WO2022181473A1 - 回転電機及び回転電機の製造方法 - Google Patents
回転電機及び回転電機の製造方法 Download PDFInfo
- Publication number
- WO2022181473A1 WO2022181473A1 PCT/JP2022/006600 JP2022006600W WO2022181473A1 WO 2022181473 A1 WO2022181473 A1 WO 2022181473A1 JP 2022006600 W JP2022006600 W JP 2022006600W WO 2022181473 A1 WO2022181473 A1 WO 2022181473A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- axis
- magnet
- magnetic pole
- magnets
- magnetic
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 238000000034 method Methods 0.000 title claims description 17
- 230000002093 peripheral effect Effects 0.000 claims abstract description 118
- 230000004907 flux Effects 0.000 claims abstract description 80
- 230000005415 magnetization Effects 0.000 claims abstract description 66
- 239000000696 magnetic material Substances 0.000 claims abstract description 18
- 238000004804 winding Methods 0.000 claims description 205
- 238000005452 bending Methods 0.000 claims description 20
- 238000013459 approach Methods 0.000 claims description 15
- 239000004020 conductor Substances 0.000 description 95
- 230000007704 transition Effects 0.000 description 48
- 239000000463 material Substances 0.000 description 32
- 230000004048 modification Effects 0.000 description 29
- 238000012986 modification Methods 0.000 description 29
- 238000010586 diagram Methods 0.000 description 28
- 238000012545 processing Methods 0.000 description 11
- 239000003507 refrigerant Substances 0.000 description 11
- 239000000853 adhesive Substances 0.000 description 10
- 230000001070 adhesive effect Effects 0.000 description 10
- 230000008859 change Effects 0.000 description 10
- 238000001514 detection method Methods 0.000 description 10
- 230000000694 effects Effects 0.000 description 9
- 238000003825 pressing Methods 0.000 description 9
- 238000003780 insertion Methods 0.000 description 7
- 230000037431 insertion Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000001816 cooling Methods 0.000 description 6
- 230000007935 neutral effect Effects 0.000 description 6
- 238000010248 power generation Methods 0.000 description 6
- 239000012790 adhesive layer Substances 0.000 description 5
- 238000006073 displacement reaction Methods 0.000 description 5
- 238000009826 distribution Methods 0.000 description 5
- 230000006870 function Effects 0.000 description 5
- 230000004323 axial length Effects 0.000 description 4
- 239000003990 capacitor Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000002826 coolant Substances 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000015654 memory Effects 0.000 description 3
- 239000011295 pitch Substances 0.000 description 3
- 229910052720 vanadium Inorganic materials 0.000 description 3
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000004590 computer program Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000010349 pulsation Effects 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000004065 semiconductor Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 230000007274 generation of a signal involved in cell-cell signaling Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910001172 neodymium magnet Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920003207 poly(ethylene-2,6-naphthalate) Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920006290 polyethylene naphthalate film Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001172 regenerating effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/18—Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/22—Rotating parts of the magnetic circuit
- H02K1/27—Rotor cores with permanent magnets
- H02K1/2786—Outer rotors
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
Definitions
- the disclosure in this specification relates to a rotating electric machine and a manufacturing method of the rotating electric machine.
- the magnet is fixed and prevented from rotating by providing unevenness on the back surface of the magnet (peripheral surface opposite to the armature side) and engaging with an engaging portion provided on the inner peripheral surface of the magnet holding portion that holds the magnet.
- Patent Document 1 Japanese Patent Document 1
- the present disclosure has been made in view of the above circumstances. To provide a rotating electrical machine capable of positioning and preventing rotation of a rotating electrical machine, and a manufacturing method of the rotating electrical machine.
- a first means for solving the above problems is a magnetic field element having a magnet portion including a plurality of magnetic poles whose polarities are alternated in the circumferential direction, and an armature arranged to face the magnet portion in the radial direction. and a rotating electric machine having a rotor that is either the field element or the armature, wherein the magnet unit includes a plurality of magnets arranged side by side in a circumferential direction, and a plurality of the magnets inside the magnet unit.
- a magnet yoke fixed to the peripheral surface or the outer peripheral surface, wherein the axis of easy magnetization in the plurality of magnets is oriented on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary, A magnet magnetic path is formed along the axis of easy magnetization, and the permeance of the plurality of magnets is calculated based on the length of the magnet magnetic path.
- recesses are formed on the q-axis side, which is the magnetic pole boundary, so that the coefficient increases in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the center of the magnetic pole.
- a convex portion is provided on the d-axis side that is the center of the magnetic pole, or a concave portion is provided on the q-axis side that is the magnetic pole boundary and a convex portion is provided on the d-axis side that is the center of the magnetic pole and, on the anti-armature side peripheral surface of the plurality of magnets, on the q-axis side, which is the magnetic pole boundary, engages in the circumferential direction with the concave portion or the convex portion of the anti-armature side peripheral surface.
- an engaging portion made of a soft magnetic material is provided for exchanging magnetic flux between the magnetic poles of the plurality of magnets having different polarities.
- the magnetization easy axes of the plurality of magnets are oriented so as to be parallel to the d-axis, which is the magnetic pole center, on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.
- a magnet magnetic path is formed along the easy axis. Therefore, compared to the case where the magnet magnetic path is formed linearly along the radial direction, the leakage magnetic flux between the magnetic poles of the magnet can be reduced, and the surface magnetic flux density of the magnet portion can be made closer to a sinusoidal wave.
- the permeance coefficient of the magnet increases in the circumferential direction from the q-axis, which is the boundary of the magnetic pole, to the d-axis, which is the center of the magnetic pole.
- a concave portion is provided on the q-axis side, which is the boundary, or a convex portion is provided on the d-axis side, which is the magnetic pole center, or a concave portion is provided on the q-axis side, which is the magnetic pole boundary, and a convex portion is provided on the d-axis side, which is the magnetic pole center.
- the length of the magnet magnetic path is adjusted by providing unevenness on the peripheral surface opposite to the armature side, and the permeance coefficient increases in the circumferential direction as it approaches the d-axis, which is the center of the magnetic pole, from the q-axis, which is the magnetic pole boundary. did.
- the surface magnetic flux density of the magnet portion can be approximated to a sine wave by appropriately superimposing the effect of the magnet shape on the effect of the magnet orientation that adjusts the direction and length of the axis of easy magnetization.
- the q-axis side which is the magnetic pole boundary, engages in the circumferential direction with the concave portion or the convex portion of the anti-armature-side peripheral surface, and the An engaging portion made of a soft magnetic material was provided for transferring magnetic flux between magnetic poles of different polarities.
- magnetic flux leakage between the magnetic poles of the magnet can be suppressed, and the surface magnetic flux density of the magnet portion can be approximated to a sine wave.
- the magnet can be positioned and prevented from rotating.
