WO2022113936A1 - Dynamo-electric machine - Google Patents

Abstract

This dynamo-electric machine (400) comprises: a rotor (410) having a magnet section (412) positioned in an annular shape; and a stator (430) having a multiphase stator winding (431), the dynamo-electric machine (400) being an inner-rotor-type dynamo-electric machine in which the rotor is positioned on the radially inner side of the stator. The dynamo-electric machine further comprises: a bottomed cylindrical first housing (450) provided in a state surrounding the stator and having a bottom part (454) on a first end side in the axial direction; and a second housing (470) provided on a second end side on the opposite side of the first housing from the first end so as to close the open end of the first housing. The rotor has a cylindrical rotation shaft (416) extending in the axial direction, and the second housing has a fixed shaft part (472) inserted inside a hollow section of the rotation shaft, a bearing (491) that rotatably supports the rotation shaft being provided between the fixed shaft part and the rotation shaft.

Description

Rotating electric machine Cross-reference of related applications

This application is based on Japanese Application No. 2020-197409 filed on November 27, 2020, and the contents of the description are incorporated herein by reference.

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

Conventionally, a rotary electric machine having a rotor having a plurality of magnetic poles and a stator having a multi-phase stator winding is known. Further, in a rotary electric machine, there is known a configuration in which a bearing is provided in a housing integrated with a stator and the rotor is rotatably supported by the bearing. For example, in Patent Document 1, in an in-wheel motor having an inner rotor structure, a housing is provided so as to surround the outer peripheral side of the stator, and a rotor is rotatably supported by a bearing at a bearing protrusion provided in the housing. Is described.

Japanese Unexamined Patent Publication No. 2004-129389

By the way, in the in-wheel motor described in Patent Document 1, the rotor is rotatably supported by a bearing at the bearing protrusion of the housing, and the housing is required to have strength for axially supporting the rotor. To. However, in the configuration in which the housing is provided as a high-strength member, the degree of freedom in improving heat dissipation and reducing the weight of the housing is limited. Therefore, it is considered that there is room for technical improvement.

The present disclosure has been made in view of the above circumstances, and an object thereof is to improve the degree of freedom in designing a rotary electric machine.

The plurality of aspects disclosed herein employ different technical means to achieve their respective objectives. The objectives, features, and effects disclosed herein will be further clarified by reference to the subsequent detailed description and accompanying drawings.

Means 1
A rotor with magnets arranged in an annular shape,
With a stator with a polyphase stator winding,
An inner rotor type rotary electric machine in which the rotor is arranged radially inside the stator.
A bottomed cylindrical first housing provided so as to surround the stator and having a bottom on the first end side in the axial direction.
A second housing provided so as to close the open end of the first housing on the second end side opposite to the first end of the first housing is provided.
The rotor has a cylindrical rotating shaft extending in the axial direction.
The second housing has a fixed shaft portion that is inserted into the hollow portion of the rotating shaft, and a bearing that rotatably supports the rotating shaft is provided between the fixed shaft portion and the rotating shaft. Has been done.

The rotary electric machine having the above configuration has an inner rotor structure, the rotor is arranged radially inside, the stator is arranged radially outside, and the rotating shaft integrally provided with the rotor is rotatably supported by a bearing. There is. Further, a bottomed cylindrical first housing is provided so as to surround the stator, and a second housing is provided so as to close the open end side (second end side) of the first housing. Then, the fixed shaft portion provided in the second housing is inserted into the hollow portion of the rotating shaft, and a bearing is provided between the fixed shaft portion and the rotating shaft.

In the above configuration, the rotation shaft of the rotor is rotatably supported via the bearing by the second housing of the first housing and the second housing, that is, the housing that is not on the side surrounding the stator. In this case, in the first housing provided so as to surround the stator, the demand for strength is relaxed as compared with the second housing. Therefore, in the first housing, the degree of freedom in design is increased by relaxing the strength requirement, and it becomes possible to easily meet the request for improvement of heat dissipation and weight reduction.

In the means 2, in the means 1, the first housing is a member having a higher thermal conductivity than the second housing, and the second housing is a member having a higher strength than the first housing.

According to the above configuration, the first housing surrounding the stator gives priority to heat dissipation, and the second housing that supports the rotating shaft via the bearing gives priority to strength. As a result, the heat generated by the stator can be suitably released from the first housing, and the support strength of the rotating shaft in the second housing can be ensured. Further, although the weight of the high-strength material tends to be heavy, since only the second housing of each housing is made of a high-strength member, the weight of the rotary electric machine can be reduced. In this case, it is possible to improve the degree of freedom in design regarding heat dissipation and weight in the rotary electric machine.

In means 3, in means 1 or 2, the rotor has a rotor carrier that supports the magnet portion, and the rotor carrier has an end plate portion on one end side in the axial direction, and the rotation thereof. The shaft is provided so as to extend from the end plate portion in the axial direction to the opposite side of the magnet portion, and the hollow portion of the rotating shaft is located on the anti-magnet portion side with respect to the end plate portion in the axial direction. The bearing is provided at a position where the rotation shaft is rotatably supported by the bearing, and rotation is imparted to the axial end portion of the rotation shaft opposite to the end plate portion by the rotary electric machine. The rotating object to be rotated can be combined.

In the above configuration, a rotor carrier is provided on one end side in the axial direction of the rotating shaft, and the rotating object can be coupled to the rotating electric machine on the other end side in the axial direction of the rotating shaft. Further, in the hollow portion of the rotating shaft, a bearing is provided at a position closer to the diamagnetic portion than the end plate portion of the rotor carrier in the axial direction. In this case, by providing the bearing at a position that does not overlap in the radial direction with respect to the magnet portion, the area inside the radial direction of the magnet portion is increased as compared with the configuration in which the bearing is provided at the position where the bearing overlaps in the radial direction with respect to the magnet portion. Can be made larger. As a result, sensors, electric parts, a mounting structure for mounting a rotary electric machine, and the like can be arranged in a region inside the radial direction of the magnet portion, and the region can be effectively used. Further, the bearing can be arranged at an appropriate position while taking into consideration that a load acts on the axial end portion on the opposite side of the rotary shaft from the end plate portion. In the in-wheel motor, the wheel corresponds to a rotating object.

In the means 4, in the means 3, the fixed shaft portion is provided so as to penetrate the through hole provided in the end plate portion, and one of both sides of the end plate portion in the axial direction is the first shaft portion. The other side is the second shaft portion, and the rotation sensor that detects the rotation of the rotor is on the outside of the first shaft portion that is radially inside the magnet portion of the first shaft portion and the second shaft portion. Is provided, and the bearing is provided on the outside of the second shaft portion.

In the above configuration, in the fixed shaft portion of the second housing, the portions on both sides of the end plate portion of the rotor carrier are the first shaft portion and the second shaft portion, respectively, and the area on the first shaft portion side. The area on the side of the second shaft portion is partitioned in the axial direction by the end plate portion. Therefore, in a configuration in which the rotation sensor is provided on the outside of the first shaft portion and the bearing is provided on the outside of the second shaft portion, the influence of the bearing on the rotation sensor can be suppressed.

In the means 5, in the means 3 or 4, a closed space surrounded by the second housing and the rotor carrier is formed inside the magnet portion in the rotor in the radial direction, and the closed space is formed. , A rotation sensor that detects the rotation of the rotor is arranged.

In the above configuration, the rotation sensor is arranged in the closed space formed by the second housing and the rotor carrier inside the magnet portion in the rotor in the radial direction. In this case, since the rotation sensor is isolated from the outside of the rotary electric machine, the installation environment of the rotation sensor can be kept good. For example, it is possible to suppress foreign matter from adhering to the rotation sensor and water exposure.

In the means 6, in any of the means 1 to 5, the rotating shaft is inserted through a through hole provided in the bottom portion of the first housing, and a sliding seal is provided between the bottom portion and the rotating shaft. Is provided.

In the above configuration, a bearing is provided between the fixed shaft portion of the second housing on the inner peripheral surface side of the rotating shaft, and slides between the outer peripheral surface side of the rotating shaft and the bottom portion of the first housing. A seal is provided. That is, the rotating shaft can rotate relative to the fixed shaft portion of the second housing by the bearing, and can rotate relative to the bottom portion of the first housing by the sliding seal. As a result, the rotating shaft is rotatably supported by each housing from the inside and the outside in the radial direction, and a support structure that enables appropriate support of the rotating shaft can be realized.

In the means 7, in any of the means 1 to 6, the second housing has a cylindrical portion having a diameter larger than that of the fixed shaft portion, and the cylindrical portion is a rotor whose diameter is inside the magnet portion in the radial direction. It is arranged so as to face the inner peripheral surface in a close state, and the radial inside of the cylindrical portion is a space portion opened to the opposite side of the fixed shaft portion in the axial direction.

In the above configuration, in the second housing, a cylindrical portion having a diameter larger than that of the fixed shaft portion faces the inner peripheral surface of the rotor in a close state, and the radial inside of the cylindrical portion is the fixed shaft portion in the axial direction. It is an open space on the other side. In this case, the inner peripheral side of the magnet portion of the rotor is covered from the inside by the cylindrical portion of the second housing to partition it from the outside, and a space portion is secured in the cylindrical portion to enable effective use thereof.

In the means 8, in the means 7, the region where the inner peripheral surface of the rotor and the cylindrical portion face each other on the radial inside of the magnet portion of the rotor is a lubricating oil path through which the lubricating oil passes.

In the above configuration, the region where the inner peripheral surface of the rotor and the cylindrical portion face each other is the lubricating oil path through which the lubricating oil passes. In this case, by limiting the area through which the lubricating oil passes inside the rotary electric machine by the cylindrical portion of the second housing, the lubricating oil can be suitably supplied.

The means 9 is a rotary electric machine used as an in-wheel motor integrally provided on the wheels of the vehicle in any of the means 1 to 8, wherein the second housing can be fixed to the vehicle body and the rotary shaft. Is fixed to the wheel so that it can rotate integrally with the wheel.

In a rotary electric machine as an in-wheel motor, the stator and the housing that holds the stator are fixed to the vehicle body, and the housing receives the vehicle weight. On that premise, this means is configured to receive the vehicle weight by the second housing of the first housing that holds the stator in a state of surrounding it and the second housing provided on the open end side of the first housing. , The second housing can be configured to give priority to load capacity. Further, in the first housing, it is not necessary to receive the weight of the vehicle, and a high heat dissipation material can be used with priority given to heat dissipation.

In the configuration in which the bearing is provided at a position that does not overlap in the radial direction with respect to the magnet portion as in the means 3, the in-wheel motor (rotary electric machine) is mounted on the vehicle body side by utilizing the area inside the radial direction of the magnet portion. A mounting structure such as a knuckle or a link for mounting on the wheel can be suitably arranged.

Further, as in the means 7, the second housing is provided with a cylindrical portion having a diameter larger than that of the fixed shaft portion, and the radial inside of the cylindrical portion is opened to the opposite side of the fixed shaft portion in the axial direction. As described above, a mounting structure such as a knuckle or a link for mounting the in-wheel motor (rotary electric machine) on the vehicle body side can be suitably arranged.

The above objectives and other objectives, features and advantages of the present disclosure will be further clarified by the following detailed description with reference to the accompanying drawings. The drawing is
FIG. 1 is a perspective view showing the entire rotary electric machine according to the first embodiment. FIG. 2 is a plan view of the rotary electric machine. FIG. 3 is a vertical cross-sectional view of the rotary electric machine. FIG. 4 is a cross-sectional view of the rotary electric machine. FIG. 5 is an exploded sectional view of the rotary electric machine. FIG. 6 is a cross-sectional view of the rotor. FIG. 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit. FIG. 8 is a diagram showing the relationship between the electric angle and the magnetic flux density for the magnet of the embodiment. FIG. 9 is a diagram showing the relationship between the electric angle and the magnetic flux density for the magnet of the comparative example. FIG. 10 is a perspective view of the stator unit. FIG. 11 is a vertical sectional view of the stator unit. FIG. 12 is a perspective view of the core assembly viewed from one side in the axial direction. FIG. 13 is a perspective view of the core assembly viewed from the other side in the axial direction. FIG. 14 is a cross-sectional view of the core assembly. FIG. 15 is an exploded cross-sectional view of the core assembly. FIG. 16 is a circuit diagram showing a connection state of partial windings in each of the three-phase windings. FIG. 17 is a side view showing the first coil module and the second coil module side by side in comparison. FIG. 18 is a side view showing the first partial winding and the second partial winding side by side in comparison. FIG. 19 is a diagram showing the configuration of the first coil module. FIG. 20 is a sectional view taken along line 20-20 in FIG. 19 (a). FIG. 21 is a perspective view showing the configuration of the insulating cover. FIG. 22 is a diagram showing the configuration of the second coil module. FIG. 23 is a sectional view taken along line 23-23 in FIG. 22 (a). FIG. 24 is a perspective view showing the configuration of the insulating cover. FIG. 25 is a diagram showing overlapping positions of film materials in a state where the coil modules are arranged in the circumferential direction. FIG. 26 is a plan view showing the assembled state of the first coil module with respect to the core assembly. FIG. 27 is a plan view showing the assembled state of the first coil module and the second coil module with respect to the core assembly. FIG. 28 is a vertical cross-sectional view showing a fixed state by the fixing pin. FIG. 29 is a perspective view of the bus bar module. FIG. 30 is a cross-sectional view showing a part of a vertical cross section of the bus bar module. FIG. 31 is a perspective view showing a state in which the bus bar module is assembled to the stator holder. FIG. 32 is a vertical sectional view of a fixed portion for fixing the bus bar module. FIG. 33 is a vertical sectional view showing a state in which the relay member is attached to the housing cover. FIG. 34 is a perspective view of the relay member. FIG. 35 is an electric circuit diagram showing a control system of a rotary electric machine. FIG. 36 is a functional block diagram showing a current feedback control process by the control device. FIG. 37 is a functional block diagram showing torque feedback control processing by the control device. FIG. 38 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit in the modified example. FIG. 39 is a diagram showing a configuration of a stator unit having an inner rotor structure. FIG. 40 is a plan view showing the assembled state of the coil module with respect to the core assembly. FIG. 41 is a perspective view showing the entire rotary electric machine according to the second embodiment. FIG. 42 is a plan view of the rotary electric machine. FIG. 43 is a vertical sectional view of the rotary electric machine. FIG. 44 is a cross-sectional view of the rotary electric machine. FIG. 45 is an exploded cross-sectional view showing the components of the rotary electric machine in an exploded manner. FIG. 46 is a perspective view showing the entire stator unit. FIG. 47 is an exploded sectional view of the stator unit. FIG. 48 is a vertical sectional view of the stator unit. FIG. 49 is a perspective view showing the configuration of the partial winding. FIG. 50 is a perspective view showing the configuration of the inner housing. FIG. 51 is a vertical cross-sectional view showing a lubricating oil path in a rotary electric machine. FIG. 52 is a vertical sectional view of a rotary electric machine in a modified example.

