、周方向に互いに外側となるスロット壁を外側壁９４２とする。この場合、各スロット９２５Ａ，９２５Ｂは、内側壁９４１どうしが平行となり、かつ外側壁９４２どうしが平行となるように設けられている。そして、一対の中間導線部９３２が、各スロット９２５Ａ，９２５Ｂにおいて内側壁９４１及び外側壁９４２に近接対向した状態で収容されている。各スロット９２５におけるヨーク９２３側の周方向幅をＷ１、反ヨーク側の周方向幅をＷ２とすると、Ｗ１＝Ｗ２となっている。 Here, in the first slot 925A and the second slot 925B, the slot walls that are inside each other in the circumferential direction are referred to as an inner side wall 941, and the slot walls that are outside each other in the circumferential direction are referred to as an outer wall 942. In this case, the slots 925A and 925B are provided so that the inner side walls 941 are parallel to each other and the outer walls 942 are parallel to each other. A pair of intermediate conductors 932 are housed in the slots 925A and 925B in a state of being close to each other with the inner side wall 941 and the outer wall 942. Assuming that the circumferential width of the yoke 923 side in each slot 925 is W1 and the circumferential width of the anti-yoke side is W2, W1 = W2.
　また、各スロット９２５Ａ，９２５Ｂにおいて内側壁９４１及び外側壁９４２は互いに平行であり、一対の中間導線部９３２の周方向の側面は互いに平行である。つまり、各スロット９２５Ａ，９２５Ｂが、周方向の幅が均一な平行スロットとして設けられている。また、部分巻線９３１Ｘの各中間導線部９３２が、周方向の幅が均一な平行導線として設けられている。 Further, in the slots 925A and 925B, the inner side wall 941 and the outer wall 942 are parallel to each other, and the side surfaces of the pair of intermediate conductors 932 in the circumferential direction are parallel to each other. That is, the slots 925A and 925B are provided as parallel slots having a uniform width in the circumferential direction. Further, each intermediate conductor portion 932 of the partial winding 931X is provided as a parallel conductor having a uniform width in the circumferential direction.
　さらに、スロット対ＳＰにおける第１スロット９２５Ａから第２スロット９２５Ｂまでの範囲の周方向中心位置と固定子中心点ＣＰとを通る直線を第１中心線Ｌ１１、第１スロット９２５Ａ及び第２スロット９２５Ｂにおいて各々の周方向中心位置を通りかつ第１中心線Ｌ１に平行な直線を第２中心線Ｌ１２とする。この場合、各スロット９２５Ａ，９２５Ｂの第２中心線Ｌ１２は互いに平行であり、かつ各スロット９２５Ａ，９２５Ｂは、第２中心線Ｌ１２に対して周方向に線対称で設けられている。 Further, a straight line passing through the circumferential center position in the range from the first slot 925A to the second slot 925B and the stator center point CP in the slot vs. SP is drawn at the first center line L11, the first slot 925A and the second slot 925B. The straight line passing through each circumferential center position and parallel to the first center line L1 is defined as the second center line L12. In this case, the second center lines L12 of the slots 925A and 925B are parallel to each other, and the slots 925A and 925B are provided line-symmetrically in the circumferential direction with respect to the second center line L12.
　図１０７において、第１スロット９２５Ａは、スロット対ＳＰを構成する左右２つスロット９２５のうち左側スロットであり、その隣の別のスロット９２５は、別のスロット対ＳＰの右側スロットとなる（具体的なスロットの並びは図１０８参照）。そのため、スロット間の各ティース９２４は、２つの内側壁９４１の間となるティース９２４（第１ティース９２４Ａ）と、２つの外側壁９４２の間となるティース９２４（第２ティース９２４Ｂ）とが交互に並ぶこととなる。この場合、各スロット９２５Ａ，９２５Ｂが第２中心線Ｌ１２に対して周方向に線対称で設けられていることにより、周方向に並ぶ各ティース９２４の大きさの均等化が可能となっている。 In FIG. 107, the first slot 925A is the left slot of the two left and right slots 925 constituting the slot vs. SP, and another slot 925 next to the first slot 925A is the right slot of the other slot vs. SP (specifically). See FIG. 108 for the arrangement of the various slots. Therefore, in each of the teeth 924 between the slots, the teeth 924 (first teeth 924A) between the two inner side walls 941 and the teeth 924 (second teeth 924B) between the two outer walls 942 alternate. It will be lined up. In this case, since the slots 925A and 925B are provided line-symmetrically in the circumferential direction with respect to the second center line L12, the sizes of the teeth 924 arranged in the circumferential direction can be equalized.
　上記構成の固定子コア９２２では、周方向に並ぶ各ティース９２４の形態が均一でなくなる。つまり、固定子コア９２２は、ヨーク９２３側の基端部の周方向幅Ｗ１１が反ヨーク側の先端部の周方向幅Ｗ１２よりも小さい第１ティース９２４Ａと、基端部の周方向幅Ｗ１１が先端部の周方向幅Ｗ１２よりも大きい第２ティース９２４Ｂとを含み、それら各ティース９２４Ａ，９２４Ｂが周方向に交互に並ぶ構成となっている。本例では特に、第１ティース９２４Ａにおける基端部の周方向幅Ｗ１１と、第２ティース９２４Ｂにおける先端部の周方向幅Ｗ１２とが同一になっている。これにより、各ティース９２４Ａ，９２４Ｂの磁気特性を等しくするようにしている。 In the stator core 922 having the above configuration, the shapes of the teeth 924 arranged in the circumferential direction are not uniform. That is, the stator core 922 has a first tooth 924A in which the circumferential width W11 of the base end portion on the yoke 923 side is smaller than the circumferential width W12 of the tip end portion on the anti-yoke side, and the circumferential width W11 of the base end portion. The second teeth 924B, which is larger than the circumferential width W12 of the tip portion, is included, and the teeth 924A and 924B are arranged alternately in the circumferential direction. In this example, in particular, the circumferential width W11 of the base end portion in the first teeth 924A and the circumferential width W12 of the tip end portion in the second teeth 924B are the same. As a result, the magnetic characteristics of the teeth 924A and 924B are made equal.