- a second means is the first means, wherein the plurality of magnets have their easy magnetization axes oriented in an arc, and the orientation center of the arc-oriented easy magnetization axes is a magnetic pole boundary in the circumferential direction. It is set on the q-axis side and radially on the armature side of the plurality of magnets, or on the armature side of the plurality of magnets on the armature side.
- the magnetic flux density can be improved while making it closer to a sine wave.
- a third means is the first or second means, wherein the easy magnetization axes of the plurality of magnets are linear easy magnetization axes having an inclination angle with respect to the radial direction, and the inclination angle varies depending on the position in the circumferential direction.
- the linear easy axis of magnetization In the circumferential direction, as it approaches the d-axis side, which is the center of the magnetic pole, from the q-axis side, which is the magnetic pole boundary, the linear easy axis of magnetization is parallel to the d-axis, which is the center of the magnetic pole.
- the inclination angle of each linear easy axis of magnetization is set to be small with respect to the radial direction.
- the magnetic flux density can be improved while making it closer to a sine wave.
- a fourth means is, in any one of the first to third means, a field element having a magnet portion including a plurality of magnetic poles with alternate polarities in the circumferential direction, and a magnetic field element facing the magnet portion in the radial direction.
- a rotating electrical machine having a rotor that is either the field element or the armature, wherein the magnet unit includes a plurality of magnets that are arranged side by side in the circumferential direction; a magnet yoke to which the plurality of magnets are fixed on the inner peripheral surface or the outer peripheral surface;
- a magnet magnetic path is formed along the axis of easy magnetization, and the permeance coefficient of the plurality of magnets calculated based on the length of the magnet magnetic path is, in the circumferential direction,
- a concave portion is provided on the anti-armature side peripheral surface of each of the plurality of magnets on the side of the q-axis, which is the magnetic pole boundary, so that the recess becomes larger as it approaches the d-axi
- a fifth means is any one of the first to fourth means, wherein the engaging portion is formed integrally with the magnet yoke so as to protrude from the inner peripheral surface or the outer peripheral surface of the magnet yoke.
- a sixth means is the magnetic yoke according to any one of the first to fifth means, wherein the magnet yoke is a cylindrical helical magnet formed by spirally winding and stacking elongated thin plate-like band members. is the core.
- the yield of materials can be improved.
- a seventh means is any one of the first to sixth means, wherein each of the magnets is provided between a d-axis as a magnetic pole center and a q-axis as a magnetic pole boundary adjacent in the circumferential direction, End faces are formed on the d-axis, which is the magnetic pole boundary, and the q-axis, which is the magnetic pole boundary, so that the gap between the d-axis side end faces of the magnet in the circumferential direction is narrower than the gap between the q-axis side end faces. , an interval between the engaging portions adjacent to each other in the circumferential direction is set.
- the d-axis end face When each magnet is provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary, which are adjacent in the circumferential direction, the d-axis end face has the same pole and repels, so compared to the q-axis side end face Gaps are likely to form. Therefore, the gap between the d-axis side end faces of the magnet in the circumferential direction is made narrower than the gap between the q-axis side end faces of the magnet by adjusting the interval between the engaging portions that engage with the magnet in the circumferential direction. This makes it possible to easily position the magnets so that the gap between the d-axis side end faces is narrower than the gap between the q-axis side end faces. Since the gap between the d-axis side end surfaces can be suppressed, a rapid change in magnetic flux density caused by the gap can be suppressed, and torque pulsation can be suppressed.
- the eighth means comprises a field magnet element having a magnet portion including a plurality of magnetic poles whose polarities are alternated in a circumferential direction, and an armature arranged to face the magnet portion in a radial direction;
- the axis is oriented parallel to the d-axis on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary.
- the magnet magnetic paths are aligned in parallel so as to form a straight line with a constant inclination angle, a magnetic magnetic path is formed along the axis of easy magnetization, and the plurality of magnet magnetic paths are calculated based on the length of the magnetic magnetic path.
- a concave portion is provided on the anti-armature side peripheral surface on the q-axis side, which is the magnetic pole boundary.
- a convex portion is provided on the d-axis side, which is the center of the magnetic pole, or a concave portion is provided on the q-axis side, which is the magnetic pole boundary, and a convex portion is provided on the d-axis side, which is the center of the magnetic pole.
- the q-axis side which is the magnetic pole boundary, engages in the circumferential direction with the concave portion or the convex portion of the anti-armature side peripheral surface, and the plurality of
- the elongated straight plate member is subjected to a bending process, a bending step of spirally winding an elongated thin plate-shaped band member to form a laminated cylindrical magnet yoke; and a fixing step of fixing the plurality of magnets to the magnet yoke, wherein the bending Before execution of the processing step, the engaging portion is formed integrally with the plate member in advance so as to protrude in the width direction thereof, and the engaging portion has unevenness that absorbs deformation due to the bending. is provided.
- the above configuration can absorb deformation due to bending, so that the shape accuracy of the engaging portion can be improved. As a result, it is possible to reliably engage the magnet and improve the positioning accuracy of the magnet.
- FIG. 1 is a perspective view showing the entire rotary electric machine in the first embodiment
- FIG. 2 is a plan view of a rotating electrical machine
- FIG. 3 is a vertical cross-sectional view of a rotating electric machine
- FIG. 4 is a cross-sectional view of a rotating electric machine
- FIG. 5 is an exploded cross-sectional view of the rotating 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 electrical angle and the magnetic flux density for the magnet of the embodiment
- FIG. 1 is a perspective view showing the entire rotary electric machine in the first embodiment
- FIG. 2 is a plan view of a rotating electrical machine
- FIG. 3 is a vertical cross-sectional view of a rotating electric machine
- FIG. 4 is a cross-sectional view of a rotating electric machine
- FIG. 5 is an exploded cross-sectional view of
- FIG. 9 is a diagram showing the relationship between the electrical 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 cross-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 the connection state of partial windings in each phase winding of three phases
- FIG. 17 is a side view showing the first coil module and the second coil module side by side for comparison
- FIG. 18 is a side view showing the first partial winding and the second partial winding side by side for comparison;
- FIG. 19 is a diagram showing the configuration of the first coil module,
- FIG. 20 is a cross-sectional view 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 cross-sectional view 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 the overlap position of the film material when the coil modules are arranged in the circumferential direction
- FIG. 26 is a plan view showing how the first coil module is attached to the core assembly;
- FIG. 20 is a cross-sectional view 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
- FIG. 27 is a plan view showing how the first coil module and the second coil module are attached to the core assembly;
- FIG. 28 is a vertical cross-sectional view showing a fixed state with a fixing pin;
- FIG. 29 is a perspective view of a busbar module;
- FIG. 30 is a cross-sectional view showing a part of the longitudinal section of the busbar module,
- FIG. 31 is a perspective view showing a state in which the busbar module is attached to the stator holder;
- FIG. 32 is a vertical cross-sectional view of a fixing portion for fixing the busbar module;
- FIG. 33 is a vertical cross-sectional view showing a state in which the relay member is attached to the housing cover;
- FIG. 34 is a perspective view of a relay member;
- FIG. 35 is an electric circuit diagram showing a control system for a rotating electrical machine
- FIG. 36 is a functional block diagram showing current feedback control processing 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 modification
- FIG. 39 is a diagram showing the configuration of a stator unit with an inner rotor structure
- FIG. 40 is a plan view showing how the coil module is attached to the core assembly
- 41 is a cross-sectional view of a magnet unit in Modification 2
- 42 is a diagram showing a magnet magnetic path of a magnet unit in Modification 2
- FIG. 43 is a diagram showing the relationship between the magnet magnetic path of the magnet unit and the contour lines of the permeance coefficient;
- FIG. 44 is a diagram showing the relationship between contour lines of permeance coefficients and anti-stator-side q-axis recesses;
- FIG. 45 is a diagram showing a comparative example of the magnet unit,
- FIG. 46 is a diagram showing the action in modification 2
- 47 is a diagram showing a magnet unit in another example of modification 2
- FIG. 48 is a diagram showing a magnet unit in another example of modification 2
- FIG. 49 is a diagram showing a magnet unit in another example of modification 2
- FIG. 50 is a diagram showing a magnet yoke in another example of modification 2;
- FIG. 51 is a diagram showing a method of manufacturing a magnet yoke in another example of modification 2;
- 52A and 52B are diagrams showing a method of manufacturing an engaging portion in another example of Modification 2.