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 numerals having different hundreds or more digits. For corresponding and / or associated parts, the description of other embodiments can be referred to.

The rotary electric machine in this embodiment is used, for example, as a vehicle power source. However, the rotary electric machine can be widely used for industrial use, vehicle use, aircraft use, home electric appliance use, OA equipment use, game machine use, and the like. In each of the following embodiments, the parts that are the same or equal to each other are designated by the same reference numerals, and the description thereof will be used for the parts having the same reference numerals.

(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. 1 is a perspective view showing the entire rotary electric machine 10, FIG. 2 is a plan view of the rotary electric machine 10, and FIG. 3 is a vertical sectional view of the rotary electric machine 10 (3-3 line sectional view of FIG. 2). ), FIG. 4 is a cross-sectional view of the rotary electric machine 10 (4-4 line cross-sectional view of FIG. 3), and FIG. 5 is an exploded cross-sectional view showing the components of the rotary electric machine 10 in an exploded manner. In the following description, in the rotary electric machine 10, the direction in which the rotary shaft 11 extends is the axial direction, the direction in which the rotary shaft 11 extends radially from the center of the rotary shaft 11 is the radial direction, and the direction in which the rotary shaft 11 extends in a circumferential shape is the circumference. The direction.

The rotary electric machine 10 is roughly divided into a rotary electric machine main body having a rotor 20, a stator unit 50 and a bus bar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotary electric machine main body. Each of these members is arranged coaxially with the rotating shaft 11 integrally provided on the rotor 20, and is assembled in the axial direction in a predetermined order to form the rotating electric machine 10. The rotating shaft 11 is supported by a pair of bearings 12 and 13 provided on the stator unit 50 and the housing 241 respectively, and can rotate in that state. The bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between them. The rotation of the rotating shaft 11 causes, for example, the axle of the vehicle to rotate. The rotary electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.

In the rotary electric machine 10, the stator unit 50 is provided so as to surround the rotary shaft 11, and the rotor 20 is arranged on the radial outside of the stator unit 50. The stator unit 50 has a stator 60 and a stator holder 70 assembled radially inside the stator. The rotor 20 and the stator 60 are arranged so as to face each other in the radial direction with an air gap in between, and the rotor 20 rotates integrally with the rotating shaft 11 so that the rotor 20 is radially outside the stator 60. Rotate. The rotor 20 corresponds to a "field magnet" and the stator 60 corresponds to an "armature".

FIG. 6 is a vertical cross-sectional view of the rotor 20. As shown in FIG. 6, the rotor 20 has a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. The rotor carrier 21 has a cylindrical portion 23 having a cylindrical shape and an end plate portion 24 provided at one end in the axial direction of the cylindrical portion 23, and is configured by integrating them. .. The rotor carrier 21 functions as a magnet holding member, and the magnet unit 22 is annularly fixed inside the cylindrical portion 23 in the radial direction. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt in a state of being inserted into the through hole 24a. The rotary shaft 11 has a flange 11a extending in a direction intersecting (orthogonal) in the axial direction, and the rotor carrier 21 is attached to the rotary shaft 11 in a state where the flange 11a and the end plate portion 24 are surface-bonded. Is fixed.

The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner peripheral surface of the magnet holder 31, and on both sides in the axial direction opposite to the end plate portion 24 of the rotor carrier 21. It has a fixed end plate 33. The magnet holder 31 has the same length dimension as the magnet 32 in the axial direction. The magnet 32 is provided in the magnet holder 31 in a state of being surrounded from the outside in the radial direction. The magnet holder 31 and the magnet 32 are fixed in contact with the end plate 33 at one end in the axial direction. The magnet unit 22 corresponds to the "magnet portion".

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

In the magnet unit 22, the magnets 32 are arranged side by side so that the polarities change alternately along the circumferential direction of the rotor 20. As a result, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 32 is a polar anisotropic 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 peripheral surface of the magnet 32 on the inner side in the radial direction (on the stator 60 side) is the magnetic flux acting surface 34 on which magnetic flux is exchanged. The magnet unit 22 concentrates the magnetic flux in the region near the d-axis, which is the center of the magnetic pole, on the magnetic flux acting surface 34 of the magnet 32. Specifically, in the magnet 32, 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 easy-magnetization axis is different on the d-axis side. The direction of is parallel to the d-axis, and the direction of the easy magnetization axis is orthogonal to the q-axis on the q-axis side. In this case, an arcuate magnetic path is formed along the direction of the easy magnetization axis. In short, the magnet 32 is configured to be 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.

In the magnet 32, since the magnet magnetic path is formed in an arc shape, the magnet magnetic path length is longer than the radial thickness dimension of the magnet 32. As a result, the permeance of the magnet 32 is increased, and it is possible to exert the same ability as a magnet having a large amount of magnets while having the same amount of magnets.

The magnet 32 constitutes one magnetic pole with two adjacent magnets in the circumferential direction as a set. That is, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 have split surfaces on the d-axis and the q-axis, respectively, and the magnets 32 are arranged in contact with each other or in close proximity to each other. .. As described above, the magnet 32 has an arcuate magnet magnetic path, and the north pole and the south pole face each other with the magnets 32 adjacent to each other in the circumferential direction on the q axis. Therefore, it is possible to improve the permeance in the vicinity of the q-axis. Further, since the magnets 32 on both sides of the q-axis attract each other, each of these magnets 32 can maintain a contact state with each other. Therefore, it also contributes to the improvement of permeance.

In the magnet unit 22, magnetic flux flows in an arc shape between adjacent N and S poles due to each magnet 32, so that the magnet path is longer than that of, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 8, 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. 9, 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 22 of the present embodiment has a difference in the magnetic flux density distribution as compared with the conventional Halbach array magnet. In FIGS. 8 and 9, the horizontal axis represents the electric angle and the vertical axis represents the magnetic flux density. Further, in FIGS. 8 and 9, 90 ° on the horizontal axis indicates the d-axis (that is, the center of the magnetic pole), and 0 ° and 180 ° on the horizontal axis indicate the q-axis.

That is, according to each magnet 32 having the above configuration, the magnet magnetic flux in the d-axis is strengthened in the magnet unit 22, and the magnetic flux change in the vicinity of the q-axis is suppressed. As a result, it is possible to suitably realize the magnet unit 22 in which the change in the surface magnetic flux from the q-axis to the d-axis is gentle at each magnetic pole.

The sine wave matching rate 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 sine wave matching ratio 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.

In the radial anisotropic magnet shown in FIG. 9, the magnetic flux density changes sharply near the q-axis. The steeper the change in the magnetic flux density, the more the eddy current increases in the stator winding 61 of the stator 60, which will be described later. Further, the change in magnetic flux on the stator winding 61 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. This makes it possible to suppress the generation of eddy currents.

In the magnet 32, a recess 35 is formed on the outer peripheral surface in the radial direction in a predetermined range including the d-axis, and a recess 36 is formed in a predetermined range including the q-axis on the inner peripheral surface in the radial direction. ing. In this case, according to the orientation of the easy-to-magnetize axis of the magnet 32, the magnetic path is shortened near the d-axis on the outer peripheral surface of the magnet 32, and the magnetic path is shortened near the q-axis on the inner peripheral surface of the magnet 32. .. Therefore, in consideration of the fact that it becomes difficult to generate a sufficient magnet magnetic flux in a place where the magnet magnetic path length is short in the magnet 32, the magnet is deleted in the place where the magnet magnetic flux is weak.

The magnet unit 22 may be configured to use the same number of magnets 32 as the magnetic poles. For example, it is preferable that the magnet 32 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. In this case, the magnet 32 has a configuration in which the center in the circumferential direction is the q-axis and the magnet 32 has a split surface on the d-axis. Further, the magnet 32 may be configured such that 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. As the magnet 32, instead of using a magnet having twice the number of magnetic poles or a magnet having the same number of magnetic poles, a configuration using an annular magnet connected in an annular shape may be used.

As shown in FIG. 3, a resolver 41 as a rotation sensor is provided at an end portion (upper end portion in the figure) opposite to the coupling portion with the rotor carrier 21 on both sides of the rotation shaft 11 in the axial direction. ing. The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator arranged so as to face each other on the radial outer side of the resolver rotor. The resolver rotor has a disk ring shape, and is provided coaxially with the rotating shaft 11 with the rotating shaft 11 inserted therein. The resolver stator has a stator core and a stator coil, and is fixed to the housing cover 242.

Next, the configuration of the stator unit 50 will be described. 10 is a perspective view of the stator unit 50, and FIG. 11 is a vertical sectional view of the stator unit 50. Note that FIG. 11 is a vertical cross-sectional view at the same position as in FIG.

The stator unit 50 has, as an outline, a stator 60 and a stator holder 70 on the inner side in the radial direction thereof. Further, the stator 60 has a stator winding 61 and a stator core 62. Then, the stator core 62 and the stator holder 70 are integrated and provided as a core assembly CA, and a plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. The stator winding 61 corresponds to the "armature winding", the stator core 62 corresponds to the "armature core", and the stator holder 70 corresponds to the "armature holding member". Further, the core assembly CA corresponds to the "support member".

First, the core assembly CA will be explained. FIG. 12 is a perspective view of the core assembly CA viewed from one side in the axial direction, FIG. 13 is a perspective view of the core assembly CA viewed from the other side in the axial direction, and FIG. 14 is a cross section of the core assembly CA. FIG. 15 is an exploded cross-sectional view of the core assembly CA.

The core assembly CA has a stator core 62 and a stator holder 70 assembled radially inside the stator core 62 as described above. So to speak, the stator core 62 is integrally assembled on the outer peripheral surface of the stator holder 70.

The stator core 62 is configured as a core sheet laminated body in which core sheets 62a made of magnetic steel sheets, which are magnetic materials, are laminated in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction. A stator winding 61 is assembled on the radial outer side of the stator core 62 on the rotor 20 side. The outer peripheral surface of the stator core 62 has a curved surface without unevenness. The stator core 62 functions as a back yoke. The stator core 62 is configured by, for example, a plurality of core sheets 62a punched out in an annular plate shape and laminated in the axial direction. However, a stator core 62 having a helical core structure may be used. In the stator core 62 having a helical core structure, a strip-shaped core sheet is used, and the core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 62 as a whole. Has been done.

In the present embodiment, the stator 60 has a slotless structure having no teeth for forming a slot, and the configuration uses any of the following (A) to (C). It may be a thing.
(A) In the stator 60, a conductor-to-conductor member is provided between each conductor portion (intermediate conductor portion 152 described later) in the circumferential direction, and the width dimension of the conductor-to-lead member in one magnetic pole in the circumferential direction is provided as the conductor-to-conductor member. Wt, the saturation magnetic flux density of the conductor-to-conductor member is Bs, the width dimension in the circumferential direction of the magnet 32 at one magnetic pole is Wm, and the residual magnetic flux density of the magnet 32 is Br, the relationship of Wt × Bs ≦ Wm × Br. A magnetic material is used.
(B) In the stator 60, a conductor-to-conductor member is provided between each conductor portion (intermediate conductor portion 152) in the circumferential direction, and a non-magnetic material is used as the conductor-to-conductor member.
(C) The stator 60 has a configuration in which no conductor-to-conductor member is provided between the conductor portions (intermediate conductor portions 152) in the circumferential direction.

Further, as shown in FIG. 15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, and the outer cylinder member 71 is radially outside and the inner cylinder member 81 is radially inside. It is configured by being assembled integrally. Each of these members 71 and 81 is made of, for example, a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

The outer cylinder member 71 is a cylindrical member having a perfect circular curved surface on both the outer peripheral surface and the inner peripheral surface, and an annular flange 72 extending inward in the radial direction is formed on one end side in the axial direction. The flange 72 is formed with a plurality of protrusions 73 extending inward in the radial direction at predetermined intervals in the circumferential direction (see FIG. 13). Further, in the outer cylinder member 71, facing surfaces 74 and 75 facing the inner cylinder member 81 in the axial direction are formed on one end side and the other end side in the axial direction, respectively, and the facing surfaces 74 and 75 are annular. An annular grooves 74a and 75a extending to the surface are formed.

Further, the inner cylinder member 81 is a cylindrical member having an outer diameter dimension smaller than the inner diameter dimension of the outer cylinder member 71, and its outer peripheral surface is a circular curved surface concentric with the outer cylinder member 71. An annular flange 82 extending radially outward is formed on one end side of the inner cylinder member 81 in the axial direction. The inner cylinder member 81 is assembled to the outer cylinder member 71 in a state of being in axial contact with the facing surfaces 74 and 75 of the outer cylinder member 71. As shown in FIG. 13, the outer cylinder member 71 and the inner cylinder member 81 are assembled to each other by fasteners 84 such as bolts. Specifically, on the inner peripheral side of the inner cylinder member 81, a plurality of protruding portions 83 extending inward in the radial direction are formed at predetermined intervals in the circumferential direction, and the axial end surface of the protruding portions 83 and the outer cylinder are formed. The protruding portions 73, 83 are fastened to each other by the fastener 84 in a state where the protruding portion 73 of the member 71 is overlapped with each other.

As shown in FIG. 14, when the outer cylinder member 71 and the inner cylinder member 81 are assembled to each other, there is an annular gap between the inner peripheral surface of the outer cylinder member 71 and the outer peripheral surface of the inner cylinder member 81. It is formed, and the gap space is a refrigerant passage 85 through which a refrigerant such as cooling water flows. The refrigerant passage 85 is provided in an annular shape in the circumferential direction of the stator holder 70. More specifically, the inner cylinder member 81 is provided with a passage forming portion 88 that protrudes radially inward on the inner peripheral side thereof and has an inlet side passage 86 and an outlet side passage 87 formed therein. Each of the passages 86 and 87 is open to the outer peripheral surface of the inner cylinder member 81. Further, on the outer peripheral surface of the inner cylinder member 81, a partition portion 89 for partitioning the refrigerant passage 85 into an inlet side and an outlet side is provided. As a result, the refrigerant flowing in from the inlet side passage 86 flows in the refrigerant passage 85 in the circumferential direction, and then flows out from the outlet side passage 87.

One end side of the inlet side passage 86 and the outlet side passage 87 extends radially and opens to the outer peripheral surface of the inner cylinder member 81, and the other end side extends axially and opens to the axial end surface of the inner cylinder member 81. It has become like. FIG. 12 shows an entrance opening 86a leading to the entrance side passage 86 and an exit opening 87a leading to the exit side passage 87. The inlet side passage 86 and the outlet side passage 87 are connected to the inlet port 244 and the outlet port 245 (see FIG. 1) attached to the housing cover 242, and the refrigerant enters and exits through the respective ports 244 and 245. It has become like.