　図１０８は、固定子コア９２２の各スロット９２５に対する部分巻線９３１Ａ，９３１Ｂの組み付けを説明するための概略図である。なお、図１０８では、説明の補助のため、各スロット９２５に１番～８番の符号を付している。 FIG. 108 is a schematic view for explaining the assembly of the partial windings 931A and 931B to each slot 925 of the stator core 922. In FIG. 108, reference numerals 1 to 8 are attached to each slot 925 for the sake of assistance in explanation.
　図１０８では、１番－４番スロット、３番－６番スロット、５番－８番スロットがそれぞれスロット対ＳＰ１，ＳＰ２，ＳＰ３となっており、これらの各スロット対ＳＰ１～ＳＰ３にそれぞれ部分巻線９３１Ａ，９３１Ｂが組み付けられる。この場合、第１部分巻線９３１Ａ及び第２部分巻線９３１Ｂのうち、渡り部９３３がヨーク９２３側に屈曲形成されている第１部分巻線９３１Ａが先にスロット対ＳＰ２に組み付けられ、その後に第２部分巻線９３１Ｂがスロット対ＳＰ１，ＳＰ３に組み付けられる。このとき、上述したように、スロット対ＳＰの各スロット９２５Ａ，９２５Ｂは、内側壁９４１どうしが平行、かつ外側壁９４２どうしが平行となるように設けられ、さらにヨーク９２３側の周方向幅Ｗ１と反ヨーク側の周方向幅Ｗ２とが同じであるため、各部分巻線９３１Ａ，９３１Ｂの径方向のスライドにより各スロット９２５Ａ，９２５Ｂへの組み付けが好適に行われるものとなっている。 In FIG. 108, the 1st-4th slots, the 3rd-6th slots, and the 5th-8th slots are slot pairs SP1, SP2, SP3, respectively, and each of these slots pairs SP1 to SP3 is partially wound. Lines 931A and 931B are assembled. In this case, of the first partial winding 931A and the second partial winding 931B, the first partial winding 931A in which the crossing portion 933 is bent toward the yoke 923 side is first assembled to the slot vs. SP2, and then. The second partial winding 931B is assembled to the slot pairs SP1 and SP3. At this time, as described above, the slots 925A and 925B of the slot vs. SP are provided so that the inner side walls 941 are parallel to each other and the outer walls 942 are parallel to each other, and further, the width W1 in the circumferential direction on the yoke 923 side is provided. Since the width W2 in the circumferential direction on the anti-yoke side is the same, the partial windings 931A and 931B are preferably assembled into the slots 925A and 925B by sliding in the radial direction.
　第１部分巻線９３１Ａは、第１部分巻線９３１Ａどうしが周方向に互いに重複しないようにして並べて配置され、第２部分巻線９３１Ｂは、第２部分巻線９３１Ｂどうしが周方向に互いに重複しないようにして並べて配置される。そして、第１部分巻線９３１Ａ及び第２部分巻線９３１Ｂが周方向に互いに重複するものとなっている。 The first partial windings 931A are arranged side by side so that the first partial windings 931A do not overlap each other in the circumferential direction, and the second partial windings 931B have the second partial windings 931B overlapping each other in the circumferential direction. They are arranged side by side so as not to. The first partial winding 931A and the second partial winding 931B overlap each other in the circumferential direction.
　本例の回転電機９００によれば、以下に示す優れた効果が得られる。 According to the rotary electric machine 900 of this example, the following excellent effects can be obtained.
　固定子コア９２２において、部分巻線９３１の一対の中間導線部９３２が収容されるスロット対ＳＰに対して、径方向からの部分巻線９３１の組み付けを可能にした。具体的には、スロット対ＳＰの第１スロット９２５Ａ及び第２スロット９２５Ｂにおいて、これら各スロット９２５Ａ，９２５Ｂの内側壁９４１どうし、外側壁９４２どうしをそれぞれ平行とするとともに、各スロット９２５のヨーク９２３側の周方向幅Ｗ１と反ヨーク側の周方向幅Ｗ２とを同じにした。この場合、内側壁９４１どうしが反ヨーク側で互いに遠ざかるように設けられている構成や、外側壁９４２どうしが反ヨーク側で互いに近づくように設けられている構成、各スロット９２５におけるヨーク９２３側の周方向幅Ｗ１が反ヨーク側の周方向幅Ｗ２よりも大きい構成（Ｗ１＞Ｗ２の構成）とは異なり、一対の中間導線部９３２を、ティース先端側の角部との干渉を生じさせることなく、さらにスロット９２５内に無駄なデッドスペースを生じさせることなく、一対の中間導線部９３２を各スロット９２５Ａ，９２５Ｂに収容することが可能になっている。つまり、各スロット９２５において内側壁９４１及び外側壁９４２に近接対向した状態で一対の中間導線部９３２を収容することが可能になっている。 In the stator core 922, the partial winding 931 can be assembled from the radial direction to the slot pair SP in which the pair of intermediate conductors 932 of the partial winding 931 are accommodated. Specifically, in the first slot 925A and the second slot 925B of the slot vs. SP, the inner side walls 941 and the outer wall 942 of each of the slots 925A and 925B are parallel to each other, and the yoke 923 side of each slot 925. The circumferential width W1 of the above and the circumferential width W2 on the anti-yoke side are made the same. In this case, the inner side walls 941 are provided so as to be separated from each other on the anti-yoke side, the outer walls 942 are provided so as to be close to each other on the anti-yoke side, and the yoke 923 side in each slot 925 is provided. Unlike the configuration in which the circumferential width W1 is larger than the circumferential width W2 on the anti-yoke side (W1> W2 configuration), the pair of intermediate conductors 932 do not interfere with the corners on the tip side of the teeth. Further, the pair of intermediate conductors 932 can be accommodated in the slots 925A and 925B without creating a wasteful dead space in the slot 925. That is, it is possible to accommodate the pair of intermediate conductors 932 in each slot 925 in a state of being close to the inner side wall 941 and the outer wall 942.