- the rotary electric machine in this embodiment is used as a vehicle power source, for example.
- the rotating electric machine can be widely used for industrial use, vehicle use, home appliance use, OA equipment use, game machine use, and the like.
- parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings, and the description of the same reference numerals is used.
- the rotary electric machine 10 is a synchronous multiphase AC motor and has an outer rotor structure (outward rotation structure). An outline of the rotating electric machine 10 is shown in FIGS. 1 to 5.
- FIG. 1 is a perspective view showing the entire rotary electric machine 10
- FIG. 2 is a plan view of the rotary electric machine 10
- FIG. 4 is a cross-sectional view of the rotating electrical machine 10 (sectional view taken along line 4-4 in FIG. 3)
- FIG. 1 is a perspective view showing the entire rotary electric machine 10
- FIG. 2 is a plan view of the rotary electric machine 10
- FIG. 4 is a cross-sectional view of the rotating electrical machine 10 (sectional view taken along line 4-4 in FIG. 3)
- the direction in which the rotating shaft 11 extends is defined as the axial direction
- the direction radially extending from the center of the rotating shaft 11 is defined as the radial direction
- the direction extending circumferentially about the rotating shaft 11 is defined as the circumferential direction. 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 busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotary electric machine main body. All of these members are arranged coaxially with respect to a rotating shaft 11 that is integrally provided with the rotor 20, and the rotary electric machine 10 is configured by being axially assembled in a predetermined order.
- the rotary shaft 11 is supported by a pair of bearings 12 and 13 respectively provided in the stator unit 50 and the housing 241, and is rotatable in that state.
- Bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged therebetween.
- the rotation of the rotating shaft 11 rotates an axle of a vehicle, for example.
- the rotary electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle body frame or the like.
- the stator unit 50 is provided so as to surround the rotating shaft 11 , and the rotor 20 is arranged radially outside the stator unit 50 .
- the stator unit 50 has a stator 60 and a stator holder 70 mounted radially inward thereof.
- the rotor 20 and the stator 60 are arranged to face each other in the radial direction with an air gap interposed therebetween. Rotate.
- the rotor 20 corresponds to the "field element" and the stator 60 corresponds to the "armature”.
- FIG. 6 is a longitudinal sectional view of the rotor 20.
- 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 while being inserted into the through hole 24a.
- the rotating shaft 11 has a flange 11a extending in a direction that intersects (perpendicularly) with the axial direction. is fixed.
- the magnet unit 22 includes a cylindrical magnet holder 31 , a plurality of magnets 32 fixed to the inner peripheral surface of the magnet holder 31 , and one of the two axial sides 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 so as to be surrounded by the magnet holder 31 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 section".
- FIG. 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22.
- FIG. 7 the direction of the axis of easy magnetization of the magnet 32 is indicated by an arrow.
- the magnets 32 are arranged so that their polarities alternate along the circumferential direction of the rotor 20. Thereby, 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.
- a radially inner peripheral surface of the magnet 32 is a magnetic flux acting surface 34 where magnetic flux is exchanged.
- the direction of the axis of easy magnetization is different between the d-axis side (portion near the d-axis) and the q-axis side (portion near the q-axis).
- the direction of the axis of easy magnetization on the q-axis side is perpendicular to the q-axis.
- an arcuate magnet magnetic path is formed along the direction of the axis of easy magnetization.
- the magnet 32 is oriented such that the axis of easy magnetization is parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.
- the magnet magnetic path length is longer than the thickness dimension of the magnet 32 in the radial direction because the magnet magnetic path is formed in an arc shape.
- the permeance of the magnet 32 is increased, and it is possible to exhibit the same ability as a magnet with a large amount of magnets, even though the amount of magnets is the same.
- a set of two magnets 32 adjacent in the circumferential direction constitutes one magnetic pole. That is, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 each have a split surface on the d-axis and the q-axis, and the magnets 32 are arranged in contact with or close to each other. .
- the magnets 32 have an arc-shaped magnet magnetic path, and along the q-axis, the N poles and the S poles of the magnets 32 that are adjacent in the circumferential direction face each other. Therefore, it is possible to improve the permeance in the vicinity of the q-axis.
- the magnets 32 on both sides of the q-axis are attracted to each other, the magnets 32 can maintain contact with each other. Therefore, it also contributes to the improvement of permeance.
- each magnet 32 causes the magnetic flux to flow in an arc between adjacent N and S poles, so the magnet magnetic path is longer than, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 8, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of the radially anisotropic magnet shown in FIG. 9 as a comparative example, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electric machine 10 can be increased. . In addition, it can be confirmed that the magnet unit 22 of the present embodiment has a different magnetic flux density distribution than the conventional Halbach array magnet. 8 and 9, the horizontal axis indicates the electrical angle, and the vertical axis indicates the magnetic flux density. 8 and 9, 90° on the horizontal axis indicates the d-axis (that is, the magnetic pole center), and 0° and 180° on the horizontal axis indicate the q-axis.
- the magnetic flux of the magnet unit 22 is strengthened along the d-axis, and the change in magnetic flux is suppressed in the vicinity of the q-axis.
- the magnet unit 22 in which the surface magnetic flux changes gradually from the q-axis to the d-axis in each magnetic pole.