Sealing materials 101 and 102 for suppressing leakage of the refrigerant in the refrigerant passage 85 are provided at the joint portion between the outer cylinder member 71 and the inner cylinder member 81 (see FIG. 15). Specifically, the sealing materials 101 and 102 are, for example, O-rings, which are accommodated in the annular grooves 74a and 75a of the outer cylinder member 71 and are provided in a state of being compressed by the outer cylinder member 71 and the inner cylinder member 81. There is.

Further, as shown in FIG. 12, the inner cylinder member 81 has an end plate portion 91 on one end side in the axial direction, and the end plate portion 91 has a hollow cylindrical boss portion 92 extending in the axial direction. It is provided. The boss portion 92 is provided so as to surround the insertion hole 93 for inserting the rotating shaft 11. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242. Further, the end plate portion 91 is provided with a plurality of support column portions 95 extending in the axial direction on the radial outer side of the boss portion 92. The support column 95 is a portion that serves as a fixing portion for fixing the bus bar module 200, and the details thereof will be described later. Further, the boss portion 92 is a bearing holding member for holding the bearing 12, and the bearing 12 is fixed to the bearing fixing portion 96 provided on the inner peripheral portion thereof (see FIG. 3).

Further, as shown in FIGS. 12 and 13, recesses 105 and 106 used for fixing a plurality of coil modules 150, which will be described later, are formed in the outer cylinder member 71 and the inner cylinder member 81.

Specifically, as shown in FIG. 12, a plurality of axial end faces of the inner cylinder member 81, specifically, an axial outer end face around the boss portion 92 in the end plate portion 91, are provided at equal intervals in the circumferential direction. A recess 105 is formed. Further, as shown in FIG. 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end surface of the outer cylinder member 71, specifically, the axially outer end surface of the flange 72. These recesses 105 and 106 are provided so as to be aligned on a virtual circle concentric with the core assembly CA. The recesses 105 and 106 are provided at the same positions in the circumferential direction, respectively, and the intervals and the number thereof are also the same.

By the way, the stator core 62 is assembled in a state where a compressive force in the radial direction is generated with respect to the stator holder 70 in order to secure the strength of the assembly with respect to the stator holder 70. Specifically, the stator core 62 is fitted and fixed to the stator holder 70 with a predetermined tightening margin by shrink fitting or press fitting. In this case, it can be said that the stator core 62 and the stator holder 70 are assembled in a state where radial stress is generated from one of them to the other. Further, when increasing the torque of the rotary electric machine 10, for example, it is conceivable to increase the diameter of the stator 60, and in such a case, the stator is used to strengthen the coupling of the stator core 62 to the stator holder 70. The tightening force of the core 62 is increased. However, if the compressive stress (in other words, the residual stress) of the stator core 62 is increased, there is a concern that the stator core 62 may be damaged.

Therefore, in the present embodiment, in a configuration in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined tightening allowance, the stator core 62 and the stator holder 70 are radially opposed to each other. A regulating portion is provided to regulate the displacement of the stator core 62 in the circumferential direction by engaging in the circumferential direction. That is, as shown in FIGS. 12 to 14, a plurality of engagements as a restricting portion are provided between the stator core 62 and the outer cylinder member 71 of the stator holder 70 in the radial direction at predetermined intervals in the circumferential direction. A member 111 is provided, and the engaging member 111 suppresses the positional deviation between the stator core 62 and the stator holder 70 in the circumferential direction. In this case, a recess may be provided in at least one of the stator core 62 and the outer cylinder member 71, and the engaging member 111 may be engaged in the recess. Instead of the engaging member 111, a convex portion may be provided on either the stator core 62 or the outer cylinder member 71.

In the above configuration, the stator core 62 and the stator holder 70 (outer cylinder member 71) are fitted and fixed with a predetermined tightening allowance, and mutual circumferential displacement is regulated by the regulation of the engaging member 111. It is provided in a state of being. Therefore, even if the tightening allowance in the stator core 62 and the stator holder 70 is relatively small, the displacement of the stator core 62 in the circumferential direction can be suppressed. Further, since the desired displacement suppressing effect can be obtained even if the tightening allowance is relatively small, damage to the stator core 62 due to an excessively large tightening allowance can be suppressed. As a result, the displacement of the stator core 62 can be appropriately suppressed.

An annular internal space is formed on the inner peripheral side of the inner cylinder member 81 so as to surround the rotation shaft 11, and in the internal space, for example, electric components constituting an inverter as a power converter are arranged. May be good. 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 a state of being in contact with the inner peripheral surface of the inner cylinder member 81, it is possible to cool the electric module by the refrigerant flowing through the refrigerant passage 85. It should be noted that, on the inner peripheral side of the inner cylinder member 81, the plurality of protruding portions 83 may be eliminated or the protruding height of the protruding portions 83 may be reduced, thereby expanding the internal space on the inner peripheral side of the inner cylinder member 81. It is possible.

Next, the configuration of the stator winding 61 assembled to the core assembly CA will be described in detail. The state in which the stator winding 61 is assembled to the core assembly CA is as shown in FIGS. 10 and 11, and the stator is radially outside the core assembly CA, that is, radially outside the stator core 62. A plurality of partial windings 151 constituting the winding 61 are assembled in a state of being arranged in the circumferential direction.

The stator winding 61 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). In the present embodiment, the stator winding 61 has a three-phase phase winding by using U-phase, V-phase, and W-phase phase windings.

As shown in FIG. 11, the stator 60 has a portion corresponding to the coil side CS that faces the magnet unit 22 in the rotor 20 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 62 is provided in a range corresponding to the coil side CS in the axial direction.

In the stator winding 61, each phase winding of each phase has a plurality of partial windings 151 (see FIG. 16), and the partial windings 151 are individually provided as coil modules 150. That is, the coil module 150 is configured by integrally providing partial windings 151 in the phase windings of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 according to the number of poles. There is. By arranging the coil modules 150 (partial winding 151) of each phase in a predetermined order in the circumferential direction, the conductors of each phase are arranged in a predetermined order in the coil side CS of the stator winding 61. It has become. FIG. 10 shows the order of arrangement of the U-phase, V-phase, and W-phase conductors in the coil side CS. In the present embodiment, the number of magnetic poles is 24, but the number is arbitrary.

In the stator winding 61, the phase windings of each phase are configured by connecting the partial windings 151 of each coil module 150 in parallel or in series for each phase. FIG. 16 is a circuit diagram showing a connection state of the partial winding 151 in each of the three-phase windings. FIG. 16 shows a state in which the partial windings 151 in the phase windings of each phase are connected in parallel.

As shown in FIG. 11, the coil module 150 is assembled on the radial outer side of the stator core 62. In this case, the coil module 150 is assembled in a state where both ends in the axial direction are projected outward in the axial direction (that is, the coil end CE side) from the stator core 62. That is, the stator winding 61 has a portion corresponding to the coil end CE protruding outward in the axial direction from the stator core 62, and a portion corresponding to the coil side CS on the inner side in the axial direction. ..

The coil module 150 has two types of shapes, one of which has a shape in which the partial winding 151 is bent in the radial direction, that is, toward the stator core 62 in the coil end CE. On the other hand, in the coil end CE, the partial winding 151 is not bent inward in the radial direction and has a shape extending linearly in the axial direction. In the following description, for convenience, the partial winding 151 having a bent shape on both ends in the axial direction is referred to as a "first partial winding 151A", and the coil module 150 having the first partial winding 151A is referred to as a "first coil". Also referred to as "module 150A". Further, the partial winding 151 having no bending shape on both ends in the axial direction is also referred to as a "second partial winding 151B", and the coil module 150 having the second partial winding 151B is also referred to as a "second coil module 150B". ..

FIG. 17 is a side view showing the first coil module 150A and the second coil module 150B side by side in comparison, and FIG. 18 shows the first partial winding 151A and the second partial winding 151B side by side. It is a side view showing side by side and contrasting. As shown in each of these figures, the coil modules 150A and 150B and the partial windings 151A and 151B have different axial lengths and different end shapes on both sides in the axial direction. The first partial winding 151A has a substantially C shape in the side view, and the second partial winding 151B has a substantially I shape in the side view. The first partial winding 151A is equipped with insulating covers 161, 162 as "first insulating covers" on both sides in the axial direction, and the second partial winding 151B is equipped with "second insulating covers" on both sides in the axial direction. Insulation covers 163 and 164 are attached.

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

Here, first, the first coil module 150A among the coil modules 150A and 150B will be described. FIG. 19A is a perspective view showing the configuration of the first coil module 150A, and FIG. 19B is a perspective view showing the components of the first coil module 150A in an exploded manner. Further, FIG. 20 is a sectional view taken along line 20-20 in FIG. 19 (a).

As shown in FIGS. 19A and 19B, the first coil module 150A has a first partial winding 151A configured by multiple winding of a conducting wire material CR and a first partial winding 151A thereof in the axial direction. It has insulating covers 161, 162 attached to one end side and the other end side. The insulating covers 161, 162 are formed of an insulating material such as synthetic resin.

The first partial winding 151A has a pair of intermediate conductor portions 152 provided in parallel and linearly with each other, and a pair of crossover portions 153A connecting the pair of intermediate conductor portions 152 at both ends in the axial direction. , These pair of intermediate conductor portions 152 and the pair of crossover portions 153A form an annular shape. The pair of intermediate conductors 152 are provided so as to be separated by a predetermined coil pitch, and the intermediate conductors 152 of the partial winding 151 of the other phase can be arranged between the pair of intermediate conductors 152 in the circumferential direction. It has become. In the present embodiment, the pair of intermediate conductors 152 are provided so as to be separated by two coil pitches, and one intermediate conductor 152 in the other two-phase partial winding 151 is arranged between the pair of intermediate conductors 152. It is configured to be.

The pair of crossover portions 153A 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. 11). Each crossover portion 153A is provided so as to be bent in a direction orthogonal to the intermediate conductor portion 152, that is, in a direction orthogonal to the axial direction.

As shown in FIG. 18, the first partial winding 151A has crossover portions 153A on both sides in the axial direction, and the second partial winding 151B has crossover portions 153B on both sides in the axial direction. The crossover portions 153A and 153B of the partial windings 151A and 151B are different in shape from each other, and in order to clarify the distinction, the crossover portion 153A of the first partial winding 151A is referred to as a "first crossover portion 153A". The crossover portion 153B of the second partial winding 151B is also referred to as "second crossover portion 153B".

In each of the partial windings 151A and 151B, the intermediate conductor portion 152 is provided as a coil side conductor portion arranged one by one in the circumferential direction in the coil side CS. Further, the crossover portions 153A and 153B are provided as coil end conductor portions in the coil end CE for connecting the intermediate conductor portions 152 having the same phase at two positions different in the circumferential direction.

As shown in FIG. 20, the first partial winding 151A 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. FIG. 20 shows a cross section of the intermediate conducting wire portion 152, and the conducting wire material CR is multiplely wound around the intermediate conducting wire portion 152 so as to be aligned in the circumferential direction and the radial direction. That is, in the first partial winding 151A, the conductors CR are arranged in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction in the intermediate conductor portion 152 so that the cross section becomes substantially rectangular. It is formed. The tip of the first crossover portion 153A is configured to be wound in multiple directions so that the conductor CRs are aligned in the axial direction and the radial direction due to the bending in the radial direction. In the present embodiment, the first partial winding 151A 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.

In the first partial winding 151A, of the first crossovers 153A on both sides in the axial direction, the end of the conductor CR is formed from one of the first crossovers 153A (the upper first crossover 153A in FIG. 19B). It is pulled out, and its end portion is a winding end portion 154, 155. The winding end portions 154 and 155 are portions where the winding start and winding end of the conductor material CR, respectively. One of the winding ends 154 and 155 is connected to the current input / output terminal, and the other is connected to the neutral point.

In the first partial winding 151A, each intermediate conducting wire portion 152 is provided with a sheet-shaped insulating coating 157 covered with the intermediate conducting wire portion 152. Note that FIG. 19A shows the first coil module 150A in a state where the intermediate conductor portion 152 is covered with the insulating coating portion 157 and the intermediate conductor portion 152 is present inside the insulating coating portion 157. However, for convenience, the corresponding portion is referred to as an intermediate conductor portion 152 (the same applies to FIG. 22A described later).

The insulating coating 157 uses a film material FM having at least the length of the insulating coating range in the intermediate wire portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152. It is provided. The film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film base material and an adhesive layer provided on one side of both surfaces of the film base material and having foamability. Then, the film material FM is wound around the intermediate conductor portion 152 in a state of being adhered by the adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.

As shown in FIG. 20, the intermediate lead wire portion 152 has a substantially rectangular cross section due to the radial and radial directions of the lead wire member CR, and the film material FM is formed around the intermediate lead wire portion 152. The insulating coating 157 is provided by covering the peripheral ends in an overlapping state. The film material FM is a rectangular sheet whose vertical dimension is longer than the axial length of the intermediate conductor portion 152 and whose horizontal dimension is longer than one circumference of the intermediate conductor portion 152, according to the cross-sectional shape of the intermediate conductor portion 152. It is wound around the intermediate conductor portion 152 with a crease. In a state where the film material FM is wound around the intermediate conductor portion 152, the gap between the conductor material CR of the intermediate conductor portion 152 and the film base material is filled by foaming in the adhesive layer. Further, in the overlapping portion OL of the film material FM, the peripheral ends of the film material FM are joined by an adhesive layer.

In the intermediate conductor portion 152, an insulating coating 157 is provided so as to cover all of the two circumferential side surfaces and the two radial side surfaces. In this case, the insulating coating 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152, that is, the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase. An overlap portion OL in which the material FM overlaps is provided. In the present embodiment, the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.

In the first partial winding 151A, the range is from the intermediate conductor portion 152 to the portion covered by the insulating covers 161, 162 (that is, the portion inside the insulating covers 161, 162) in the first crossover portions 153A on both sides in the axial direction. The insulating coating body 157 is provided. Speaking of FIG. 17, in the first coil module 150A, the range of AX1 is a portion not covered by the insulating covers 161, 162, and the insulating coating 157 is provided in a range extended vertically from the range AX1. ..

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

The insulating cover 161 is mounted on the first crossover 153A on one axial side of the first partial winding 151A, and the insulating cover 162 is mounted on the first crossover 153A on the other axial direction of the first partial winding 151A. Will be done. Of these, the configuration of the insulating cover 161 is shown in FIGS. 21 (a) and 21 (b). 21 (a) and 21 (b) are perspective views of the insulating cover 161 viewed from two different directions.