　また、各部分巻線９３１は２以上のティース９２４を跨ぐように配置されるものであり、周方向に隣り合いかつ一部が重複した状態で並ぶ各部分巻線９３１においてコイルエンド部分での干渉が懸念されるが、それら各部分巻線９３１において渡り部９３３が軸方向に互いに離間しているため、部分巻線９３１どうしの干渉を招くことなく各部分巻線９３１を配置できる。その結果、固定子コア９２２に対して固定子巻線９２１を好適に組み付けることができる固定子９２０の実現が可能になっている。 Further, each partial winding 931 is arranged so as to straddle two or more teeth 924, and interference at the coil end portion in each partial winding 931 arranged adjacent to each other in the circumferential direction and partially overlapping. However, since the crossing portions 933 of the partial windings 931 are separated from each other in the axial direction, the partial windings 931 can be arranged without causing interference between the partial windings 931. As a result, it is possible to realize a stator 920 in which the stator winding 921 can be suitably assembled to the stator core 922.
　上記構成によれば、スロット９２５内の導体占積率を向上することができ、回転電機９００の損失低減・発熱量の抑制を実現できる。 According to the above configuration, the conductor space factor in the slot 925 can be improved, and the loss of the rotary electric machine 900 can be reduced and the amount of heat generated can be suppressed.
　スロット対ＳＰにおける第１中心線Ｌ１１と、第１スロット９２５Ａ及び第２スロット９２５Ｂの各々の第２中心線Ｌ１２とが互いに平行になるように構成したため、スロット対ＳＰに対する部分巻線９３１の組み付けを好適に実現できる。つまり、部分巻線９３１を第１中心線Ｌ１１に沿って平行にスライドさせることで、部分巻線９３１を好適に組み付けることができる。また、第１スロット９２５Ａ及び第２スロット９２５Ｂを、第１中心線Ｌ１１に平行な第２中心線Ｌ１２に対して周方向に線対称で設けることで、固定子コア９２２において周方向に並ぶ各ティース９２４の大きさの均等化を図る上で有利な構成となっている。 Since the first center line L11 in the slot vs. SP and the second center line L12 of each of the first slot 925A and the second slot 925B are configured to be parallel to each other, the partial winding 931 is assembled to the slot vs. SP. It can be preferably realized. That is, the partial winding 931 can be suitably assembled by sliding the partial winding 931 in parallel along the first center line L11. Further, by providing the first slot 925A and the second slot 925B in line symmetry in the circumferential direction with respect to the second center line L12 parallel to the first center line L11, each teeth arranged in the circumferential direction in the stator core 922. It has an advantageous configuration for equalizing the size of the 924.
　各スロット９２５を、周方向の幅が均一な平行スロットとして設けるとともに、部分巻線９３１の各中間導線部９３２を、周方向の幅が均一な平行導線として設けたため、固定子巻線９２１の占積率の向上を図ることができる。 Since each slot 925 is provided as a parallel slot having a uniform width in the circumferential direction and each intermediate conductor portion 932 of the partial winding 931 is provided as a parallel conductor having a uniform width in the circumferential direction, the stator winding 921 is occupied. The product ratio can be improved.
　また、各スロット９２５を平行スロットとした構成では、スロット９２５間のティース９２４の形状や大きさを合わせ込むことが可能となり、各ティース９２４での鉄量の均等化を図る上で有利な構成となっている。 Further, in the configuration in which each slot 925 is a parallel slot, it is possible to match the shape and size of the teeth 924 between the slots 925, which is an advantageous configuration for equalizing the amount of iron in each tooth 924. It has become.
　部分巻線９３１を、導体断面が四角形形状をなす角線を多重に巻回してなる構成とし、角線の集合体である導線集合部の横断面を四角形形状をなすものとした。この場合、固定子巻線９２１における一層の占積率向上を図ることができる。 The partial winding 931 has a configuration in which square wires having a quadrangular cross section of the conductor are wound in multiple directions, and the cross section of the conductor assembly portion, which is an aggregate of the square wires, has a quadrangular shape. In this case, the space factor of the stator winding 921 can be further improved.