- the sine wave matching rate of the magnetic flux density distribution should be, for example, 40% or more. By doing so, the amount of magnetic flux at the central portion of the waveform can be reliably improved compared to the case of using radially oriented magnets and parallel oriented magnets having a sine wave matching rate of about 30%. Further, if the sine wave matching rate is 60% or more, the amount of magnetic flux in the central portion of the waveform can be reliably improved compared to a magnetic flux concentrated array such as the Halbach array.
- the magnetic flux density changes sharply near the q-axis.
- the steeper the change in magnetic flux density the greater the eddy current in the stator windings 61 of the stator 60, which will be described later.
- the magnetic flux change on the stator winding 61 side also becomes steep.
- the magnetic flux density distribution becomes a magnetic flux waveform close to a sine wave. Therefore, in the vicinity of the q-axis, the change in magnetic flux density is smaller than the change in magnetic flux density of the radially anisotropic magnet. Thereby, generation of eddy current can be suppressed.
- the magnet 32 has a recessed portion 35 formed in a predetermined range including the d-axis on the radially outer peripheral surface thereof, and a recessed portion 36 formed in a predetermined range including the q-axis on the radially inner peripheral surface thereof. ing.
- the magnet magnetic path is shortened near the d-axis on the outer peripheral surface of the magnet 32, and the magnetic magnetic path is shortened near the q-axis on the inner peripheral surface of the magnet 32. .
- the magnet is removed at a location where the magnet magnetic flux is weak.
- the magnet unit 22 may be configured to use the same number of magnets 32 as the number of magnetic poles.
- the magnet 32 may be 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.
- the magnet 32 has a configuration in which the center in the circumferential direction is the q-axis and the split surface is along the d-axis.
- the magnet 32 may have a configuration in which the center in the circumferential direction is the d-axis instead of the q-axis.
- ring magnets connected in an annular shape may be used.
- a resolver 41 as a rotation sensor is provided at the opposite end (upper end in the drawing) of the connecting portion to the rotor carrier 21 among both sides of the rotating shaft 11 in the axial direction.
- the resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator disposed radially outside the resolver rotor so as to face each other.
- the resolver rotor has a disk-ring shape, and is provided coaxially with the rotating shaft 11 in a state in which the rotating shaft 11 is inserted therethrough.
- the resolver stator has a stator core and stator coils and is fixed to housing cover 242 .
- FIG. 10 is a perspective view of the stator unit 50
- FIG. 11 is a longitudinal sectional view of the stator unit 50.
- FIG. 11 is a longitudinal sectional view at the same position as in FIG.
- the stator unit 50 generally includes a stator 60 and a radially inner stator holder 70 .
- the stator 60 has a stator winding 61 and a stator core 62 .
- the stator core 62 and the stator holder 70 are integrally 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”
- the stator holder 70 corresponds to the "armature holding member”.
- the core assembly CA corresponds to the "supporting member”.
- FIG. 12 is a perspective view of the core assembly CA seen from one side in the axial direction
- FIG. 13 is a perspective view of the core assembly CA seen from the other side in the axial direction
- FIG. 14 is a cross-sectional view of the core assembly CA.
- 15 is an exploded cross-sectional view of the core assembly CA.
- the core assembly CA has the stator core 62 and the stator holder 70 assembled radially inward thereof, as described above.
- the stator core 62 is integrally attached to the outer peripheral surface of the stator holder 70 .
- the stator core 62 is configured as a core sheet laminate in which core sheets 62a made of electromagnetic steel sheets, which are magnetic bodies, are laminated in the axial direction, and has a cylindrical shape with a predetermined thickness in the radial direction.
- a stator winding 61 is assembled on the radially 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 irregularities.
- the stator core 62 functions as a back yoke.
- the stator core 62 is configured by laminating a plurality of core sheets 62a, which are formed by punching into, for example, an annular plate shape, in the axial direction.
- stator core 62 having a helical core structure may also be used.
- a band-shaped core sheet is used, and the core sheet is wound in an annular shape and laminated in the axial direction to form the overall cylindrical stator core 62 . It is
- the stator 60 has a slotless structure that does not have teeth for forming slots. can be anything.
- an inter-conductor member is provided between each conductor portion (intermediate conductor portion 152 described later) in the circumferential direction, and as the inter-conductor member, the width dimension of the inter-conductor member in one magnetic pole in the circumferential direction is Wt, the saturation magnetic flux density of the inter-conductor member is Bs, the width dimension of the magnet 32 in the circumferential direction in one magnetic pole is Wm, and the residual magnetic flux density of the magnet 32 is Br.
- a magnetic material is used.
- stator 60 In the stator 60, a member between conductors is provided between each conductor portion (intermediate conductor portion 152) in the circumferential direction, and a non-magnetic material is used as the member between conductors.
- the stator 60 has a configuration in which no member between conductors is provided between conductors (intermediate conductors 152) in the circumferential direction.
- the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81.
- the outer cylinder member 71 is radially outside and the inner cylinder member 81 is radially inside. It is configured by being integrally assembled.
- Each of these members 71 and 81 is made of, for example, metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).
- the outer cylindrical member 71 is a cylindrical member whose outer peripheral surface and inner peripheral surface are both perfectly circular curved surfaces, and an annular flange 72 extending radially inward is formed on one axial end side. A plurality of protrusions 73 extending radially inward are formed on the flange 72 at predetermined intervals in the circumferential direction (see FIG. 13). Opposing surfaces 74 and 75 are formed on the outer cylindrical member 71 at one axial end side and the other axial end side, respectively, to face the inner cylindrical member 81 in the axial direction. Annular grooves 74a and 75a are formed extending to.
- 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 perfectly circular curved surface concentric with the outer cylinder member 71 .
- An annular flange 82 extending radially outward is formed on one axial end side of the inner cylindrical member 81 .
- the inner cylinder member 81 is attached to the outer cylinder member 71 while being in contact with the facing surfaces 74 and 75 of the outer cylinder member 71 in the axial direction. As shown in FIG. 13, the outer cylinder member 71 and the inner cylinder member 81 are assembled together with fasteners 84 such as bolts.
- a plurality of projections 83 extending radially inward are formed at predetermined intervals in the circumferential direction.
- the protrusions 73 and 83 of the member 71 are fastened together with fasteners 84 while the protrusions 73 of the member 71 are overlapped with each other.
- an annular gap is formed between the inner peripheral surface of the outer tubular member 71 and the outer peripheral surface of the inner tubular member 81 when the outer tubular member 71 and the inner tubular member 81 are assembled together.
- the gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows.
- the coolant passage 85 is provided annularly in the circumferential direction of the stator holder 70 .
- the inner cylindrical member 81 is provided with a passage forming portion 88 that protrudes radially inward on its inner peripheral side and in which an inlet side passage 86 and an outlet side passage 87 are formed, Each of these passages 86 and 87 opens on the outer peripheral surface of the inner cylindrical member 81 .