As shown in FIGS. 21 (a) and 21 (b), the insulating cover 161 includes a pair of side surface portions 171 which are side surfaces in the circumferential direction, an outer surface portion 172 on the outer side in the axial direction, and an inner surface portion 173 on the inner side in the axial direction. It has a front surface portion 174 on the inner side in the radial direction. Each of these parts 171 to 174 is formed in a plate shape, and is connected to each other in a three-dimensional shape so that only the radial outer side is open. Each of the pair of side surface portions 171 is provided so as to extend toward the axis of the core assembly CA in the assembled state with the core assembly CA. Therefore, in a state where a plurality of first coil modules 150A are arranged side by side in the circumferential direction, the side surface portions 171 of the insulating cover 161 face each other in an abutting or approaching state in each of the adjacent first coil modules 150A. As a result, in each of the first coil modules 150A adjacent to each other in the circumferential direction, a suitable annular arrangement is possible while being mutually insulated.

In the insulating cover 161, the outer surface portion 172 is provided with an opening 175a for pulling out the winding end portion 154 of the first partial winding 151A, and the front surface portion 174 is provided with the winding end of the first partial winding 151A. An opening 175b for pulling out the portion 155 is provided. In this case, one winding end portion 154 is drawn out from the outer surface portion 172 in the axial direction, while the other winding end portion 155 is drawn out from the front surface portion 174 in the radial direction.

Further, in the insulating cover 161, the pair of side surface portions 171 has a semicircular shape extending in the axial direction at positions at both ends in the circumferential direction of the front surface portion 174, that is, at positions where each side surface portion 171 and the front surface portion 174 intersect. A recess 177 is provided. Further, the outer surface portion 172 is provided with a pair of protrusions 178 extending in the axial direction at positions symmetrical to both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

The explanation of the recess 177 of the insulating cover 161 is supplemented. As shown in FIG. 20, the first crossover portion 153A of the first partial winding 151A has a curved shape that is convex in the radial direction, that is, toward the core assembly CA, out of the radial inside and outside. In such a configuration, a gap is formed between the first crossover portions 153A adjacent to each other in the circumferential direction so as to be wider toward the tip end side of the first crossover portion 153A. Therefore, in the present embodiment, the recess 177 is provided on the side surface portion 171 of the insulating cover 161 at a position outside the curved portion of the first crossover portion 153A by utilizing the gap between the first crossover portions 153A arranged in the circumferential direction. It has a structure.

It should be noted that the first partial winding 151A may be provided with a temperature detection unit (thermistor), and in such a configuration, the insulating cover 161 may be provided with an opening for drawing out a signal line extending from the temperature detection unit. In this case, the temperature detection unit can be suitably accommodated in the insulating cover 161.

Although detailed explanation by illustration is omitted, the insulating cover 162 on the other side in the axial direction has substantially the same configuration as the insulating cover 161. The insulating cover 162 has a pair of side surface portions 171, an outer surface portion 172 on the outer side in the axial direction, an inner surface portion 173 on the inner side in the axial direction, and a front surface portion 174 on the inner side in the radial direction, similarly to the insulating cover 161. .. Further, in the insulating cover 162, the pair of side surface portions 171 are provided with semicircular recesses 177 at positions at both ends in the circumferential direction of the front surface portion 174, and the outer surface portion 172 is provided with a pair of protrusions 178. .. The difference from the insulating cover 161 is that the insulating cover 162 does not have an opening for pulling out the winding ends 154 and 155 of the first partial winding 151A.

In the insulating covers 161, 162, the height dimension in the axial direction (that is, the width dimension in the axial direction in the pair of side surface portions 171 and the front surface portion 174) is different. Specifically, as shown in FIG. 17, the axial height dimension W11 of the insulating cover 161 and the axial height dimension W12 of the insulating cover 162 are W11> W12. That is, when the conductor material CR is wound multiple times, it is necessary to switch (lane change) the winding stage of the conductor material CR in a direction orthogonal to the winding winding direction (circumferential direction), which is caused by the switching. It is conceivable that the winding width will increase. Supplementally, of the insulating covers 161, 162, the insulating cover 161 is a portion that covers the first crossing portion 153A on the side including the winding start and winding end of the conducting wire material CR, and includes the winding start and winding end of the conducting wire material CR. As a result, the winding allowance (overlapping allowance) of the conductor material CR is larger than that of the other portions, and as a result, the winding width may be increased. Taking this point into consideration, the axial height dimension W11 of the insulating cover 161 is larger than the axial height dimension W12 of the insulating cover 162. As a result, unlike the case where the height dimensions W11 and W12 of the insulating covers 161, 162 have the same dimensions, the inconvenience that the number of turns of the conducting wire material CR is limited by the insulating covers 161, 162 is suppressed. It has become.

Next, the second coil module 150B will be described.

FIG. 22A is a perspective view showing the configuration of the second coil module 150B, and FIG. 22B is a perspective view showing the components of the second coil module 150B in an exploded manner. Further, FIG. 23 is a cross-sectional view taken along the line 23-23 in FIG. 22 (a).

As shown in FIGS. 22 (a) and 22 (b), the second coil module 150B includes a second partial winding 151B configured by multiple winding the conductor CR as in the first partial winding 151A, and a second partial winding 151B thereof. The second partial winding 151B has insulating covers 163 and 164 attached to one end side and the other end side in the axial direction. The insulating covers 163 and 164 are formed of an insulating material such as synthetic resin.

The second partial winding 151B has a pair of intermediate conductor portions 152 provided in parallel and linearly with each other, and a pair of second crossover portions 153B connecting the pair of intermediate conductor portions 152 at both ends in the axial direction. The pair of intermediate conductors 152 and the pair of second crossovers 153B form an annular shape. The pair of intermediate conductors 152 in the second partial winding 151B has the same configuration as the intermediate conductors 152 of the first partial winding 151A. On the other hand, the pair of second crossover portions 153B has a different configuration from the first crossover portion 153A of the first partial winding 151A. The second crossover portion 153B of the second partial winding 151B is provided so as to extend linearly in the axial direction from the intermediate conductor portion 152 without being bent in the radial direction. In FIG. 18, the differences between the partial windings 151A and 151B are clearly shown in comparison.

In the second partial winding 151B, the end of the conductor CR is formed from one of the second crossovers 153B (the upper second crossover 153B in FIG. 22B) of the second crossovers 153B on both sides in the axial direction. It is pulled out, and its end portion is a winding end portion 154, 155. Then, in the second partial winding 151B as well as the first partial winding 151A, one of the winding ends 154 and 155 is connected to the current input / output terminal, and the other is connected to the neutral point. It has become.

In the second partial winding 151B, similarly to the first partial winding 151A, each intermediate conducting wire portion 152 is provided with a sheet-shaped insulating coating 157 covered. The insulating coating 157 uses a film material FM having at least the length of the insulating coating range in the intermediate wire portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152. It is provided.

The configuration of the insulating coating 157 is almost the same for each of the partial windings 151A and 151B. That is, as shown in FIG. 23, the film material FM is covered around the intermediate conductor portion 152 in a state where the end portions in the circumferential direction are overlapped. In the intermediate conductor portion 152, the insulating coating 157 is provided so as to cover all of the two circumferential side surfaces and the two radial side surfaces. In this case, the insulating coating 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152, that is, the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase. An overlap portion OL in which the material FM overlaps is provided. In the present embodiment, the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.

In the second partial winding 151B, the range from the intermediate conductor portion 152 to the portion covered by the insulating covers 163 and 164 in the second crossover portions 153B on both sides in the axial direction (that is, the portion inside the insulating covers 163 and 164). The insulating coating body 157 is provided. Speaking of FIG. 17, in the second coil module 150B, the range of AX2 is a portion not covered by the insulating covers 163 and 164, and the insulating covering 157 is provided in a range extended vertically from the range AX2. ..

In each of the partial windings 151A and 151B, the insulating coating 157 is provided in a range including a part of the crossover portions 153A and 153B. That is, the partial windings 151A and 151B are provided with an insulating coating 157 at the intermediate conductor portion 152 and the portion of the crossover portions 153A and 153B that extends linearly following the intermediate conductor portion 152. However, since the axial lengths of the partial windings 151A and 151B are different, the axial range of the insulating coating 157 is also different.

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

The insulating cover 163 is mounted on the second crossover 153B on one axial side of the second partial winding 151B, and the insulating cover 164 is mounted on the second crossover 153B on the other axial direction of the second partial winding 151B. Will be done. Of these, the configuration of the insulating cover 163 is shown in FIGS. 24 (a) and 24 (b). 24 (a) and 24 (b) are perspective views of the insulating cover 163 as viewed from two different directions.

As shown in FIGS. 24A and 24B, the insulating cover 163 includes a pair of side surface portions 181 which are side surfaces in the circumferential direction, an outer surface portion 182 on the outer side in the axial direction, and a front surface portion 183 on the inner side in the radial direction. It has a rear surface portion 184 on the outer side in the radial direction. Each of these portions 181 to 184 is formed in a plate shape, and is connected to each other in a three-dimensional shape so that only the inner side in the axial direction is opened. Each of the pair of side surface portions 181 is provided so as to extend toward the axis of the core assembly CA in the assembled state with the core assembly CA. Therefore, in a state where the plurality of second coil modules 150B are arranged side by side in the circumferential direction, the side surface portions 181 of the insulating cover 163 face each other in an abutting or approaching state in each of the adjacent second coil modules 150B. As a result, in each of the second coil modules 150B adjacent to each other in the circumferential direction, a suitable annular arrangement is possible while being mutually insulated.

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

The front surface portion 183 of the insulating cover 163 is provided with a protruding portion 186 protruding inward in the radial direction. The projecting portion 186 is provided at a central position between one end and the other end in the circumferential direction of the insulating cover 163 so as to project radially inward from the second crossover portion 153B. The protrusion 186 has a tapered shape that tapers toward the inside in the radial direction in a plan view, and a through hole 187 extending in the axial direction is provided at the tip thereof. If the protruding portion 186 protrudes radially inward from the second crossover portion 153B and has a through hole 187 at the center position between one end and the other end in the circumferential direction of the insulating cover 163, the protruding portion 186 has a through hole 187. The configuration is arbitrary. However, assuming an overlapping state with the insulating cover 161 inside in the axial direction, it is desirable that the cover is formed narrow in the circumferential direction in order to avoid interference with the winding ends 154 and 155.

The protruding portion 186 has an axially thin stepped thickness at the tip portion on the inner side in the radial direction, and a through hole 187 is provided in the thinned lower step portion 186a. This low step portion 186a corresponds to a portion where the height of the inner cylinder member 81 from the axial end face is lower than the height of the second crossover portion 153B in the assembled state of the second coil module 150B with respect to the core assembly CA. ..

Further, as shown in FIG. 23, the protruding portion 186 is provided with a through hole 188 penetrating in the axial direction. This makes it possible to fill the space between the insulating covers 161, 163 through the through holes 188 in a state where the insulating covers 161, 163 overlap in the axial direction.

Although detailed explanation by illustration is omitted, the insulating cover 164 on the other side in the axial direction has substantially the same configuration as the insulating cover 163. Like the insulating cover 163, the insulating cover 164 has a pair of side surface portions 181, an outer surface portion 182 on the outer side in the axial direction, a front surface portion 183 on the inner side in the radial direction, and a rear surface portion 184 on the outer side in the radial direction. It has a through hole 187 provided at the tip of the portion 186. Further, the difference from the insulating cover 163 is that the insulating cover 164 does not have an opening for pulling out the winding ends 154 and 155 of the second partial winding 151B.

In the insulating covers 163 and 164, the width dimensions of the pair of side surface portions 181 in the radial direction are different. Specifically, as shown in FIG. 17, the radial width dimension W21 of the side surface portion 181 of the insulating cover 163 and the radial width dimension W22 of the side surface portion 181 of the insulating cover 164 are W21> W22. .. That is, of the insulating covers 163 and 164, the insulating cover 163 is a portion that covers the second crossing portion 153B on the side including the winding start and winding end of the conducting wire material CR, and includes the winding start and winding end of the conducting wire material CR. As a result, the winding allowance (overlapping allowance) of the conductor material CR may be larger than that of the other portions, and as a result, the winding width may be increased. Taking this point into consideration, the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164. As a result, unlike the case where the width dimensions W21 and W22 of the insulating covers 163 and 164 are the same, the inconvenience that the number of turns of the conducting wire material CR is limited by the insulating covers 163 and 164 can be suppressed. ing.

FIG. 25 is a diagram showing the overlap position of the film material FM in a state where the coil modules 150A and 150B are arranged in the circumferential direction. As described above, in the coil modules 150A and 150B, the intermediate conductor portion 152 is overlapped with the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, that is, the circumferential side surface of the intermediate conductor portion 152. The film material FM is covered with the film material (see FIGS. 20 and 23). When the coil modules 150A and 150B are arranged in the circumferential direction, the overlap portion OL of the film material FM is arranged on the same side (on the right side in the circumferential direction in the figure) on both sides in the circumferential direction. ing. As a result, in each of the intermediate conductor portions 152 of the partial windings 151A and 151B having different phases adjacent to each other in the circumferential direction, the overlapping portions OL of the film material FM do not overlap each other in the circumferential direction. In this case, a maximum of three film material FMs are overlapped between the intermediate conductor portions 152 arranged in the circumferential direction.

Next, the configuration related to the assembly of the coil modules 150A and 150B to the core assembly CA will be described.

The coil modules 150A and 150B have different axial lengths, and the shapes of the crossover portions 153A and 153B of the partial windings 151A and 151B are different from each other. It is configured to be attached to the core assembly CA with the second crossover 153B of the second coil module 150B on the inside in the direction and on the outside in the axial direction. Regarding the insulating covers 161 to 164, the insulating covers 161 and 163 are vertically overlapped on one end side in the axial direction of each of the coil modules 150A and 150B, and the insulating covers 162 and 164 are vertically overlapped on the other end side in the axial direction. In the closed state, each of these insulating covers 161 to 164 is fixed to the core assembly CA.

FIG. 26 is a plan view showing a state in which a plurality of insulating covers 161 are arranged in the circumferential direction in a state where the first coil module 150A is assembled to the core assembly CA, and FIG. 27 is a plan view showing the first coil module 150A and the first coil module 150A to the core assembly CA. It is a top view which shows the state which a plurality of insulating covers 161, 163 are arranged in the circumferential direction in the assembled state of 2 coil modules 150B. Further, FIG. 28A is a vertical sectional view showing a state before fixing by the fixing pin 191 in the assembled state of the coil modules 150A and 150B with respect to the core assembly CA, and FIG. 28B is a vertical sectional view showing the state before being fixed with respect to the core assembly CA. It is a vertical sectional view which shows the state after being fixed by the fixing pin 191 in the assembled state of each coil module 150A, 150B.

As shown in FIG. 26, in a state where a plurality of first coil modules 150A are assembled to the core assembly CA, a plurality of insulating covers 161 are arranged with the side surface portions 171 in contact with each other or in close contact with each other. Each insulating cover 161 is arranged so that the boundary line LB facing the side surface portions 171 and the recess 105 on the axial end surface of the inner cylinder member 81 coincide with each other. In this case, when the side surface portions 171 of the insulating covers 161 adjacent to each other in the circumferential direction are in contact with each other or are in an approaching state, each recess 177 of the insulating cover 161 forms a through hole portion extending in the axial direction, and the through hole portion thereof is formed. The positions of the holes and the recesses 105 are set to match.