　上記のとおり固定子コア９２２の各スロット９２５に対して部分巻線９３１（詳しくは部分巻線９３１の一対の中間導線部９３２）を径方向から組み付け可能にする構成では、周方向に並ぶ各ティース９２４の形態が均一でなくなり、「基端部の周方向幅Ｗ１１＜先端部の周方向幅Ｗ１２」となる第１ティース９２４Ａと、「基端部の周方向幅Ｗ１１＞先端部の周方向幅Ｗ１２」となる第２ティース９２４Ｂとが含まれることとなる。かかる構成において、第１ティースに９２４Ａおける基端部の周方向幅Ｗ１１と、第２ティース９２４Ｂにおける先端部の周方向幅Ｗ１２とを同一にしたため、各スロット９２５の周方向の最小幅を一様に合わせることができる。これにより、固定子コア９２２において局所的に磁気飽和が生じることを抑制でき、局所的な磁気飽和に起因する性能低下を抑制することができる。 As described above, in the configuration in which the partial winding 931 (specifically, the pair of intermediate lead portions 932 of the partial winding 931) can be assembled to each slot 925 of the stator core 922 from the radial direction, the teeth arranged in the circumferential direction The first teeth 924A in which the form of the 924 becomes non-uniform and "the circumferential width W11 of the base end <the circumferential width W12 of the tip portion" and "the circumferential width W11 of the base end portion> the circumferential width of the tip portion". The second teeth 924B which becomes "W12" will be included. In such a configuration, since the circumferential width W11 of the base end portion in the first teeth 924A and the circumferential width W12 of the tip end portion in the second teeth 924B are made the same, the minimum width in the circumferential direction of each slot 925 is uniform. Can be adjusted to. As a result, it is possible to suppress the occurrence of local magnetic saturation in the stator core 922, and it is possible to suppress the deterioration of performance due to the local magnetic saturation.
　第１部分巻線９３１Ａの第１渡り部９３３Ａを径方向外側に折り曲げるとともに、第２部分巻線９３１Ｂの第２渡り部９３３Ｂを、第１部分巻線９３１Ａの第１渡り部９３３Ａに対して軸方向に離間する位置に設ける構成とした。これにより、これら各部分巻線９３１Ａ，９３１Ｂにおいて渡り部９３３Ａ，９３３Ｂどうしの干渉を好適に回避でき、組み付け性に優れる構成を実現できる。 The first crossover 933A of the first partial winding 931A is bent radially outward, and the second crossover 933B of the second partial winding 931B is shafted with respect to the first crossover 933A of the first partial winding 931A. It is configured to be provided at a position separated in the direction. As a result, interference between the crossover portions 933A and 933B can be suitably avoided in each of these partial windings 931A and 931B, and a configuration excellent in assembling property can be realized.
　１極対において相ごとに１つずつの割合で部分巻線９３１を設け、固定子コア９２２で言えば、周方向において１相１極あたり１個の割合でスロット９２５が設けられるシングルスロット仕様とした。この場合、２種類の部分巻線９３１を用いれば、部分巻線９３１どうしの干渉の回避が可能となり、製造の観点からしても有利な構成を実現することができる。 A single slot specification in which a partial winding 931 is provided for each phase in a pair of poles, and a slot 925 is provided for one pole per phase in the circumferential direction in terms of the stator core 922. did. In this case, if two types of partial windings 931 are used, interference between the partial windings 931 can be avoided, and an advantageous configuration can be realized from the viewpoint of manufacturing.
　以下に、変形例１６に関する別例を説明する。 An alternative example relating to the modified example 16 will be described below.
　・図１０９に示すように、スロット対ＳＰの各スロット９２５Ａ，９２５Ｂにおいて、内側壁９４１どうしが反ヨーク側で互いに近づくように設けられるとともに、外側壁９４２どうしが反ヨーク側で互いに遠ざかるように設けられていてもよい。また、図１０９に示す各スロット９２５Ａ，９２５Ｂにおいて、内側壁９４１どうし及び外側壁９４２どうしのいずれかが平行となるように設けられていてもよい。図１０９の構成では、各スロット９２５においてヨーク９２３側の周方向幅Ｗ１、反ヨーク側の周方向幅Ｗ２は、Ｗ１＜Ｗ２となっている。 As shown in FIG. 109, in the slots 925A and 925B of the slot vs. SP, the inner side walls 941 are provided so as to approach each other on the anti-yoke side, and the outer walls 942 are provided so as to be separated from each other on the anti-yoke side. It may have been. Further, in the slots 925A and 925B shown in FIG. 109, either the inner side wall 941 or the outer wall 942 may be provided so as to be parallel to each other. In the configuration of FIG. 109, in each slot 925, the circumferential width W1 on the yoke 923 side and the circumferential width W2 on the anti-yoke side are W1 <W2.
　・図１１０に示すように、スロット９１５のヨーク９２３側の奥側壁９４３を、固定子コア９２２の反ヨーク側の内周面ＳＡと同心の円ＣＬに沿う向きで設ける構成としてもよい。ここで、各スロット９２５において奥行き方向の中心線（第２中心線Ｌ１２）がスロット対ＳＰの中心線（第１中心線Ｌ１１）に平行となる構成では、スロット中心線（第２中心線Ｌ１２）がコア内周面ＳＡの法線方向とは異なる向きになるが、上記のとおりスロット９１５の奥側壁９４３を円ＣＬに沿う向きで設けることで、スロット９２５の径方向寸法（奥行き寸法）を周方向に同一にすることができる。各スロット９２５は、横断面形状が略平行四辺形となっている。また、部分巻線９３１において中間導線部９３２の横断面は、スロット形状に合わせて略平行四辺形状となっている。 As shown in FIG. 110, the back side wall 943 on the yoke 923 side of the slot 915 may be provided in a direction along the circular CL concentric with the inner peripheral surface SA on the anti-yoke side of the stator core 922. Here, in the configuration in which the center line in the depth direction (second center line L12) is parallel to the center line of the slot vs. SP (first center line L11) in each slot 925, the slot center line (second center line L12) Is in a direction different from the normal direction of the core inner peripheral surface SA, but as described above, by providing the inner side wall 943 of the slot 915 in the direction along the circular CL, the radial dimension (depth dimension) of the slot 925 can be rotated. Can be the same in direction. Each slot 925 has a substantially parallelogram in cross-sectional shape. Further, in the partial winding 931 the cross section of the intermediate conductor portion 932 has a substantially parallel four-sided shape according to the slot shape.