- a partition portion 89 is provided on the outer peripheral surface of the inner cylindrical member 81 for partitioning the refrigerant passage 85 into an inlet side and an outlet side. Thereby, the refrigerant flowing in from the inlet side passage 86 flows in the circumferential direction through the refrigerant passage 85 and then flows out from the outlet side passage 87 .
- One end 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 extends axially to open to the axial end surface of the inner cylinder member 81 .
- It's like 12 shows an inlet opening 86a leading to the inlet side passage 86 and an outlet opening 87a leading to the outlet side passage 87.
- FIG. The inlet-side passage 86 and the outlet-side passage 87 communicate with an inlet port 244 and an outlet port 245 (see FIG. 1) attached to the housing cover 242, through which the refrigerant flows in and out. It's like
- Sealing materials 101 and 102 for suppressing leakage of the refrigerant from 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).
- the sealing members 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 provided in a state of being compressed by the outer cylinder member 71 and the inner cylinder member 81.
- the inner cylindrical 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. is provided.
- the boss portion 92 is provided so as to surround an insertion hole 93 through which the rotating shaft 11 is inserted.
- the boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242 .
- the end plate portion 91 is provided with a plurality of strut portions 95 extending in the axial direction outside the boss portion 92 in the radial direction.
- the strut portion 95 is a fixing portion for fixing the busbar module 200, and the details thereof will be described later.
- the boss portion 92 serves as a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on the inner peripheral portion thereof (see FIG. 3).
- the outer cylinder member 71 and the inner cylinder member 81 are formed with recesses 105 and 106 used for fixing a plurality of coil modules 150, which will be described later.
- a plurality of grooves are formed at equal intervals in the circumferential direction on the axial end face of the inner cylindrical member 81 , more specifically, on the axial outer end face of the end plate portion 91 around the boss portion 92 .
- a recess 105 is formed.
- a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end face of the outer cylinder member 71 , more specifically, on the axial outer end face of the flange 72 .
- These concave portions 105 and 106 are arranged 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, and have the same interval and number.
- the stator core 62 is assembled to the stator holder 70 in a state in which a radial compressive force is generated in order to secure the strength of assembly to the stator holder 70 .
- the stator core 62 is fitted and fixed to the stator holder 70 with a predetermined interference by shrink fitting or press fitting.
- the stator core 62 and the stator holder 70 are assembled in a state in which one of them exerts a radial stress on the other.
- the diameter of the stator 60 for example.
- the clamping force of core 62 is increased.
- the compressive stress (in other words, residual stress) of the stator core 62 is increased, there is concern that the stator core 62 will be damaged.
- the radially opposing portions of the stator core 62 and the stator holder 70 are provided with:
- a restriction portion is provided to restrict displacement of the stator core 62 in the circumferential direction by engagement in the circumferential direction. 12 to 14, between the stator core 62 and the outer cylindrical member 71 of the stator holder 70 in the radial direction, a plurality of engagement members serving as restricting portions are provided at predetermined intervals in the circumferential direction.
- a member 111 is provided, and the engagement member 111 suppresses circumferential positional deviation between the stator core 62 and the stator holder 70 .
- At least one of the stator core 62 and the outer cylindrical member 71 may be provided with a concave portion, and the engagement member 111 may be engaged with the concave portion.
- the engaging member 111 a configuration may be adopted in which a convex portion is provided on either the stator core 62 or the outer cylindrical member 71. FIG.
- the stator core 62 and the stator holder 70 are fitted and fixed with a predetermined interference, and in addition, the engaging member 111 restricts mutual displacement in the circumferential direction. It is installed in the Therefore, even if the interference between 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. Moreover, since a desired displacement suppression effect can be obtained even if the interference is relatively small, damage to the stator core 62 due to excessive interference can be suppressed. As a result, displacement of the stator core 62 can be properly suppressed.
- An annular inner space is formed on the inner peripheral side of the inner cylindrical member 81 so as to surround the rotating shaft 11, and electric parts constituting an inverter as a power converter, for example, are arranged in the inner space. good too.
- An electrical component is, for example, an electrical module in which semiconductor switching elements and capacitors are packaged.
- stator winding 61 assembled to the core assembly CA The state in which the stator windings 61 are assembled to the core assembly CA is as shown in FIGS.
- a plurality of partial windings 151 forming 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 is formed in a cylindrical (annular) shape by arranging the phase windings of each phase in a predetermined order in the circumferential direction.
- the stator winding 61 is configured to have three phase windings by using U-phase, V-phase, and W-phase windings.
- the stator 60 includes, in the axial direction, a portion corresponding to the coil side CS of the rotor 20 that faces the magnet unit 22 in the radial direction, and a coil end that is axially outside the coil side CS. and a portion corresponding to CE.
- the stator core 62 is provided in a range corresponding to the coil side CS in the axial direction.
- each phase winding 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 the partial windings 151 of the phase windings of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 corresponding to the number of poles. there is By arranging the coil modules 150 (partial windings 151) of each phase in a predetermined order in the circumferential direction, the conductor portions of each phase are arranged in a predetermined order on the coil side CS of the stator winding 61. It has become.
- FIG. 10 shows the arrangement order of the U-phase, V-phase, and W-phase conductor portions in the coil side CS. In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.
- the phase winding of each phase is 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 the connection state of partial windings 151 in each phase winding of three phases.
- FIG. 16 shows a state in which the partial windings 151 of the phase windings of each phase are connected in parallel.
- the coil module 150 is assembled radially outside the stator core 62 .
- the coil module 150 is assembled in a state in which both axial end portions of the coil module 150 protrude axially outward (that is, to 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 projecting axially outward from the stator core 62 and a portion corresponding to the coil side CS axially inward. .
- the coil module 150 has two shapes, one of which has a shape in which the partial windings 151 are bent radially inward at the coil ends CE, that is, toward the stator core 62 side. In the other, the partial winding 151 is not bent inward in the radial direction at the coil end CE and has a shape extending linearly in the axial direction.
- the partial winding 151 having a bent shape at both ends in the axial direction will be referred to as the "first partial winding 151A”
- the coil module 150 having the first partial winding 151A will be referred to as the "first coil”. module 150A”.
- the partial winding 151 that does not have a bent shape on both ends in the axial direction is also called a “second partial winding 151B", and the coil module 150 having the second partial winding 151B is also called a “second coil module 150B”. .
- FIG. 17 is a side view showing the first coil module 150A and the second coil module 150B arranged side by side for comparison, and FIG. It is a side view shown side by side for comparison.
- the coil modules 150A and 150B and the partial windings 151A and 151B have different lengths in the axial direction and different end shapes on both sides in the axial direction.
- the first partial winding 151A has a substantially C shape when viewed from the side
- the second partial winding 151B has a substantially I shape when viewed from the side.