Further, as shown in FIG. 27, the second coil module 150B is further assembled to the integral body of the core assembly CA and the first coil module 150A. Along with this assembly, a plurality of insulating covers 163 are arranged with the side surface portions 181 in contact with each other or in close contact with each other. In this state, the crossover portions 153A and 153B are arranged so as to intersect each other on a circle in which the intermediate conductor portions 152 are lined up in the circumferential direction. In each insulating cover 163, the protruding portion 186 overlaps the insulating cover 161 in the axial direction, and the through hole 187 of the protruding portion 186 is axially connected to the through hole portion formed by each recess 177 of the insulating cover 161. Will be placed.

At this time, the protruding portion 186 of the insulating cover 163 is guided to a predetermined position by the pair of protruding portions 178 provided on the insulating cover 161 so that the through hole portion on the insulating cover 161 side and the recess 105 of the inner cylinder member 81 are guided. The position of the through hole 187 on the insulating cover 163 side is aligned with the above. That is, in the state where the coil modules 150A and 150B are assembled to the core assembly CA, the concave portion 177 of the insulating cover 161 is located on the back side of the insulating cover 163, so that the protruding portion with respect to the concave portion 177 of the insulating cover 161. It may be difficult to align the through hole 187 of 186. In this respect, the pair of protrusions 178 of the insulation cover 161 guides the protrusion 186 of the insulation cover 163, which facilitates the alignment of the insulation cover 163 with respect to the insulation cover 161.

Then, as shown in FIGS. 28 (a) and 28 (b), the insulating cover 161 is fixed by the fixing pin 191 as a fixing member in a state of being engaged with the overlapping portion of the insulating cover 161 and the protruding portion 186 of the insulating cover 163. Will be done. More specifically, in a state where the recess 105 of the inner cylinder member 81, the recess 177 of the insulating cover 161 and the through hole 187 of the insulating cover 163 are aligned, the fixing pins are inserted into the recesses 105, 177 and the through hole 187. 191 is inserted. As a result, the insulating covers 161 and 163 are integrally fixed to the inner cylinder member 81. According to this configuration, the coil modules 150A and 150B adjacent to each other in the circumferential direction are fixed to the core assembly CA by a common fixing pin 191 at the coil end CE. The fixing pin 191 is preferably made of a material having good thermal conductivity, for example, a metal pin.

As shown in FIG. 28 (b), the fixing pin 191 is assembled to the lower step portion 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end portion of the fixing pin 191 protrudes above the lower step portion 186a, but does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion between the insulating cover 161 and the protruding portion 186 (lower step portion 186a) of the insulating cover 163, and has a margin for protruding upward. When the fixing pin 191 is inserted into the recesses 105 and 177 and the through hole 187 (that is, when the fixing pin 191 is fixed), it may be easier to perform the work. Further, since the upper end portion of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, it is possible to suppress the inconvenience that the shaft length of the stator 60 becomes long due to the protruding portion of the fixing pin 191. It has become a thing.

After fixing the insulating covers 161 and 163 with the fixing pins 191, the adhesive is filled through the through holes 188 provided in the insulating cover 163. As a result, the insulating covers 161 and 163 that overlap in the axial direction are firmly coupled to each other. In FIGS. 28 (a) and 28 (b), the through hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163 for convenience, but in reality, the through hole 188 is formed in the thin plate portion formed by lightening or the like. It has a provided configuration.

As shown in FIG. 28 (b), the fixing position of each insulating cover 161 and 163 by the fixing pin 191 is the axial end surface of the stator holder 70 radially inside the stator core 62 (left side in the figure). The stator holder 70 is fixed by the fixing pin 191. That is, the first crossover portion 153A is fixed to the axial end face of the stator holder 70. In this case, since the stator holder 70 is provided with the refrigerant passage 85, the heat generated in the first partial winding 151A is directly from the first crossover portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. It is transmitted to. Further, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, and heat transfer to the stator holder 70 side is promoted through the fixing pin 191. With such a configuration, the cooling performance of the stator winding 61 is improved.

In the present embodiment, 18 insulating covers 161, 163 are arranged so as to be stacked inside and outside the axial direction in the coil end CE, while the same number of insulating covers 161 and 163 are arranged on the axial end face of the stator holder 70. Recesses 105 are provided at 18 locations. The 18 recesses 105 are fixed by the fixing pin 191.

Although not shown, the same applies to the insulating covers 162 and 164 on the opposite side in the axial direction. That is, first, when assembling the first coil module 150A, the side surface portions 171 of the insulating covers 162 adjacent to each other in the circumferential direction are in contact with each other or are in close contact with each other, and the concave portions 177 of the insulating cover 162 extend in the axial direction. A through-hole portion is formed, and the position of the through-hole portion coincides with the position of the recess 106 on the axial end surface of the outer cylinder member 71. Then, by assembling the second coil module 150B, the positions of the through holes 187 on the insulating cover 164 side match the through holes on the insulating cover 163 side and the recesses 106 on the outer cylinder member 71, and the recesses 106 and 177 are aligned. By inserting the fixing pin 191 into the through hole 187, the insulating covers 162 and 164 are integrally fixed to the outer cylinder member 71.

When assembling the coil modules 150A and 150B to the core assembly CA, all the first coil modules 150A are attached to the outer peripheral side of the core assembly CA first, and then all the second coil modules 150B are assembled. It is preferable to perform fixing with the fixing pin 191. Alternatively, the two first coil modules 150A and the one second coil module 150B are first fixed to the core assembly CA with one fixing pin 191 and then the first coil module 150A is assembled. , The assembly of the second coil module 150B and the fixing by the fixing pin 191 may be repeated in this order.

Next, the bus bar module 200 will be described.

The bus bar module 200 is electrically connected to the partial winding 151 of each coil module 150 at the stator winding 61, and one end of the partial winding 151 of each phase is connected in parallel for each phase, and each partial winding thereof is connected. It is a winding connection member that connects the other end of 151 at a neutral point. 29 is a perspective view of the bus bar module 200, and FIG. 30 is a cross-sectional view showing a part of a vertical cross section of the bus bar module 200.

The bus bar module 200 has an annular portion 201 forming an annular portion, a plurality of connection terminals 202 extending from the annular portion 201, and three input / output terminals 203 provided for each phase winding. The annular portion 201 is formed in an annular shape by, for example, an insulating member such as a resin.

As shown in FIG. 30, the annular portion 201 has a substantially annular plate shape and has laminated plates 204 laminated in multiple layers (five layers in this embodiment) in the axial direction, and each of these laminated plates 204 has a laminated plate 204. Four bus bars 211 to 214 are provided so as to be sandwiched between them. Each of the bus bars 211 to 214 has an annular shape, and is composed of a U-phase bus bar 211, a V-phase bus bar 212, a W-phase bus bar 213, and a neutral point bus bar 214. .. The bus bars 211 to 214 are arranged in the annular portion 201 so as to face each other in the axial direction. Each laminated plate 204 and each bus bar 211 to 214 are joined to each other by an adhesive. It is desirable to use an adhesive sheet as the adhesive. However, it may be configured to apply a liquid or semi-liquid adhesive. The connection terminals 202 are connected to the bus bars 211 to 214 so as to project radially outward from the annular portion 201, respectively.

A protrusion 201a extending in an annular shape is provided on the upper surface of the annular portion 201, that is, on the upper surface of the laminated plate 204 on the most surface layer side of the laminated plate 204 provided in the five layers.

The bus bar module 200 may be provided in a state where the bus bars 211 to 214 are embedded in the annular portion 201, and the bus bars 211 to 214 arranged at predetermined intervals are integrally insert-molded. It may be a thing. Further, the arrangement of the bus bars 211 to 214 is not limited to the configuration in which all the bus bars are arranged in the axial direction and all the plate surfaces are oriented in the same direction. It may be configured to line up in a row, or to include those having different plate surface extending directions.

In FIG. 29, the connection terminals 202 are provided so as to be aligned in the circumferential direction of the annular portion 201 and extend in the axial direction on the outer side in the radial direction. The connection terminal 202 includes a connection terminal connected to the U-phase bus bar 211, a connection terminal connected to the V-phase bus bar 212, a connection terminal connected to the W-phase bus bar 213, and a neutral point. Includes a connection terminal connected to the bus bar 214 for. The number of connection terminals 202 is the same as the number of winding ends 154 and 155 of each partial winding 151 in the coil module 150, and each connection terminal 202 is provided with winding ends 154 of each partial winding 151. 155 are connected one by one. As a result, the bus bar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151, respectively.

The input / output terminal 203 is made of, for example, a bus bar material, and is provided in a direction extending in the axial direction. The input / output terminal 203 includes a U-phase input / output terminal 203U, a V-phase input / output terminal 203V, and a W-phase input / output terminal 203W. These input / output terminals 203 are connected to the bus bars 211 to 213 for each phase in the annular portion 201. Through each of these input / output terminals 203, power is input / output from an inverter (not shown) to the phase windings of each phase of the stator winding 61.

The bus bar module 200 may be integrally provided with a current sensor that detects the phase current of each phase. In this case, it is preferable that the bus bar module 200 is provided with a current detection terminal, and the detection result of the current sensor is output to a control device (not shown) through the current detection terminal.

Further, the annular portion 201 has a plurality of protruding portions 205 projecting to the inner peripheral side as a fixed portion to the stator holder 70, and the protruding portion 205 is formed with a through hole 206 extending in the axial direction. ing.

FIG. 31 is a perspective view showing a state in which the bus bar module 200 is assembled to the stator holder 70, and FIG. 32 is a vertical sectional view of a fixed portion for fixing the bus bar module 200. Please refer to FIG. 12 for the configuration of the stator holder 70 before assembling the bus bar module 200.

In FIG. 31, the bus bar module 200 is provided on the end plate portion 91 so as to surround the boss portion 92 of the inner cylinder member 81. The bus bar module 200 is fixed to the stator holder 70 (inner cylinder member 81) by fastening fasteners 217 such as bolts in a state where the bus bar module 200 is positioned by assembling the inner cylinder member 81 to the support column portion 95 (see FIG. 12). ing.

More specifically, as shown in FIG. 32, the end plate portion 91 of the inner cylinder member 81 is provided with a strut portion 95 extending in the axial direction. Then, the bus bar module 200 is fixed to the support portion 95 by the fastener 217 in a state where the support portion 95 is inserted into the through holes 206 provided in the plurality of protrusion portions 205. In the present embodiment, the bus bar module 200 is fixed by using the retainer plate 220 made of a metal material such as iron. The retainer plate 220 is between the fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted, the pressing portion 223 that presses the upper surface of the annular portion 201 of the bus bar module 200, and the fastened portion 222 and the pressing portion 223. It has a bend portion 224 provided in the.

In the mounted state of the retainer plate 220, the fastener 217 is screwed to the support column 95 of the inner cylinder member 81 with the fastener 217 inserted into the insertion hole 221 of the retainer plate 220. Further, the pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the bus bar module 200. In this case, the retainer plate 220 is pushed downward in the figure as the fastener 217 is screwed into the support column 95, and the annular portion 201 is pressed downward by the pressing portion 223 accordingly. Since the downward pressing force in the figure generated by the screwing of the fastener 217 is transmitted to the pressing portion 223 through the bend portion 224, the pressing is performed by the pressing portion 223 with the elastic force of the bend portion 224. ing.

As described above, an annular protrusion 201a is provided on the upper surface of the annular portion 201, and the tip of the retainer plate 220 on the pressing portion 223 side can come into contact with the protrusion 201a. As a result, it is possible to prevent the downward pressing force of the retainer plate 220 from escaping radially outward. That is, the pressing force generated by the screwing of the fastener 217 is properly transmitted to the pressing portion 223 side.

As shown in FIG. 31, in the assembled state of the bus bar module 200 with respect to the stator holder 70, the input / output terminal 203 is 180 degrees opposite to the inlet opening 86a and the outlet opening 87a leading to the refrigerant passage 85 in the circumferential direction. It is provided at the position where. However, these input / output terminals 203 and the openings 86a and 87a may be provided together at the same position (that is, a close position).

Next, a relay member 230 for electrically connecting the input / output terminal 203 of the bus bar module 200 to an external device outside the rotary electric machine 10 will be described.

As shown in FIG. 1, in the rotary electric machine 10, the input / output terminal 203 of the bus bar module 200 is provided so as to project outward from the housing cover 242, and is connected to the relay member 230 on the outside of the housing cover 242. There is. The relay member 230 is a member that relays the connection between the input / output terminal 203 for each phase extending from the bus bar module 200 and the power line for each phase extending from an external device such as an inverter.

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

The relay member 230 has a main body portion 231 fixed to the housing cover 242 and a terminal insertion portion 232 to be inserted into the through hole 242a of the housing cover 242. The terminal insertion portion 232 has three insertion holes 233 through which the input / output terminals 203 of each phase are inserted one by one. The three insertion holes 233 have long cross-sectional openings, and are formed side by side in directions in which the longitudinal directions are substantially the same.

Three relay bus bars 234 provided for each phase are attached to the main body 231. The relay bus bar 234 is bent and formed in a substantially L shape, and is fixed to the main body 231 by fasteners 235 such as bolts, and the input / output terminal 203 is inserted into the insertion hole 233 of the terminal insertion portion 232. It is fixed to the tip of the bolt by a fastener 236 such as a bolt and a nut.

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

Next, the configuration of the control system that controls the rotary electric machine 10 will be described. FIG. 35 is an electric circuit diagram of the control system of the rotary electric machine 10, and FIG. 36 is a functional block diagram showing a control process by the control device 270.

As shown in FIG. 35, the stator winding 61 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 260 corresponding to a power converter is connected to the stator winding 61. There is. The inverter 260 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 261 and a lower arm switch 262 is provided for each phase. Each of these switches 261,262 is turned on and off by the driver 263, and the phase winding of each phase is energized by the on / off. Each switch 261,262 is composed of a semiconductor switching element such as a MOSFET or an IGBT. Further, to the upper and lower arms of each phase, a charge supply capacitor 264 for supplying the charge required for switching to each switch 261,262 is connected in parallel with the series connection body of the switches 261,262.

One end of the U-phase winding, V-phase winding, and W-phase winding is connected to the intermediate connection point between the switches 261,262 of the upper and lower arms, 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 control device 270 includes a microcomputer including a CPU and various memories, and performs energization control by turning on / off each switch 261,262 based on various detection information in the rotary electric machine 10 and a request for power running drive and power generation. .. The detection information of the rotary electric machine 10 includes, for example, the rotation angle (electric angle information) of the rotor 20 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 270 performs on / off control of each switch 261,262 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or rectangular wave control. The control device 270 may be a built-in control device built in the rotary electric machine 10 or an external control device provided outside the rotary electric machine 10.