　上記構成によれば、スロット９２５の径方向寸法（奥行き寸法）が周方向に同一になることで、スロット９２５内において余剰スペースを生じさせることなく好適に部分巻線９３１を配置することができる。つまり、スロット９２５の径方向寸法が周方向に同一である構成では、スロット９２５の径方向寸法が周方向に異なる構成（例えば図１０７の構成）に比べて、スロット９２５内において径方向外側又は径方向内側の余剰スペースを生じにくくすることができ、部分巻線９３１の組み付けを一層好適なものとすることができる。 According to the above configuration, since the radial dimension (depth dimension) of the slot 925 is the same in the circumferential direction, the partial winding 931 can be suitably arranged in the slot 925 without creating an excess space. That is, in the configuration in which the radial dimensions of the slots 925 are the same in the circumferential direction, the radial outer diameter or the diameter in the slot 925 is different from that in the configuration in which the radial dimensions of the slots 925 are different in the circumferential direction (for example, the configuration of FIG. 107). It is possible to make it difficult to generate excess space inside in the direction, and it is possible to make the assembly of the partial winding 931 more suitable.
　・図１１１（ａ）の構成では、固定子コア９２２においてティース９２４の先端に、スロット９２５の開口部を狭めるように周方向に延びる鍔部９５１が設けられている。鍔部９５１は、ティース先端の塑性変形部９５２が塑性変形された状態で設けられている。又は、図１１１（ｂ）に示すように、固定子コア９２２のティース先端に鍔形成部材９５３が固定されることで鍔部９５１が形成される構成であってもよい。 In the configuration of FIG. 111A, a flange portion 951 extending in the circumferential direction is provided at the tip of the teeth 924 in the stator core 922 so as to narrow the opening of the slot 925. The collar portion 951 is provided in a state in which the plastically deformed portion 952 at the tip of the tooth is plastically deformed. Alternatively, as shown in FIG. 111B, the flange portion 951 may be formed by fixing the flange forming member 953 to the tip of the teeth of the stator core 922.
　上記構成によれば、ティース先端に設けられた鍔部９５１により、部分巻線９３１の脱落等を抑制できるものとなっている。また、鍔部９５１は、ティース先端の塑性変形部９５２が塑性変形された状態、又はティース先端に鍔形成部材９５３が固定された状態で形成されており、固定子コア９２２に対して部分巻線９３１が径方向から組み付けられることに何ら支障を及ぼすことなく所望の鍔構造を設けることができる。 According to the above configuration, the flange portion 951 provided at the tip of the tooth can prevent the partial winding 931 from falling off. Further, the collar portion 951 is formed in a state where the plastically deformed portion 952 at the tip of the tooth is plastically deformed or a flange forming member 953 is fixed to the tip of the tooth, and is partially wound with respect to the stator core 922. A desired collar structure can be provided without causing any trouble in assembling the 931 from the radial direction.
　・図１０７で説明した構成では、「基端部の周方向幅Ｗ１１＜先端部の周方向幅Ｗ１２」となる第１ティース９２４Ａと、「基端部の周方向幅Ｗ１１＞先端部の周方向幅Ｗ１２」となる第２ティース９２４Ｂにおいて、第１ティース９２４Ａの周方向幅Ｗ１１と第２ティース９２４Ｂの周方向幅Ｗ１２とを同一にしたが、これを変更してもよい。例えば、全てのティース９２４において先端部の周方向幅Ｗ１２を同一にする構成、又は全てのティース９２４において基端部の周方向幅Ｗ１１を同一にする構成としてもよい。 In the configuration described with reference to FIG. 107, the first teeth 924A having "the circumferential width W11 of the base end portion <the circumferential width W12 of the tip portion" and "the circumferential width W11 of the base end portion> the circumferential direction of the tip portion". In the second teeth 924B having the width W12, the circumferential width W11 of the first teeth 924A and the circumferential width W12 of the second teeth 924B are made the same, but this may be changed. For example, all the teeth 924 may have the same circumferential width W12 at the tip, or all the teeth 924 may have the same circumferential width W11 at the base end.
　・固定子巻線９２１において各部分巻線９３１の互いの干渉を抑制する構成として、以下に示す構成を用いることが可能である。 -In the stator winding 921, the configuration shown below can be used as a configuration for suppressing mutual interference between the partial windings 931.
　図１１２（ａ）に示す構成では、第１部分巻線９３１Ａにおいて、図示上側の渡り部が軸方向に延びるよう設けられ、図示下側の渡り部が径方向コア側に屈曲されて設けられている。また、第２部分巻線９３１Ｂにおいて、上側渡り部が径方向反コア側に屈曲されて設けられ、下側渡り部が軸方向に延びるよう設けられている。この場合、各部分巻線９３１Ａ，９３１Ｂが固定子コア９２２に組み付けられた状態では、各渡り部が軸方向に互いに離間し、渡り部どうしの互いの干渉が回避されるようになっている。 In the configuration shown in FIG. 112A, in the first partial winding 931A, the upper crossover portion shown in the drawing is provided so as to extend in the axial direction, and the lower crossover portion shown in the drawing is provided so as to be bent toward the radial core side. There is. Further, in the second partial winding 931B, the upper crossover portion is provided so as to be bent toward the radial opposite core side, and the lower crossover portion is provided so as to extend in the axial direction. In this case, when the partial windings 931A and 931B are assembled to the stator core 922, the crossovers are separated from each other in the axial direction so that the crossovers do not interfere with each other.