- Insulating covers 161 and 162 as “first insulating covers” are mounted on both axial sides of the first partial winding 151A, and “second insulating covers” are mounted on both axial sides of the second partial winding 151B. insulating covers 163 and 164 are attached.
- FIG. 19(a) is a perspective view showing the configuration of the first coil module 150A
- FIG. 19(b) is an exploded perspective view showing components of the first coil module 150A
- 20 is a cross-sectional view taken along the line 20-20 in FIG. 19(a).
- the first coil module 150A includes a first partial winding 151A formed by multiple windings of a conductive wire CR, and an axial It has insulating covers 161 and 162 attached to one end and the other end.
- the insulating covers 161 and 162 are molded from an insulating material such as synthetic resin.
- the first partial winding 151A has a pair of intermediate conductor portions 152 that are provided in parallel and linearly, and a pair of transition portions 153A that connect the pair of intermediate conductor portions 152 at both ends in the axial direction.
- the pair of intermediate conductor portions 152 and the pair of bridging portions 153A form an annular shape.
- the pair of intermediate conductor portions 152 are spaced apart by a predetermined coil pitch, and the intermediate conductor portion 152 of the partial winding 151 of the other phase can be arranged between the pair of intermediate conductor portions 152 in the circumferential direction.
- the pair of intermediate conductor portions 152 are provided two coil pitches apart, and one intermediate conductor portion 152 of the partial winding 151 of the other two phases is arranged between the pair of intermediate conductor portions 152. It is configured to be
- the pair of transition portions 153A has the same shape on both sides in the axial direction, and both are provided as portions corresponding to the coil ends CE (see FIG. 11).
- Each bridging 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.
- the first partial winding 151A has transition portions 153A on both axial sides
- the second partial winding 151B has transition portions 153B on both axial sides.
- the transition portions 153A and 153B of the partial windings 151A and 151B are different in shape from each other.
- the transition portion 153B of the second partial winding 151B is also referred to as "second transition portion 153B.”
- the intermediate conductor portions 152 are provided as coil side conductor portions arranged one by one in the circumferential direction on the coil side CS.
- each of the bridge portions 153A and 153B is provided as a coil end wire portion that connects the in-phase intermediate wire portions 152 at two different positions in the circumferential direction in the coil end CE.
- the first partial winding 151A is formed by winding a conductor CR in multiple layers so that the cross section of the conductor assembly portion is square.
- FIG. 20 shows a cross section of the intermediate conductor portion 152, in which the conductor material CR is wound multiple times so as to be aligned in the circumferential direction and the radial direction. That is, the first partial winding 151A has a substantially rectangular cross section by arranging the conductors CR in the intermediate conductor portion 152 in a plurality of rows in the circumferential direction and in a plurality of rows in the radial direction. formed.
- the conductor CR is wound in multiple layers so as to line up in the axial direction and the radial direction by bending in the radial direction.
- the first partial winding 151A is formed by concentrically winding the conductor CR.
- the method of winding the conductor CR is arbitrary, and instead of the concentric winding, the conductor CR may be wound multiple times by alpha winding.
- the end portion of the conductor CR extends from one of the first transition portions 153A on both sides in the axial direction (the upper first transition portion 153A in FIG. 19B). It is pulled out, and its ends are winding ends 154 and 155 .
- the winding end portions 154 and 155 are the portions that become the winding start and the winding end of the conductor 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.
- Each intermediate conductor portion 152 of the first partial winding 151A is provided with a sheet-shaped insulating cover 157 covered thereon.
- FIG. 19A shows the first coil module 150A in a state in which the intermediate conductor portion 152 is covered with the insulating covering 157, and the intermediate conducting wire portion 152 exists inside the insulating covering 157.
- that portion is referred to as an intermediate conductor portion 152 (the same applies to FIG. 22(a), which will be described later).
- the insulating covering 157 uses a film material FM having at least the length of the insulating covering range in the axial direction of the intermediate conductor portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152.
- the film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film substrate and a foamable adhesive layer provided on one of both surfaces of the film substrate. The film material FM is wound around the intermediate conductor portion 152 in a state of being adhered by an adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.
- the intermediate conductor portion 152 has a substantially rectangular cross section by arranging the conductor materials CR in the circumferential direction and the radial direction.
- An insulating cover 157 is provided by covering the ends in an overlapping state.
- the film material FM is a rectangular sheet whose longitudinal dimension is longer than the axial length of the intermediate conductor portion 152 and whose lateral dimension is longer than the length of one circumference of the intermediate conductor portion 152. It is wound around the intermediate conductor portion 152 in a creased state. In the state in which the film material FM is wound around the intermediate wire portion 152, the gap between the wire material CR of the intermediate wire portion 152 and the film substrate is filled by the foaming of the adhesive layer. Also, in the overlapping portion OL of the film material FM, the ends of the film material FM in the circumferential direction are joined together by an adhesive layer.
- An insulating covering 157 is provided on the intermediate conductor portion 152 so as to cover all of the two circumferential side surfaces and the two radial side surfaces.
- the insulating covering 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152 , the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase.
- An overlapping portion OL is provided where the material FM overlaps.
- the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.
- an insulating covering 157 is provided. Referring to FIG. 17, the range AX1 in the first coil module 150A is a portion not covered by the insulating covers 161 and 162, and the insulating cover 157 is provided in a range extending vertically beyond the range AX1. .
- the insulating cover 161 is attached to the first transition portion 153A on one axial side of the first partial winding 151A, and the insulating cover 162 is attached to the first transition portion 153A on the other axial side of the first partial winding 151A.
- 21(a) and 21(b) show the structure of the insulating cover 161 among them.
- 21A and 21B are perspective views of the insulating cover 161 viewed from two different directions.
- the insulating cover 161 includes a pair of side surface portions 171 serving as side surfaces in the circumferential direction, 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 radially inner front portion 174 .
- Each of these portions 171 to 174 is formed in a plate shape, and is connected to each other in a three-dimensional shape so that only the outer side in the radial direction is open.
- Each of the pair of side surface portions 171 is provided in a direction extending toward the axial center of the core assembly CA when assembled to the core assembly CA.
- the side portions 171 of the insulating covers 161 of the adjacent first coil modules 150A face each other in an abutting or approaching state.
- the first coil modules 150A that are adjacent in the circumferential direction can be insulated from each other and can be preferably arranged in a ring shape.
- 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
- the front portion 174 is provided with the winding end portion of the first partial winding 151A.
- An opening 175b is provided through which the portion 155 is drawn out. In this case, one winding end portion 154 is pulled out from the outer surface portion 172 in the axial direction, while the other winding end portion 155 is pulled out from the front surface portion 174 in the radial direction.
- the pair of side surface portions 171 are provided with axially extending semicircular grooves at positions corresponding to both ends of the front surface portion 174 in the circumferential direction, i.e., positions at which the side surface portions 171 and the front surface portion 174 intersect.
- a recess 177 is provided.