By the way, since the rotary electric machine 10 of the present embodiment has a slotless structure (teethless structure), the inductance of the stator 60 is reduced and the electric time constant is reduced, and the electric time constant thereof is reduced. Under the situation where the constant is small, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed. In this respect, since the capacitor 264 for charge supply is connected in parallel to the series connection of the switches 261,262 of each phase, the wiring inductance becomes low, and even in the configuration where the switching speed is increased, an appropriate surge Countermeasures are possible.

The high potential side terminal of the inverter 260 is connected to the positive electrode terminal of the DC power supply 265, and the low potential side terminal is connected to the negative electrode terminal (ground) of the DC power supply 265. The DC power supply 265 is composed of, for example, an assembled battery in which a plurality of single batteries are connected in series. Further, a smoothing capacitor 266 is connected in parallel with the DC power supply 265 to the high potential side terminal and the low potential side terminal of the inverter 260.

FIG. 36 is a block diagram showing a current feedback control process for controlling each phase current of the U, V, and W phases.

In FIG. 36, the current command value setting unit 271 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 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 272 sets the current detection value (three phase currents) by the current sensor provided for each phase as the d-axis in the field direction (direction of an axis of a magnetic field, or field direction). 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 273 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 274 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 273 and 274, 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 275 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. Each of the above units 271 to 275 is a feedback control unit that performs feedback control of the fundamental wave current according to the dq conversion theory, and the command voltages of the U phase, the V phase, and the W phase are the feedback control values.

The operation signal generation unit 276 uses a well-known triangular wave carrier comparison method to generate an operation signal of the inverter 260 based on a three-phase command voltage. Specifically, the operation signal generation unit 276 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 by the power supply voltage and the carrier signal such as the triangular wave signal. Generates an operation signal (duty signal). The switch operation signal generated by the operation signal generation unit 276 is output to the driver 263 of the inverter 260, and the switch 261 and 262 of each phase are turned on and off by the driver 263.

Next, the torque feedback control process will be described. This process is mainly used for the purpose of increasing the output and reducing the loss of the rotary electric machine 10 under operating conditions in which the output voltage of the inverter 260 becomes large, such as in a high rotation region and a high output region. The control device 270 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotary electric machine 10.

FIG. 37 is a block diagram showing torque feedback control processing corresponding to the U, V, and W phases.

The voltage amplitude calculation unit 281 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.

Similar to the dq conversion unit 272, the dq conversion unit 282 converts the current detection value by the current sensor provided for each phase into a d-axis current and a q-axis current. The torque estimation unit 283 calculates the torque estimation value corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. The torque estimation unit 283 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 284 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 284 calculates the voltage phase command using the PI feedback method based on the deviation of the torque estimation value with respect to the power running torque command value or the generated torque command value.

The operation signal generation unit 285 generates an operation signal of the inverter 260 based on the voltage amplitude command, the voltage phase command, and the electric angle θ. Specifically, the operation signal generation unit 285 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 the switch operation signal of the upper and lower arms in each phase is generated by the PWM control based on the magnitude comparison with the carrier signal such as a triangular wave signal. The switch operation signal generated by the operation signal generation unit 285 is output to the driver 263 of the inverter 260, and the switches 261, 262 of each phase are turned on and off by the driver 263.

Incidentally, the operation signal generation unit 285 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. Then, a switch operation signal may be generated.

(Modification example)
Hereinafter, a modified example of the first embodiment will be described.

-The configuration of the magnet 32 in the magnet unit 22 may be changed as follows. In the magnet unit 22 shown in FIG. 38, the direction of the easy-to-magnetize axis is oblique with respect to the radial direction in the magnet 32, and a linear magnet magnetic path is formed along the direction of the easy-to-magnetize axis. That is, in the magnet 32, the direction of the easy axis of magnetization between the magnetic flux acting surface 34a on the stator 60 side (inner in the radial direction) and the magnetic flux acting surface 34b on the anti-stator side (outer in the radial direction) is with respect to the d-axis. It is slanted and is configured to be linearly oriented so as to approach the d-axis on the stator 60 side and away from the d-axis on the anti-stator side in the circumferential direction. Also in this configuration, the magnet path length of the magnet 32 can be made longer than the thickness dimension in the radial direction, and the permeance can be improved.

-It is also possible to use Halbach array magnets in the magnet unit 22.

In each partial winding 151, the bending direction of the crossover 153 may be either inside or outside in the radial direction, and the first crossover 153A is bent toward the core assembly CA in relation to the core assembly CA. Or the first crossover 153A may be bent to the opposite side of the core assembly CA. Further, if the second crossover portion 153B is in a state of straddling a part of the first crossover portion 153A in the circumferential direction on the outer side in the axial direction of the first crossover portion 153A, it can be either inside or outside in the radial direction. It may be folded.

-The partial winding 151 may not have two types of partial windings 151 (first partial winding 151A, second partial winding 151B), but may have one type of partial winding 151. Specifically, the partial winding 151 may be formed so as to form a substantially L-shape or a substantially Z-shape when viewed from the side. When the partial winding 151 is formed in a substantially L shape in a side view, the crossover 153 is bent either inside or outside in the radial direction on one end side in the axial direction, and the crossover portion 153 is radially formed on the other end side in the axial direction. The configuration is such that it is provided without being bent. Further, when the partial winding 151 is formed in a substantially Z shape in a side view, the crossover portion 153 is bent in the opposite directions in the radial direction on one end side in the axial direction and the other end side in the axial direction. In any case, it is preferable that the coil module 150 is fixed to the core assembly CA by the insulating cover covering the crossover portion 153 as described above.

-In the above-mentioned configuration, in the stator winding 61, the configuration in which all the partial windings 151 are connected in parallel for each phase winding has been described, but this may be changed. For example, all the partial windings 151 for each phase winding may be divided into a plurality of parallel connection groups, and the plurality of parallel connection groups may be connected in series. That is, all n partial windings 151 in each phase winding are divided into two sets of parallel connection groups of n / 2 pieces and three sets of parallel connection groups of n / 3 pieces each, and these are connected in series. It may be configured to connect. Alternatively, the stator winding 61 may be configured such that a plurality of partial windings 151 are all connected in series for each phase winding.

The stator winding 61 in the rotary electric machine 10 may have a configuration having two-phase windings (U-phase winding and V-phase winding). In this case, for example, in the partial winding 151, a pair of intermediate conductors 152 are provided one coil pitch apart, and the intermediate conductors 152 in the other one-phase partial winding 151 are provided between the pair of intermediate conductors 152. It suffices if it is configured so that one is arranged.

-It is also possible to embody the rotary electric machine 10 as an inner rotor type surface magnet type rotary electric machine instead of the outer rotor type surface magnet type rotary electric machine. 39 (a) and 39 (b) are diagrams showing the configuration of the stator unit 300 in the case of an inner rotor structure. Of these, FIG. 39 (a) is a perspective view showing a state in which the coil modules 310A and 310B are assembled to the core assembly CA, and FIG. 39 (b) is a partial winding 311A and 311B included in the coil modules 310A and 310B. It is a perspective view which shows. In this example, the core assembly CA is configured by assembling the stator holder 70 to the radially outer side of the stator core 62. Further, a plurality of coil modules 310A and 310B are assembled inside the stator core 62 in the radial direction.

The partial winding 311A has substantially the same configuration as the first partial winding 151A described above, and is bent toward the core assembly CA side (diameter outside) with the pair of intermediate conductor portions 312 and both sides in the axial direction. It has a formed crossover portion 313A. Further, the partial winding 311B has substantially the same configuration as the second partial winding 151B described above, and has a pair of intermediate conductor portions 312 and a crossover portion 313A on both sides in the axial direction in the circumferential direction on the outer side in the axial direction. It has a crossover portion 313B provided so as to straddle the. An insulating cover 315 is attached to the crossover 313A of the partial winding 311A, and an insulating cover 316 is attached to the crossover 313B of the partial winding 311B.

The insulating cover 315 is provided with semicircular recesses 317 extending in the axial direction on the side surface portions on both sides in the circumferential direction. Further, the insulating cover 316 is provided with a protruding portion 318 protruding radially outward from the crossover portion 313B, and a through hole 319 extending in the axial direction is provided at the tip end portion of the protruding portion 318.

FIG. 40 is a plan view showing a state in which the coil modules 310A and 310B are assembled to the core assembly CA. In FIG. 40, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end surface of the stator holder 70. Further, the stator holder 70 has a cooling structure using a liquid refrigerant or air, and it is preferable that a plurality of heat radiation fins are formed on the outer peripheral surface thereof, for example, as an air cooling structure.

In FIG. 40, the insulating covers 315 and 316 are arranged so as to overlap in the axial direction. Further, a recess 317 provided on the side surface portion of the insulating cover 315 and a through hole 319 provided at a central position between one end and the other end in the circumferential direction of the insulating cover 316 in the protruding portion 318 of the insulating cover 316. Are connected in the axial direction, and each part thereof is fixed by a fixing pin 321.

Further, in FIG. 40, the fixing positions of the insulating covers 315 and 316 by the fixing pin 321 are the axial end faces of the stator holder 70 radially outside the stator core 62, and the stator holder 70 has a fixing position. On the other hand, it is configured to be fixed by the fixing pin 321. In this case, since the stator holder 70 is provided with a cooling structure, the heat generated by the partial windings 311A and 311B is easily transferred to the stator holder 70. Thereby, the cooling performance of the stator winding 61 can be improved.

The stator 60 used in the rotary electric machine 10 may have a protrusion (for example, a tooth) extending from the back yoke. Also in this case, it suffices as long as the coil module 150 or the like is assembled to the stator core to the back yoke.

-The rotary electric machine is not limited to the one with a star-shaped connection, but may be one with a Δ connection.

-As the rotary electric machine 10, instead of the rotary field type rotary electric machine in which the field magnet is a rotor and the stator is a stator, a rotary armature type in which the armature is a rotor and the field magnet is a stator. It is also possible to adopt a rotary electric machine.

(Second Embodiment)
Next, the rotary electric machine 400 in the second embodiment will be described. The rotary electric machine 400 of the present embodiment is used as an in-wheel motor of a vehicle. The outline of the rotary electric machine 400 is shown in FIGS. 41 to 45. 41 is a perspective view showing the entire rotary electric machine 400, FIG. 42 is a plan view of the rotary electric machine 400, and FIG. 43 is a vertical cross-sectional view of the rotary electric machine 400 (cross-sectional view taken along lines 43-43 of FIG. 42). 44 is a cross-sectional view of the rotary electric machine 400 (a cross-sectional view taken along the line 44-44 in FIG. 43), and FIG. 45 is an exploded cross-sectional view showing the components of the rotary electric machine 400 in an exploded manner.

The rotary electric machine 400 is an inner rotor type surface magnet type rotary electric machine. The rotary electric machine 400 is roughly classified into a rotary electric machine main body having a rotor 410 and a stator unit 420 including a stator 430, and an inner housing 470 fixed to the stator unit 420 is not shown. The wheel support member 401 fixed to the vehicle body and fixed to the rotor 410 is fixed to the wheel of a wheel (not shown). In the present embodiment, the wheel wheel coupled to the wheel support member 401 is an object to be rotated by the rotary electric machine 400. The inner housing 470 and the wheel support member 401 are required to have high strength, and are made of, for example, a steel material.

The configuration of the rotor 410 will be described below.

As shown in FIG. 45, the rotor 410 has a substantially cylindrical rotor carrier 411 and an annular magnet unit 412 fixed to the rotor carrier 411. The rotor carrier 411 has a cylindrical portion 413 having a cylindrical shape and an end plate portion 414 provided at one end in the axial direction of the tubular portion 413, and is annular to the radial outer side of the tubular portion 413. The magnet unit 412 is fixed to the. The rotor carrier 411 functions as a magnet holding member. The end plate portion 414 has a cylindrical boss portion 415 extending toward the magnet unit 412 in the axial direction at the center thereof. A through hole 415a is formed in the boss portion 415. In the rotor carrier 411, the tubular portion 413 and the boss portion 415 extend in the same axial direction from the end plate portion 414 and are provided so as to be double inside and outside.

The magnet unit 412 is composed of a plurality of permanent magnets arranged so that the polarities alternate along the circumferential direction of the rotor 410. The magnet unit 412 corresponds to the "magnet portion". As a result, the magnet unit 412 has a plurality of magnetic poles in the circumferential direction. The magnet unit 412 has the configuration described as the magnet unit 22 in FIGS. 6 and 7 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 configured by using a sintered neodymium magnet having a density Br of 1.0 [T] or more.

Similar to the magnet unit 22 of FIG. 7, the magnet unit 412 has a plurality of polar anisotropy permanent magnets, and each of these magnets has a d-axis side (a portion closer to the d-axis) and a q-axis side. The direction of the easy-magnetization axis is different from that of (the part closer to the q-axis), the direction of the easy-magnetization axis is parallel to the d-axis on the d-axis side, and the direction of the easy-magnetization axis is orthogonal to the q-axis on the q-axis side. It is oriented toward magnetizing. In this case, an arcuate magnetic path is formed along the direction of the easy magnetization axis. In short, each magnet is configured to be 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.

It is preferable that the magnets of the magnet unit 412 are fixed to each other by adhesion or the like in the circumferential direction, and a fixing member such as a yarn is attached to the outer peripheral portion to be integrated. Further, it is preferable that an annular end plate member is attached to the axial end portion of each magnet.

Further, the rotor 410 has a cylindrical rotating shaft 416 provided so as to extend from the end plate portion 414 of the rotor carrier 411 to the side opposite to the magnet unit 412. The rotary shaft 416 is concentric with the cylindrical portion 413 and the boss portion 415 of the rotor carrier 411, and is fixed to the end plate portion 414 by a fixing tool 417 such as a bolt. The rotary shaft 416 has an inner diameter larger than the inner diameter of the boss portion 415. Therefore, the end plate portion 414 of the rotor carrier 411 has a collar-shaped protruding portion that protrudes inward in the radial direction on the inner peripheral side of the rotating shaft 416.

A wheel support member 401 is fixed to the other end of the rotary shaft 416 in the axial direction opposite to the rotor carrier 411 by a fixture 402 such as a bolt, and the wheel support member 401 rotates together with the rotor 410. The rotary shaft 416 may be formed of, for example, a steel material.

Next, the configuration of the stator unit 420 will be described. FIG. 46 is a perspective view showing the entire stator unit 420, FIG. 47 is an exploded sectional view of the stator unit 420, and FIG. 48 is a vertical sectional view of the stator unit 420.

The stator unit 420, as an outline thereof, has a stator 430, an outer housing 450 provided so as to surround the stator 430, and a wiring module 460. The stator 430 has a stator winding 431 and a stator core 432. The outer housing 450 has a bottomed cylindrical shape, and the inner housing 470 is assembled to the open end side, which is one end side in the axial direction. The outer housing 450 corresponds to the "first housing", and the inner housing 470 corresponds to the "second housing".