　図１１２（ｂ）に示す構成では、第１部分巻線９３１Ａ及び第２部分巻線９３１Ｂにおいて、上側渡り部が径方向反コア側に屈曲されて設けられ、下側渡り部が径方向コア側に屈曲されて設けられている。この場合、各部分巻線９３１Ａ，９３１Ｂは軸方向に互いにオフセットされた状態で固定子コア９２２に組み付けられ、その状態では、各渡り部が軸方向に互いに離間し、渡り部どうしの互いの干渉が回避されるようになっている。 In the configuration shown in FIG. 112B, in the first partial winding 931A and the second partial winding 931B, the upper crossover portion is provided so as to be bent toward the radial opposite core side, and the lower crossover portion is provided on the radial core side. It is bent and provided. In this case, the partial windings 931A and 931B are assembled to the stator core 922 in a state of being offset from each other in the axial direction, and in that state, the crossovers are separated from each other in the axial direction, and the crossovers interfere with each other. Is designed to be avoided.
　図１１２（ｃ）に示す構成では、第１部分巻線９３１Ａにおいて、上側渡り部及び下側渡り部が径方向コア側に屈曲されて設けられている。また、第２部分巻線９３１Ｂにおいて、上側渡り部及び下側渡り部が径方向反コア側に屈曲されて設けられている。この場合、各部分巻線９３１Ａ，９３１Ｂが固定子コア９２２に組み付けられた状態では、各渡り部が径方向に互いに離間し、渡り部どうしの互いの干渉が回避されるようになっている。 In the configuration shown in FIG. 112 (c), in the first partial winding 931A, the upper crossover portion and the lower crossover portion are provided so as to be bent toward the radial core side. Further, in the second partial winding 931B, the upper crossover portion and the lower crossover portion are provided so as to be bent toward the opposite core side in the radial direction. In this case, when the partial windings 931A and 931B are assembled to the stator core 922, the crossovers are separated from each other in the radial direction so that the crossovers do not interfere with each other.
　・シングルスロット仕様の固定子９２０ではコギングトルクが課題となる。この点、回転子９１０が、軸方向において、磁石ユニット９１２における磁極位置を周方向に異ならせたスキュー構造を有しているとよい。これにより、占積率を向上しつつコギングトルクを抑制した回転電機９００を実現できる。回転子９１０について具体的なスキュー構造を図１１３（ａ），（ｂ）に示す。図１１３（ａ），（ｂ）は、回転子９１０の正面図であり、同図には磁石ユニット９１２の磁石９１３を１極分のみ示している。 ・ Cogging torque becomes an issue with the stator 920 with single slot specifications. In this respect, it is preferable that the rotor 910 has a skew structure in which the magnetic pole positions of the magnet unit 912 are different in the circumferential direction in the axial direction. As a result, it is possible to realize a rotary electric machine 900 in which the cogging torque is suppressed while improving the space factor. Specific skew structures for the rotor 910 are shown in FIGS. 113 (a) and 113 (b). FIGS. 113 (a) and 113 (b) are front views of the rotor 910, and the figure shows only one pole of the magnet 913 of the magnet unit 912.
　図１１３（ａ）に示す回転子９１０は、斜めスキュー構造を有しており、軸方向において周方向位置を斜めに変化させるようにして磁石９１３が設けられている。また、図１１３（ｂ）に示す回転子９１０は、段スキュー構造を有しており、軸方向において周方向位置を段差状に変化させるようにして磁石９１３が設けられている。 The rotor 910 shown in FIG. 113A has an oblique skew structure, and a magnet 913 is provided so as to obliquely change the circumferential position in the axial direction. Further, the rotor 910 shown in FIG. 113B has a step skew structure, and a magnet 913 is provided so as to change the circumferential position in the axial direction in a stepped manner.
　・回転電機９００はアウタロータ式の回転電機であってもよい。アウタロータ式とする場合、固定子９２０において、円筒状のヨーク９２３の径方向外側に複数のティース９２４が設けられており、各ティース間のスロット９２５には径方向外側から各部分巻線９３１が組み付けられる。 -The rotary electric machine 900 may be an outer rotor type rotary electric machine. In the case of the outer rotor type, in the stator 920, a plurality of teeth 924 are provided on the radial outside of the cylindrical yoke 923, and each partial winding 931 is assembled from the radial outside to the slot 925 between the teeth. Be done.
　（変形例１５～１６における他の別例）
　・回転電機７００，９００において固定子巻線は２相の相巻線（Ｕ相巻線及びＶ相巻線）を有する構成であってもよい。この場合、例えば回転電機９００の部分巻線９３１では、一対の中間導線部９３２が、周方向における互いの中心間距離で２スロットピッチに相当する距離を離して設けられ、一対の中間導線部９３２の間に、他１相の部分巻線９３１における中間導線部９３２が１つ配置される構成となっていればよい。 (Other alternative examples in the modified examples 15 to 16)
-In the rotary electric machines 700 and 900, the stator winding may have a configuration having two-phase phase windings (U-phase winding and V-phase winding). In this case, for example, in the partial winding 931 of the rotary electric machine 900, a pair of intermediate conductors 932 are provided at a distance corresponding to a two-slot pitch in the distance between the centers in the circumferential direction, and the pair of intermediate conductors 932 are provided. It suffices that one intermediate conducting wire portion 932 in the other one-phase partial winding 931 is arranged between the two.
　・回転電機７００、９００として、界磁子を回転子とする回転界磁形の回転電機に代えて、電機子を回転子とする回転電機子形の回転電機を採用することも可能である。 -As the rotating electric machines 700 and 900, it is also possible to adopt a rotating armature type rotating electric machine having an armature as a rotor instead of a rotating field type rotating electric machine using a field magnet as a rotor.