- the outer surface portion 172 is provided with a pair of projections 178 extending in the axial direction at symmetrical positions on both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.
- the first transition portion 153A of the first partial winding 151A has a curved shape that protrudes toward the radially inner side of the radially inner and outer sides, that is, the core assembly CA side. In such a configuration, a gap is formed between the first transition portions 153A adjacent in the circumferential direction, the gap becoming wider toward the distal end side of the first transition portion 153A.
- a recess 177 is provided at a position outside the curved portion of the first transition portion 153A in the side portion 171 of the insulating cover 161 by utilizing the gap between the first transition portions 153A arranged in the circumferential direction. It is configured.
- the first partial winding 151A may be provided with a temperature detection section (thermistor), and in such a configuration, the insulating cover 161 may be provided with an opening for drawing out the signal line extending from the temperature detection section.
- the temperature detection section can be suitably accommodated inside the insulating cover 161 .
- 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 axially outer outer surface portion 172, an axially inner inner surface portion 173, and a radially inner front surface portion 174.
- the pair of side surface portions 171 are provided with semicircular recesses 177 at positions corresponding to both ends of the front surface portion 174 in the circumferential direction, and the outer surface portion 172 is provided with a pair of protrusions 178.
- a difference from the insulating cover 161 is that the insulating cover 162 does not have openings for drawing out the winding ends 154 and 155 of the first partial winding 151A.
- the insulating covers 161 and 162 have different axial height dimensions (that is, the axial width dimensions of the pair of side surface portions 171 and the front surface portion 174). 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 satisfy W11>W12. That is, when the conductor CR is wound in multiple layers, it is necessary to switch (lane change) the winding stage of the conductor CR in a direction perpendicular to the winding direction (wound direction). It is conceivable that the winding width increases as a result.
- the insulating cover 161 is a portion that covers the first transition portion 153A on the side including the winding start and winding end of the conductor CR, and includes the winding start and winding end of the conductor CR.
- the winding allowance (overlapping allowance) of the conductor material CR becomes larger than that of the other portions, and as a result, the winding width can be increased.
- the axial height dimension W11 of the insulating cover 161 is larger than the axial height dimension W12 of the insulating cover 162 .
- FIG. 22(a) is a perspective view showing the configuration of the second coil module 150B
- FIG. 22(b) is an exploded perspective view showing components of the second coil module 150B
- FIG. 23 is a cross-sectional view taken along the line 23-23 in FIG. 22(a).
- the second coil module 150B includes a second partial winding 151B formed by multiple windings of the conductor material CR in the same manner as the first partial winding 151A, and It has insulating covers 163 and 164 attached to one axial end side and the other axial end side of the second partial winding 151B.
- the insulating covers 163 and 164 are made of an insulating material such as synthetic resin.
- the second partial winding 151B has a pair of intermediate conductor portions 152 that are provided in parallel and linearly, and a pair of second transition portions 153B that connect the pair of intermediate conductor portions 152 at both ends in the axial direction.
- the pair of intermediate conductor portions 152 and the pair of second bridging portions 153B form an annular shape.
- a pair of intermediate conductor portions 152 in the second partial winding 151B has the same configuration as the intermediate conductor portions 152 in the first partial winding 151A.
- the pair of second bridging portions 153B is different in configuration from the first bridging portion 153A of the first partial winding 151A.
- the second transition 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.
- the differences between the partial windings 151A and 151B are clearly shown in comparison.
- the end portion of the conductor CR extends from one second transition portion 153B (second transition portion 153B on the upper side in FIG. 22B) of the second transition portions 153B on both sides in the axial direction. It is pulled out, and its ends are winding ends 154 and 155 .
- 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's becoming
- each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157, similarly to the first partial winding 151A.
- the insulating covering 157 uses a film material FM having at least the length of the insulating covering range in the axial direction of the intermediate conductor portion 152 as an axial dimension, and the film material FM is wound around the intermediate conductor portion 152. is provided.
- the configuration of the insulating cover 157 is also substantially the same for the partial windings 151A and 151B. That is, as shown in FIG. 23, the film material FM covers the periphery of the intermediate conductor portion 152 in a state in which the ends in the circumferential direction are overlapped.
- an insulating covering 157 is provided so as to cover all of two circumferential side surfaces and two radial side surfaces.
- the insulating covering 157 surrounding the intermediate conductor portion 152 has a film on one of the two circumferential side surfaces of the intermediate conductor portion 152 , the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase.
- An overlapping portion OL is provided where the material FM overlaps.
- the pair of intermediate conductor portions 152 are provided with overlapping portions OL on the same side in the circumferential direction.
- an insulating covering 157 is provided. Referring to FIG. 17, the range AX2 in the second coil module 150B is a portion not covered by the insulating covers 163 and 164, and the insulating cover 157 is provided in a range extending vertically beyond the range AX2. .
- each of the partial windings 151A and 151B the insulating covering 157 is provided in a range including part of the transition portions 153A and 153B. That is, each of the partial windings 151A and 151B is provided with an insulating coating 157 on the intermediate conductor portion 152 and on the portions of the connecting portions 153A and 153B that extend straight from the intermediate conductor portion 152. As shown in FIG. However, since the partial windings 151A and 151B have different axial lengths, the axial ranges of the insulating coatings 157 are also different.
- the insulating cover 163 is attached to the second transition portion 153B on one axial side of the second partial winding 151B, and the insulating cover 164 is attached to the second transition portion 153B on the other axial side of the second partial winding 151B.
- 24(a) and 24(b) show the structure of the insulating cover 163 among them.
- 24A and 24B are perspective views of the insulating cover 163 viewed from two different directions.
- the insulating cover 163 includes a pair of side surface portions 181 serving as side surfaces in the circumferential direction, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184 .
- Each of these parts 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 open.
- Each of the pair of side surface portions 181 is provided in a direction extending toward the axial center of the core assembly CA when assembled to the core assembly CA.
- the side portions 181 of the insulating covers 163 of the adjacent second coil modules 150B face each other in an abutting or approaching state.
- the second coil modules 150B that are adjacent in the circumferential direction can be insulated from each other and can be preferably arranged in a ring shape.
- 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 portion of the second partial winding 151B.
- An opening 185b is provided through which the portion 155 is drawn out.
- a front surface portion 183 of the insulating cover 163 is provided with a protruding portion 186 protruding radially inward.
- the protruding portion 186 is provided at a central position between one end and the other end of the insulating cover 163 in the circumferential direction so as to protrude radially inward from the second transition portion 153B.
- the protruding portion 186 has a tapered shape that tapers toward the inner side in the radial direction in plan view, and a through hole 187 extending in the axial direction is provided at the distal end portion of the protruding portion 186 .