In the stator 430, the stator winding 431 has a three-phase phase winding, and each phase phase winding is composed of a plurality of partial windings 441. The partial winding 441 is provided according to the number of poles of the rotary electric machine 400, and a plurality of partial windings 441 are connected in parallel or in series for each phase. In the present embodiment, the number of magnetic poles is 24, but the number is arbitrary.

As shown in FIG. 48, the stator 430 corresponds to a portion corresponding to the coil side CS radially facing the stator core 432 in the axial direction and a coil end CE corresponding to the axially outer side of the coil side CS. It has a part to be used. The coil side CS is also a portion that faces the magnet unit 412 of the rotor 410 in the radial direction. The partial winding 441 is assembled radially inside the stator core 432. In this case, the partial winding 441 is assembled in a state where both ends in the axial direction are projected outward in the axial direction (that is, the coil end CE side) from the stator core 432.

FIG. 49 is a perspective view showing the configuration of the partial winding 441. The partial winding 441 is configured by winding the conducting wire material in multiple turns. The partial winding 441 has a pair of intermediate conductor portions 442 provided in parallel and linearly with each other, and a pair of crossover portions 443 and 444 connecting the pair of intermediate conductor portions 442 at both ends in the axial direction. , These pair of intermediate conductor portions 442 and the pair of crossover portions 443 and 444 form an annular shape. The pair of intermediate conductors 442 are provided so as to be separated by a predetermined coil pitch, and the intermediate conductors 442 of the partial winding 441 of the other phase can be arranged between the pair of intermediate conductors 442 in the circumferential direction. It has become. In the present embodiment, the pair of intermediate conductors 442 are provided so as to be separated by two coil pitches, and one intermediate conductor 442 in the other two-phase partial winding 441 is arranged between the pair of intermediate conductors 442. It is configured to be.

In the partial winding 441, each intermediate conductor portion 442 is provided with a sheet-shaped insulating coating 445 in a covered state. The configuration of the insulating coating 445 is the same as that of the insulating coating 157 of the partial winding 151 in the first embodiment described above. That is, the insulating coating 445 uses a film material having at least the length of the insulating coating range in the intermediate conducting wire portion 442 as the axial dimension, and the film material is wound around the intermediate conducting wire portion 442. It is provided. Further, the insulating coating body 445 is provided in a state where the peripheral end portions of the film material are overlapped with each other around the intermediate conductor portion 442.

Each of the crossover portions 443 and 444 on both sides in the axial direction is provided as a portion corresponding to the coil end CE (see FIG. 48), and one of the crossover portions 443 and 444 of each crossover portion 443 is formed to be bent in the radial direction. ing. That is, in the partial winding 441, the coil end portion (crossover portion) is bent in the radial direction on one end side in the axial direction, and the coil end portion (crossover portion) is not bent in the radial direction on the other end side in the axial direction. , It has a substantially L shape when viewed from the side.

In each partial winding 441, the intermediate conductor portion 442 is provided as a coil side conductor portion arranged one by one in the circumferential direction in the coil side CS. Further, each crossover portion 443, 444 is provided as a coil end lead wire portion for connecting the intermediate lead wire portions 442 of the same phase at two positions different in the circumferential direction in the coil end CE.

In the partial winding 441, similarly to the above-mentioned partial winding 151, the conductor material is formed by being wound in multiple directions so that the cross section of the conductor assembly portion becomes a quadrangle. Speaking of the intermediate conductor portion 442, the conductors are arranged in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction, so that the cross section is formed to have a substantially rectangular shape (see FIG. 20). ).

It is preferable that the partial winding 441 has an insulating cover attached to the coil end portion (crossover portion), and the insulating cover ensures the insulation between the coil end portions of each partial winding 441. The insulating cover is, for example, as shown in FIGS. 19A and 19B, and is assembled radially to the crossover 443 of the partial winding 441, or as shown in FIGS. 22A and 22B. It is preferable that the partial winding 441 is assembled to the crossover 443 from the axial direction.

As shown in FIG. 47, in the stator 430, a plurality of partial windings 441 are arranged side by side in the circumferential direction. Specifically, the plurality of partial windings 441 are half of each and the assembly direction is reversed in the axial direction and the radial direction, and the half of the partial windings 441 are on the bending side on one end side in the axial direction (upper side in the figure). The crossover 443 is assembled in a state of being bent outward in the radial direction, and the other half of the partial windings 441 have the crossover 443 on the bending side inward in the radial direction on the other end side in the axial direction (lower side in the figure). It can be assembled in a bent state. In this case, interference between the crossover portions 443 and 444 is avoided at both ends in the axial direction, and the intermediate conductor portions 442 are arranged so as to line up in the circumferential direction in that state. In reality, an insulating coating body 445 is interposed between the intermediate conducting wire portions 442, and the insulating coating body 445 insulates each other (interphase insulation).

The stator winding 431 is formed in an annular shape by a plurality of partial windings 441, and the stator core 432 is assembled on the radial outer side thereof. The stator core 432 is configured as a core sheet laminated body in which core sheets made of magnetic steel sheets, which are magnetic materials, are laminated in the axial direction, and has a cylindrical shape having a predetermined thickness in the radial direction. The inner peripheral surface and the outer peripheral surface of the stator core 432 have a curved surface without unevenness. The stator core 432 functions as a back yoke. The stator core 432 is configured by, for example, a plurality of core sheets punched and formed in the shape of an annulus plate and laminated in the axial direction. However, a stator core 432 having a helical core structure may be used.

The stator winding 431 may be assembled to the stator core 432 by individually assembling the partial winding 441 to the stator core 432, or an annular stator may be assembled by the plurality of partial windings 441. After forming the winding 431, the stator winding 431 may be assembled to the stator core 432.

As shown in FIG. 48, the outer housing 450 has a cylindrical outer cylinder member 451 and an inner cylinder member 452, respectively, with the outer cylinder member 451 being radially outside and the inner cylinder member 452 being radially inside. It is composed by assembling them together. Each of these members 451 and 452 is made of a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

The inner diameter of the outer cylinder member 451 is larger than the outer diameter of the inner cylinder member 452. Therefore, in a state where the inner cylinder member 452 is assembled inside the outer cylinder member 451 in the radial direction, an annular gap is formed between the respective members 451 and 452, and the gap space allows the refrigerant such as cooling water to flow. It is a refrigerant passage 453 to be made to flow. The refrigerant passage 453 is provided in an annular shape in the circumferential direction of the outer housing 450. Although not shown, the outer cylinder member 451 is formed with an inlet side passage which is an inlet of the refrigerant and an outlet side passage which is an outlet of the refrigerant, and the refrigerant flowing from the inlet side passage is a refrigerant passage. It flows in the circumferential direction through 453 and then flows out from the exit side passage.

As shown in FIG. 47, the outer cylinder member 451 and the inner cylinder member 452 have a flange extending radially outward on one end side in the axial direction, and by assembling a fixture such as a bolt to the flange, the outer cylinder member 451 and the inner cylinder member 452 are attached to the outside. The cylinder member 451 and the inner cylinder member 452 are integrally connected. The outer cylinder member 451 may be provided with heat radiation fins as a heat radiation portion so as to extend radially outward.

A stator core 432 is assembled inside the outer housing 450 in the radial direction, specifically, inside the inner cylinder member 452 in the radial direction. Assembling the stator core 432 to the outer housing 450 (inner cylinder member 452) is performed by, for example, bonding. Further, the stator core 432 may be fitted and fixed to the outer housing 450 with a predetermined tightening margin by shrink fitting or press fitting.

Further, as shown in FIG. 48, the outer cylinder member 451 has a bottom portion 454 on one end side in the axial direction, and a through hole 455 is formed in the center of the bottom portion 454. The rotation shaft 416 of the rotor 410 can be inserted into the through hole 455 (see FIG. 43).

The bottom portion 454 of the outer cylinder member 451 is provided with an annular groove 456 so as to extend in the axial direction from the end face on the inner side in the axial direction. The annular groove 456 is a coil end accommodating portion for accommodating the coil end portion of the stator winding 431 when the stator 430 is assembled to the outer housing 450. That is, as described above, the stator winding 431 is composed of a plurality of partial windings 441, and the coil end portion (crossing portion) is bent in the radial direction on one end side in the axial direction of the partial winding 441, and the shaft. On the other end side in the direction, the coil end portion (crossing portion) is not bent in the radial direction. In this case, a part of the coil end portion in the partial winding 441, that is, the crossover portion 444 which is not bent in the radial direction protrudes in the axial direction, and the protruding portion is accommodated in the annular groove 456. ..

Next, the wiring module 460 will be described. The wiring module 460 is a winding connection member electrically connected to each partial winding 441 in the stator winding 431, and the wiring module 460 allows the partial windings 441 of each phase to be connected in parallel or in series for each phase. And the phase windings of each phase are connected to the neutral point. The wiring module 460 is provided on one end side of both ends of the stator winding 431 in the axial direction, specifically on the side opposite to the end plate portion 414 of the rotor carrier 411 (see FIG. 43).

As shown in FIG. 47, the wiring module 460 has an annular portion 461 forming an annular shape and a plurality of connection terminals 462 provided side by side in the circumferential direction along the annular portion 461. The annular portion 461 is formed in an annular shape by, for example, an insulating member such as a resin. Wiring for each phase and wiring for the neutral point (both are not shown) are embedded in the annular portion 461, and a connection terminal 462 is electrically connected to each of these wirings. The connection terminal 462 is provided for each partial winding 441 and is fixed in a direction extending in the axial direction.

As shown in FIG. 46, in the stator winding 431, crossover portions 444 that are not bent in the radial direction are arranged side by side in an annular shape, and a wiring module 460 is provided so as to surround the crossover portions 444 from the outside in the radial direction. Has been done. That is, the annular portion 461 of the wiring module 460 is formed to have a larger diameter than the annular portion formed by the crossover portions 444 arranged in the circumferential direction. The wiring module 460 is provided with fixing pins 463 at predetermined intervals in the circumferential direction as fixing portions for fixing the wiring module 460. The fixing pin 463 extends in the axial direction, and one end thereof is fixed to the stator core 432 or the outer housing 450, so that the wiring module 460 is attached by the stator unit 420.

FIG. 50 is a perspective view showing the configuration of the inner housing 470. The inner housing 470 is provided on one end side in the axial direction and is fixed to the outer housing 450 on the large diameter portion 471, and is provided on the other end side in the axial direction and is provided on the other end side in the axial direction and supports the rotating shaft 416 of the rotor 410. An intermediate cylinder portion 473 having a diameter of 472 and having a diameter smaller than that of the large diameter portion 471 and a diameter larger than that of the fixed shaft portion 472 is provided between the large diameter portion 471 and the fixed shaft portion 472 in the axial direction. There is. The fixed shaft portion 472 may have a hollow portion extending in the axial direction as shown in the figure. The intermediate cylinder portion 473 corresponds to the "cylindrical portion".

The large diameter portion 471 has a diameter dimension corresponding to the coil end portion (crossing portion) on one end side in the axial direction of the stator winding 431 and the wiring module 460. The large diameter portion 471 is provided with an annular accommodating portion 474 that accommodates the coil end portion of the stator winding 431 and the wiring module 460. The accommodating portion 474 is provided as an annular groove portion that opens toward the center side of the rotary electric machine 400 in the axial direction.

Further, the large diameter portion 471 is provided with a mounting portion 475 for mounting the terminal block 480. The mounting portion 475 has a hollow portion 476 that protrudes radially outward and extends radially in the large diameter portion 471, and the hollow portion 476 communicates with the accommodating portion 474. The terminal block 480 is a wiring connection portion that is electrically connected to the wiring module 460, and power can be input / output for each phase by connecting a power line for each phase extending from an external device (not shown). It has become. In the state where the terminal block 480 is attached to the mounting portion 475, the wiring terminal 481 of the terminal block 480 is electrically connected to the wiring module 460 by a relay line (not shown) via the hollow portion 476 of the mounting portion 475. There is. The terminal block 480 can be separated from the inner housing 470 by a screw or the like, and the terminal block 480 can be changed, for example, when the specifications such as electric power are different.

In the present embodiment, the wiring module 460 is provided on the radial outside of the coil end portion of the stator winding 431 (the radial outside of the crossing portion 444). Therefore, the wiring module 460 and the terminal block 480 can be connected without straddling the coil end portion (crossover portion 444) of the stator winding 431 in the radial direction.

In the inner housing 470, the fixed shaft portion 472 is formed with an outer dimension smaller than the inner diameter dimension of the rotary shaft 416 of the rotor 410, and the intermediate cylinder portion 473 is formed with an outer dimension smaller than the inner diameter dimension of the rotor carrier 411. Has been done.

Further, in the inner housing 470, the fixed shaft portion 472 and the intermediate cylinder portion 473 are closed by the intermediate end plate portion 477, and the intermediate end plate portion 477 has an annular shape for fixing the resolver 493, which will be described later. 478 is formed.

Next, the overall configuration of the rotary electric machine 400 including the rotor 410, the stator unit 420, and the inner housing 470 described above will be described.

As shown in FIG. 43, a bearing 491 is attached to the fixed shaft portion 472 of the inner housing 470, and the rotary shaft 416 of the rotor 410 is rotatably supported by the bearing 491. The bearing 491 is, for example, a radial ball bearing, and has an outer ring and an inner ring, and a plurality of balls arranged between the outer ring and the inner ring. The inner ring of the bearing 491 is assembled on the fixed shaft portion 472 side, and the outer ring is assembled on the rotating shaft 416 side. The bearing 491 may be a roller bearing (needle-shaped roller bearing, conical roller bearing) in which rollers are used instead of balls as rolling elements. Further, as the bearing 491, two bearings may be arranged side by side in the axial direction.

The rotating shaft 416 is provided so as to extend from the end plate portion 414 of the rotor carrier 411 to the opposite side of the magnet unit 412 in the axial direction, and the bearing 491 is provided so as to extend in the axial direction from the end plate portion 414 to the anti-magnet unit. It is provided at a position on the side. In this case, the bearing 491 is provided at a position that does not overlap in the radial direction with respect to the magnet unit 412.

Here, the outer housing 450 is made of a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP), and the inner housing 470 is made of, for example, a steel material. That is, the outer housing 450 is a member having higher thermal conductivity than the inner housing 470, and the inner housing 470 is a member having higher strength than the outer housing 450. In this case, the outer housing 450 surrounding the stator 430 gives priority to heat dissipation, and the inner housing 470 that supports the rotating shaft 416 via the bearing 491 gives priority to strength. As a result, the heat generated by the stator 430 is suitably released from the outer housing 450, and the supporting strength of the rotating shaft 416 in the inner housing 470 can be ensured.