　この明細書における開示は、例示された実施形態に制限されない。開示は、例示された実施形態と、それらに基づく当業者による変形態様を包含する。例えば、開示は、実施形態において示された部品および／または要素の組み合わせに限定されない。開示は、多様な組み合わせによって実施可能である。開示は、実施形態に追加可能な追加的な部分をもつことができる。開示は、実施形態の部品および／または要素が省略されたものを包含する。開示は、ひとつの実施形態と他の実施形態との間における部品および／または要素の置き換え、または組み合わせを包含する。開示される技術的範囲は、実施形態の記載に限定されない。開示されるいくつかの技術的範囲は、請求の範囲の記載によって示され、さらに請求の範囲の記載と均等の意味及び範囲内での全ての変更を含むものと解されるべきである。 The disclosure in this specification is not limited to the illustrated embodiments. The disclosure includes exemplary embodiments and modifications by those skilled in the art based on them. For example, disclosure is not limited to the parts and / or element combinations shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiments. Disclosures include those in which the parts and / or elements of the embodiment are omitted. Disclosures include the replacement or combination of parts and / or elements between one embodiment and another. The technical scope disclosed is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the claims description and should be understood to include all modifications within the meaning and scope equivalent to the claims statement.

Claims (10)

  1. 　周方向に極性が交互となる複数の磁極を含む磁石部（９１２）を有する界磁子（９１０）と、
    　相あたり複数の部分巻線（９３１）からなる相巻線を有する多相の電機子巻線（９２１）と、前記電機子巻線に一体に設けられる電機子コア（９２２）とを備える電機子（９２０）と、
    を備える回転電機（９００）であって、
    　前記電機子コアは、円筒状のヨーク（９２３）と、該ヨークの径方向内側又は径方向外側において周方向に所定間隔で設けられた複数のティース（９２４）とを有し、前記各ティースどうしの間に、径方向に延びるスロット（９２５）が形成されており、
    　前記部分巻線は、周方向に所定間隔を離して設けられる一対の中間導線部（９３２）と、軸方向一端側及び他端側に設けられ前記一対の中間導線部を環状に接続する渡り部（９３３）とを有し、前記スロットに前記中間導線部が収容され、かつ２以上の前記ティースを跨ぐように配置されるものであり、
    　前記電機子コアにおいて２つ一組のスロットである第１スロット（９２５Ａ）及び第２スロット（９２５Ｂ）が前記一対の中間導線部がそれぞれ収容されるスロット対（ＳＰ）であり、
    　前記第１スロット及び前記第２スロットは、周方向に互いに内側となる内側壁（９４１）どうしが平行又は反ヨーク側で互いに近づき、かつ周方向に互いに外側となる外側壁（９４２）どうしが平行又は反ヨーク側で互いに遠ざかるように設けられ、それら各スロットにおける前記ヨーク側の周方向幅（Ｗ１）が、反ヨーク側の周方向幅（Ｗ２）以下の大きさとなっており、
    　前記一対の中間導線部が、前記内側壁及び前記外側壁に近接対向した状態で前記第１スロット及び前記第２スロットに収容されており、
    　周方向に隣り合いかつ一部が重複した状態で並べて配置された前記各部分巻線において前記渡り部が軸方向又は径方向に互いに離間している回転電機。     A field magnet (910) having a magnet portion (912) including a plurality of magnetic poles having alternating polarities in the circumferential direction, and a field magnet (910).
    An armature including a multi-phase armature winding (921) having a phase winding composed of a plurality of partial windings (931) per phase, and an armature core (922) integrally provided with the armature winding. (920) and
    It is a rotary electric machine (900) equipped with
    The armature core has a cylindrical yoke (923) and a plurality of teeth (924) provided at predetermined intervals in the circumferential direction on the radial inner side or the radial outer side of the yoke, and each of the teeth is provided with each other. A slot (925) extending in the radial direction is formed between the two.
    The partial winding has a pair of intermediate conductors (932) provided at predetermined intervals in the circumferential direction and a crossover portion provided on one end side and the other end side in the axial direction to connect the pair of intermediate conductors in an annular shape. (933), the intermediate conducting wire portion is accommodated in the slot, and is arranged so as to straddle two or more of the teeth.
    The first slot (925A) and the second slot (925B), which are a set of two slots in the armature core, are a slot pair (SP) in which the pair of intermediate conductors are housed, respectively.
    In the first slot and the second slot, the inner side walls (941) that are inside each other in the circumferential direction are parallel to each other or approach each other on the anti-yoke side, and the outer walls (942) that are outward to each other in the circumferential direction are parallel to each other. Alternatively, they are provided so as to be separated from each other on the anti-yoke side, and the circumferential width (W1) on the yoke side in each of these slots is smaller than the circumferential width (W2) on the anti-yoke side.
    The pair of intermediate conductors are housed in the first slot and the second slot in a state of being close to the inner side wall and the outer wall.
    A rotary electric machine in which the crossovers are separated from each other in the axial direction or the radial direction in the partial windings arranged side by side in a state of being adjacent to each other in the circumferential direction and partially overlapping.
  2. 　前記スロット対における前記第１スロットから前記第２スロットまでの範囲の周方向中心位置と電機子中心点とを通る直線を第１中心線（Ｌ１１）、前記第１スロット及び前記第２スロットにおいて各々の周方向中心位置を通りかつ前記第１中心線に平行な直線を第２中心線（Ｌ１２）とする場合に、前記第１スロット及び前記第２スロットにおいて前記第２中心線は互いに平行であり、かつ前記第１スロット及び前記第２スロットは、前記第２中心線に対して周方向に線対称で設けられている請求項１に記載の回転電機。 A straight line passing through the circumferential center position and the armature center point in the range from the first slot to the second slot in the slot pair is drawn at the first center line (L11), the first slot and the second slot, respectively. When the straight line passing through the center position in the circumferential direction and parallel to the first center line is defined as the second center line (L12), the second center lines are parallel to each other in the first slot and the second slot. The rotary electric machine according to claim 1, wherein the first slot and the second slot are provided line-symmetrically in the circumferential direction with respect to the second center line.