Further, on the radial outer side of the rotor 410, the stator unit 420 is arranged so as to surround the rotor 410. The stator unit 420 is assembled to the outer peripheral side of the rotor 410 in a state where one end side (open end side) in the axial direction of the outer housing 450 is fixed to the large diameter portion 471 of the inner housing 470 by a fixing tool such as a bolt. ing. That is, the inner housing 470 is provided so as to close the open end on the open end side of the outer housing 450.

An annular sliding seal 492 is provided between the bottom portion 454 of the outer cylinder member 451 and the rotating shaft 416 in the outer housing 450. That is, as a support structure for the rotary shaft 416 with respect to the stator unit 420 and the inner housing 470, a bearing 491 is provided on the inner peripheral surface side of the rotary shaft 416 between the fixed shaft portion 472 of the inner housing 470 and the rotary shaft. On the outer peripheral surface side of the 416, a sliding seal 492 is provided between the outer housing 450 and the bottom portion 454. As a result, the rotating shaft 416 can rotate relative to the fixed shaft portion 472 of the inner housing 470 by the bearing 491, and can rotate relative to the bottom portion 454 of the outer housing 450 by the sliding seal 492. .. As the sliding seal 492, an annular seal made of synthetic resin, rubber, or the like can be used.

In a state where the rotor 410 and the inner housing 470 are integrated via the bearing 491, an annular closed space SA surrounded by the rotor carrier 411 and the inner housing 470 is formed on the inner peripheral side of the rotor carrier 411. It is formed. A resolver 493 as a rotation sensor is provided in the closed space SA. The resolver 493 has an annular shape, and has a resolver stator fixed to a protruding portion 478 of an inner housing 470 which is a fixed object and a resolver rotor fixed to a boss portion 415 of a rotor carrier 411 which is a rotating object. Have. The resolver rotors are arranged so as to face each other inside the resolver stator in the radial direction.

Here, the fixed shaft portion 472 of the inner housing 470 is provided in a state of penetrating the through hole 415a provided in the end plate portion 414 of the rotor carrier 411, and is provided on both sides of the end plate portion 414 in the axial direction. One side is the first shaft portion 472a, and the other side is the second shaft portion 472b (see FIG. 45). Then, of the first shaft portion 472a and the second shaft portion 472b, a resolver 493 is provided on the outside of the first shaft portion 472a which is radially inside the rotor carrier 411 (magnet unit 412), and the second shaft portion is provided. A bearing 491 is provided on the outside of the 472b. In this case, the area on the first shaft portion 472a side and the area on the second shaft portion 472b side are partitioned in the axial direction by the end plate portion 414, and the influence of the bearing 491 on the resolver 493 is suppressed. ing.

Then, with the stator unit 420 and the inner housing 470 assembled to the rotor 410, the wheel support member 401 is fixed to one end in the axial direction by a fixture 402 such as a bolt.

In the rotary electric machine 400, the intermediate cylinder portion 473 of the inner housing 470 is arranged so as to face the inner peripheral surface (rotor inner peripheral surface) of the rotor carrier 411 in a close state. The radial inside of the intermediate cylinder portion 473 is a space portion SX opened on the opposite side of the fixed shaft portion 472 in the axial direction. In this case, it is preferable that a mounting structure such as a knuckle or a link for mounting the rotary electric machine 400 on the vehicle body side is arranged in the space portion SX.

Further, inside the rotor carrier 411 in the radial direction, the region where the inner peripheral surface (rotor inner peripheral surface) of the rotor carrier 411 and the intermediate cylinder portion 473 face each other is a lubricating oil path through which the lubricating oil passes. .. In this case, it is preferable that the lubricating oil flows along the path of arrow Y shown in FIG. That is, the lubricating oil flows into the inner space of the rotary electric machine 400 from the inlet portion provided in the large diameter portion 471 of the inner housing 470. Then, after passing the lubricating oil through the first region where the rotor carrier 411 and the intermediate cylinder portion 473 face each other and the second region where the rotor carrier 411 and the fixed shaft portion 472 face each other, the inner housing 470 Lubricating oil may be discharged from the outlet provided in the large diameter portion 471. In the first region, the lubricating oil flows in the circumferential direction in addition to the axial direction.

According to the present embodiment described in detail above, the following excellent effects can be obtained.

In the rotary electric machine 400, the rotation shaft 416 is rotatably supported via the bearing 491 by the inner housing 470 of the outer housing 450 and the inner housing 470, that is, the housing not on the side surrounding the stator 430. In this case, in the outer housing 450 provided so as to surround the stator 430, the demand for strength is relaxed as compared with the inner housing 470. Therefore, in the outer housing 450, the degree of freedom in design is increased by relaxing the strength requirement, and it becomes possible to easily meet the request for improvement of heat dissipation and weight reduction.

The outer housing 450 surrounding the stator 430 gives priority to heat dissipation, and the inner housing 470 that supports the rotating shaft 416 via the bearing 491 gives priority to strength. As a result, the heat generated by the stator 430 can be suitably released from the outer housing 450, and the supporting strength of the rotating shaft 416 in the inner housing 470 can be secured. Further, although the weight of the high-strength material tends to be heavy, since only the inner housing 470 of each housing is used as a high-strength member, the weight of the rotary electric machine 400 can be reduced. In this case, the degree of freedom in design regarding heat dissipation and weight can be improved in the rotary electric machine 400.

A bearing 491 is provided in the hollow portion of the rotating shaft 416 at a position on the anti-magnet unit side of the end plate portion 414 of the rotor carrier 411 in the axial direction. In this case, by providing the bearing 491 at a position that does not overlap in the radial direction with respect to the magnet unit 412, the diameter of the magnet unit 412 is compared with the configuration in which the bearing 491 is provided at a position that overlaps in the radial direction with respect to the magnet unit 412. The area inside the direction can be increased. As a result, sensors, electric parts, a mounting structure for mounting a rotary electric machine, and the like can be arranged in a region inside the magnet unit 412 in the radial direction, and the region can be effectively used. Further, in the rotary electric machine 400 as an in-wheel motor, the bearing 491 is positioned appropriately while taking into consideration that a load acts on the rotary shaft 416 at the axial end portion (tip portion) on the opposite side of the end plate portion 414. Can be placed in.

In the fixed shaft portion 472 of the inner housing 470, the portions on both sides of the rotor carrier 411 with the end plate portion 414 sandwiched between them are the first shaft portion 472a and the second shaft portion 472b, respectively, and the area on the first shaft portion 472a side. The area on the side of the second shaft portion 472b is partitioned in the axial direction by the end plate portion 414. Then, a resolver 493 was provided on the outside of the first shaft portion 472a, and a bearing 491 was provided on the outside of the second shaft portion 472b. In this case, the influence of the bearing 491 on the resolver 493 can be suppressed.

Inside the rotor carrier 411 in the radial direction, the resolver 493 was placed in the closed space SA formed by the rotor carrier 411 and the inner housing 470. In this case, since the resolver 493 is isolated from the outside of the rotary electric machine 400, the installation environment of the resolver 493 can be kept good. For example, it is possible to suppress the adhesion of foreign matter to the resolver 493 and the water exposure.

The rotating shaft 416 can be rotated relative to the fixed shaft portion 472 of the inner housing 470 by the bearing 491, and can be rotated relative to the bottom portion 454 of the outer housing 450 by the sliding seal 492. As a result, the rotary shaft 416 is rotatably supported by the housings 450 and 470 from the inside and the outside in the radial direction, respectively, and a support structure that enables appropriate support of the rotary shaft 416 can be realized.

Since the sliding seal 492 is used instead of the bearing as the support structure of the rotary shaft 416 for the outer housing 450, it is considered that the support strength requirement for the outer housing 450 is relatively small, and the heat dissipation performance of the outer housing 450 deteriorates. Is suppressed.

In the inner housing 470, an intermediate cylinder portion 473 having a diameter larger than that of the fixed shaft portion 472 is opposed to the inner peripheral surface (rotor inner peripheral surface) of the rotor carrier 411 in a close state, and the intermediate cylinder portion 473 is radially oriented. The inside is a space portion SX opened on the opposite side of the fixed shaft portion 472 in the axial direction. In this case, the inner peripheral side of the rotor carrier 411 is covered from the inside by the intermediate cylinder portion 473 of the inner housing 470 to partition the outside from the outside, and the space portion SX is secured in the intermediate cylinder portion 473 so that the space portion SX can be effectively used. It is supposed to be.

The region where the inner peripheral surface (rotor inner peripheral surface) of the rotor carrier 411 and the intermediate cylinder portion 473 of the inner housing 470 face each other was used as a lubricating oil path through which the lubricating oil passes. In this case, by limiting the region through which the lubricating oil passes inside the rotary electric machine 400 by the intermediate cylinder portion 473 of the inner housing 470, the lubricating oil can be suitably supplied.

In the rotary electric machine 400 as an in-wheel motor, the stator 430 and the housing that holds the stator are fixed to the vehicle body, and the housing receives the vehicle weight. On that premise, in the present embodiment, of the outer housing 450 held around the stator 430 and the inner housing 470 provided on the open end side of the outer housing 450, the inner housing 470 receives the vehicle weight. Therefore, the inner housing 470 can be configured to give priority to the load capacity. Further, in the outer housing 450, it is not necessary to receive the weight of the vehicle, and a high heat dissipation material can be used with priority given to heat dissipation.

(Modified example of the second embodiment)
The configuration of the rotary electric machine 400 may be changed as shown in FIG. 52. In the rotary electric machine 400 of FIG. 52, the position of the resolver 493 is changed, and the resolver 493 is attached to the tip of the fixed shaft portion 472 of the inner housing 470. In this case, it is not necessary to secure the installation area of the resolver 493 in the closed space SA, and the intermediate end plate portion 477 can be brought closer to the end plate portion 414 of the rotor carrier 411. Therefore, as compared with the configuration of FIG. 43, the intermediate cylinder portion 473 of the inner housing 470 can be expanded in the axial direction. That is, the intermediate cylinder portion 473 and the intermediate end plate portion 477 of the inner housing 470 are configured to face each other in close proximity to the rotor carrier 411. Thereby, in the inner housing 470, the volume of the space portion SX in the intermediate cylinder portion 473 can be expanded.

In the above configuration, in the rotor 410, the rotor carrier 411 and the rotary shaft 416 are used as separate members, and the rotary shaft 416 is fixed to the end plate portion 414 of the rotor carrier 411 by a fixture 417. , This may be changed so that the rotor carrier 411 and the rotating shaft 416 are integrally molded.

-In the rotary electric machine 400, as the cooling structure of the outer housing 450, a cooling structure (water cooling structure) by circulating the refrigerant in the refrigerant passage 453 may not be provided, but only an air cooling structure such as an air cooling fin may be provided.

-The configuration of the stator winding 431 may be changed. For example, instead of the centralized winding structure using a plurality of partial windings 441, the stator winding 431 may be configured by a distributed winding structure such as wave winding. Further, in the stator 430, instead of the slotless structure in which the stator core 432 is not provided with a slot, a slot may be provided in the stator core 432 and the stator winding 431 may be wound around the slot.

-The use of the rotary electric machine 400 may be other than the traveling motor of the vehicle, and may be a rotary electric machine widely used for moving objects including aircraft, and a rotary electric machine used for industrial or household electric equipment. ..

The disclosure in this specification is not limited to the exemplified embodiments. Disclosures include exemplary embodiments and modifications by those skilled in the art based on them. For example, the disclosure is not limited to the parts and / or combinations of elements shown in the embodiments. Disclosure can be carried out in various combinations. The disclosure can have additional parts that can be added to the embodiment. 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 description.

Claims (9)

1. A rotor (410) having a magnet portion (412) arranged in an annular shape, and
   With a stator (430) having a polyphase stator winding (431),
   An inner rotor type rotary electric machine (400) in which the rotor is arranged radially inside the stator.
   A bottomed cylindrical first housing (450) provided so as to surround the stator and having a bottom portion (454) on the first end side in the axial direction.
   A second housing (470) provided so as to close the open end of the first housing on the second end side opposite to the first end of the first housing is provided.
   The rotor has a cylindrical rotating shaft (416) extending in the axial direction.
   The second housing has a fixed shaft portion (472) inserted into the hollow portion of the rotating shaft, and rotatably supports the rotating shaft between the fixed shaft portion and the rotating shaft. A rotary electric machine provided with a bearing (491).
2. The first housing is a member having higher thermal conductivity than the second housing.
   The rotary electric machine according to claim 1, wherein the second housing is a member having higher strength than the first housing.
3. The rotor has a rotor carrier (411) that supports the magnet portion.
   The rotor carrier has an end plate portion (414) on one end side in the axial direction.
   The rotating shaft is provided so as to extend from the end plate portion to the opposite side of the magnet portion in the axial direction.
   The bearing is provided in the hollow portion of the rotating shaft at a position closer to the anti-magnet portion than the end plate portion in the axial direction, and the rotating shaft is rotatably supported by the bearing.
   The rotary electric machine according to claim 1 or 2, wherein a rotating object to which rotation is applied by the rotary electric machine can be coupled to an axial end portion of the rotating shaft opposite to the end plate portion.
4. The fixed shaft portion is provided in a state of penetrating a through hole (415a) provided in the end plate portion, and one of both sides of the end plate portion in the axial direction is the first shaft portion (472a) and the other. The side is the second shaft portion (472b),
   A rotation sensor (493) for detecting the rotation of the rotor is provided on the outside of the first shaft portion, which is the radial inner side of the magnet portion, among the first shaft portion and the second shaft portion, and the second shaft portion is provided. The rotary electric machine according to claim 3, wherein the bearing is provided on the outside of the portion.
5. A closed space (SA) surrounded by the second housing and the rotor carrier is formed inside the magnet portion in the rotor in the radial direction.
   The rotary electric machine according to claim 3 or 4, wherein a rotation sensor (493) for detecting the rotation of the rotor is arranged in the closed space.
6. A claim that the rotating shaft is inserted through a through hole (455) provided in the bottom portion of the first housing, and a sliding seal (492) is provided between the bottom portion and the rotating shaft. The rotary electric machine according to any one of 1 to 5.
7. The second housing has a cylindrical portion (473) having a diameter larger than that of the fixed shaft portion.
   The cylindrical portion is arranged so as to face the inner peripheral surface of the rotor, which is radially inside the magnet portion, in a close state.
   The rotary electric machine according to any one of claims 1 to 6, wherein the radial inside of the cylindrical portion is a space portion opened on the opposite side of the fixed shaft portion in the axial direction.
8. The rotary electric machine according to claim 7, wherein the region where the inner peripheral surface of the rotor and the cylindrical portion face each other in the radial inside of the magnet portion of the rotor is a lubricating oil path through which the lubricating oil passes.
9. A rotary electric machine used as an in-wheel motor integrally installed on the wheels of a vehicle.
   The rotation according to any one of claims 1 to 8, wherein the second housing can be fixed to the vehicle body, and the rotating shaft can be integrally rotated with the wheel by being fixed to the wheel. Electric.

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