  3. 　前記第１スロット及び前記第２スロットの各々において前記内側壁及び前記外側壁は互いに平行であり、前記一対の中間導線部の周方向の側面は互いに平行である請求項２に記載の回転電機。 The rotary electric machine according to claim 2, wherein in each of the first slot and the second slot, the inner side wall and the outer wall are parallel to each other, and the circumferential side surfaces of the pair of intermediate conducting wires are parallel to each other.
  4. 　前記部分巻線は、導体断面が四角形形状をなす角線を多重に巻回されることで構成されており、前記角線の集合体である導線集合部の横断面が四角形形状をなしている請求項３に記載の回転電機。 The partial winding is formed by winding a plurality of square wires having a quadrangular cross section of a conductor, and the cross section of a conductor collecting portion, which is an aggregate of the square wires, has a quadrangular shape. The rotary electric machine according to claim 3.
  5. 　前記電機子コアにおいて周方向に並ぶ前記各ティースは、前記ヨーク側の基端部の周方向幅（Ｗ１１）が反ヨーク側の先端部の周方向幅（Ｗ１２）よりも小さい第１ティース（９２４Ａ）と、前記基端部の周方向幅が前記先端部の周方向幅よりも大きい第２ティース（９２４Ｂ）とを含み、
    　前記第１ティースにおける前記基端部の周方向幅と、前記第２ティースにおける前記先端部の周方向幅とが同一である請求項２～４のいずれか１項に記載の回転電機。     Each of the teeth arranged in the circumferential direction in the armature core has a first tooth (924A) in which the circumferential width (W11) of the base end portion on the yoke side is smaller than the circumferential width (W12) of the tip end portion on the anti-yoke side. ) And the second tooth (924B) in which the circumferential width of the base end portion is larger than the circumferential width of the tip end portion.
    The rotary electric machine according to any one of claims 2 to 4, wherein the circumferential width of the base end portion in the first tooth and the circumferential width of the tip end portion in the second tooth are the same.
  6. 　前記スロットの前記ヨーク側の奥側壁（９４３）が、前記電機子コアの反ヨーク側の内周面と同心の円（ＣＬ）に沿う向きで設けられている請求項２～５のいずれか１項に記載の回転電機。 Any one of claims 2 to 5 in which the inner wall surface (943) on the yoke side of the slot is provided so as to be oriented along a circle (CL) concentric with the inner peripheral surface on the anti-yoke side of the armature core. The rotary armature described in the section.
  7. 　周方向に隣り合いかつ一部が重複した状態で並べて配置される前記各部分巻線として第１部分巻線（９３１Ａ）及び第２部分巻線（９３１Ｂ）を用い、
    　前記第１部分巻線では、前記渡り部が径方向内側又は径方向外側に折り曲げられ、
    　前記第２部分巻線では、前記渡り部が、前記第１部分巻線の渡り部に対して軸方向又は径方向に離間する位置に設けられている請求項１～６のいずれか１項に記載の回転電機。     The first partial winding (931A) and the second partial winding (931B) are used as the partial windings arranged side by side in the circumferential direction so as to be adjacent to each other and partially overlapped.
    In the first partial winding, the crossover is bent radially inward or radially outward.
    In any one of claims 1 to 6, in the second partial winding, the crossover is provided at a position separated in the axial direction or the radial direction from the crossover of the first partial winding. The rotating electric machine described.
  8. 　前記ティースの先端に、前記スロットの開口部を狭めるように周方向に延びる鍔部（９５１）を有しており、
    　前記鍔部は、ティース先端の塑性変形部（９５２）が塑性変形された状態、又はティース先端に鍔形成部材（９５３）が固定された状態で形成されている請求項１～７のいずれか１項に記載の回転電機。     The tip of the tooth has a flange portion (951) extending in the circumferential direction so as to narrow the opening of the slot.
    The collar portion is any one of claims 1 to 7 in which the plastically deformed portion (952) at the tip of the tooth is plastically deformed, or the collar forming member (953) is fixed to the tip of the tooth. The rotary electric machine described in the section.
  9. 　前記部分巻線は、１極対において相ごとに１つずつ設けられている請求項１～８のいずれか１項に記載の回転電機。 The rotary electric machine according to any one of claims 1 to 8, wherein the partial winding is provided one by one for each phase in one pole pair.
  10. 　前記界磁子は、軸方向において、前記磁石部における磁極位置を周方向に異ならせたスキュー構造を有している請求項９に記載の回転電機。 The rotary electric machine according to claim 9, wherein the field magnet has a skew structure in which the magnetic pole positions in the magnet portion are different in the circumferential direction in the axial direction.
PCT/JP2020/044052 2019-11-27 2020-11-26 Rotary electrical machine WO2021107026A1 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010506549A (en) * 2006-10-04 2010-02-25 コンバーチーム リミテッド Stator for rotating electrical machine
JP2019122249A (en) * 2017-12-28 2019-07-22 株式会社デンソー Rotary electric machine

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2010506549A (en) * 2006-10-04 2010-02-25 コンバーチーム リミテッド Stator for rotating electrical machine
JP2019122249A (en) * 2017-12-28 2019-07-22 株式会社デンソー Rotary electric machine

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