- the protruding portion 186 protrudes radially inward from the second bridging portion 153B and has a through hole 187 at a central position between one end and the other end of the insulating cover 163 in the circumferential direction. Its configuration is arbitrary. However, assuming an overlapping state with the insulating cover 161 on the inner side in the axial direction, it is desirable that the width is narrow in the circumferential direction so as to avoid interference with the winding end portions 154 and 155 .
- the protruding portion 186 has a stepped thickness in the axial direction at the radially inner tip portion, and a through hole 187 is provided in the thinned low step portion 186a.
- the low step portion 186a corresponds to a portion where the height from the axial end surface of the inner tubular member 81 is lower than the height of the second transition portion 153B in the assembled state of the second coil module 150B to the core assembly CA. .
- the projecting portion 186 is provided with a through hole 188 penetrating in the axial direction.
- the gap between the insulating covers 161 and 163 can be filled with the adhesive through the through hole 188 when the insulating covers 161 and 163 overlap in the axial direction.
- the insulating cover 164 on the other side in the axial direction has substantially the same configuration as the insulating cover 163 . Similar to the insulating cover 163, the insulating cover 164 has a pair of side surface portions 181, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184. A through hole 187 is provided at the tip of the portion 186 . Also, as a difference from the insulating cover 163, the insulating cover 164 is configured so as not to have openings for pulling out the winding ends 154 and 155 of the second partial winding 151B.
- the width dimension in the radial direction of the pair of side portions 181 is 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 satisfy W21>W22. . That is, of the insulating covers 163 and 164, the insulating cover 163 is a portion that covers the second transition portion 153B on the side including the winding start and the winding end of the conductor CR, and includes the winding start and the winding end of the conductor CR.
- the winding allowance (overlapping allowance) of the conductor CR becomes larger than that of the other portions, and as a result, the winding width may increase.
- the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164 .
- the problem that the number of turns of the conductor CR is limited by the insulating covers 163 and 164 is suppressed. ing.
- FIG. 25 is a diagram showing overlapping positions of the film material FM when the coil modules 150A and 150B are arranged in the circumferential direction.
- a portion of the partial winding 151 of the other phase that faces the intermediate conductor portion 152 that is, the circumferential side surface of the intermediate conductor portion 152 is overlapped around the intermediate conductor portion 152.
- the film material FM is covered (see FIGS. 20 and 23).
- the overlapping portions OL of the film material FM are arranged on the same side (the right side in the circumferential direction in the drawing) among both sides in the circumferential direction. ing.
- the overlapping portions OL of the film material FM do not overlap in the circumferential direction in each of the intermediate conductor portions 152 of the out-of-phase partial windings 151A and 151B that are circumferentially adjacent to each other.
- a maximum of three film materials FM are overlapped between the intermediate conductor portions 152 arranged in the circumferential direction.
- Coil modules 150A and 150B have different axial lengths, and crossover portions 153A and 153B of partial windings 151A and 151B have different shapes.
- the second coil module 150B is attached to the core assembly CA with the second transition portion 153B of the second coil module 150B facing axially outward.
- the insulating covers 161 to 164 the insulating covers 161 and 163 are axially overlapped on one axial end side of each of the coil modules 150A and 150B, and the insulating covers 162 and 164 are axially overlapped on the other axial end side.
- Each of the 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 when the first coil module 150A is attached to the core assembly CA.
- FIG. 11 is a plan view showing a state in which a plurality of insulating covers 161 and 163 are arranged in a circumferential direction in an assembled state of the two-coil module 150B;
- FIG. 28(a) is a vertical cross-sectional view showing the coil modules 150A and 150B assembled to the core assembly CA before being fixed by the fixing pins 191
- FIG. 10 is a vertical cross-sectional view showing a state after fixing by a fixing pin 191 in an assembled state of each coil module 150A, 150B;
- the plurality of insulating covers 161 are arranged with the side surface portions 171 in contact with or close to each other.
- Each insulating cover 161 is arranged such that the boundary line LB where the side surface portions 171 face each other and the concave portion 105 of the axial end surface of the inner cylindrical member 81 are aligned.
- the side portions 171 of the insulating covers 161 that are adjacent in the circumferential direction come into contact with each other or come close to each other, so that the concave portions 177 of the insulating covers 161 form through holes extending in the axial direction. The positions of the hole and the recess 105 are aligned.
- the second coil module 150B is further assembled to the integral body of the core assembly CA and the first coil module 150A.
- the plurality of insulating covers 163 are arranged with the side portions 181 in contact with each other or close to each other.
- the transition portions 153A and 153B are arranged so as to intersect each other on a circle on which the intermediate conductor portions 152 are arranged in the circumferential direction.
- Each insulating cover 163 is configured such that the projecting portion 186 overlaps the insulating cover 161 in the axial direction, and the through hole 187 of the projecting portion 186 is axially connected to the through hole formed by the recessed portions 177 of the insulating cover 161. are placed.
- the protruding portion 186 of the insulating cover 163 is guided to a predetermined position by a 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 concave portion 105 of the inner cylinder member 81 are aligned.
- the position of the through hole 187 on the side of the insulating cover 163 is matched with . That is, when the coil modules 150A and 150B are assembled to the core assembly CA, the recessed portion 177 of the insulating cover 161 is located on the inner side of the insulating cover 163, so that the protruding portion is located with respect to the recessed portion 177 of the insulating cover 161.
- the projection 186 of the insulating cover 163 is guided by the pair of projections 178 of the insulating cover 161, so that the insulating cover 163 can be easily aligned with the insulating cover 161. As shown in FIG.
- the circumferentially adjacent coil modules 150A and 150B are fixed to the core assembly CA by the common fixing pin 191 at the coil end CE.
- the fixing pin 191 is desirably made of a material with good thermal conductivity, such as a metal pin.
- the fixing pin 191 is attached to the low step portion 186a of the projecting portion 186 of the insulating cover 163. As shown in FIG. In this state, the upper end of the fixing pin 191 protrudes above the lower stepped portion 186a, but does not protrude above the upper surface of the insulating cover 163 (outer surface portion 182). 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 projecting portion 186 (lower step portion 186a) of the insulating cover 163, and has a margin that protrudes upward.
- the fixing pin 191 can be easily inserted into the recesses 105 and 177 and the through hole 187 (that is, when fixing the fixing pin 191).
- 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 axial length of the stator 60 is increased due to the protrusion of the fixing pin 191. It has become a thing.
- the through holes 188 provided in the insulating cover 163 are filled with adhesive.
- the through hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163 for the sake of convenience. It has a set configuration.
- the positions where the insulating covers 161 and 163 are fixed by the fixing pins 191 are on the axial end surface of the stator holder 70 radially inside (on the left side in the drawing) of the stator core 62. , and is fixed to the stator holder 70 by fixing pins 191 . That is, the first transition portion 153A is configured to be fixed to the axial end surface of the stator holder 70 . In this case, since the stator holder 70 is provided with the coolant passage 85, the heat generated in the first partial winding 151A directly flows from the first transition portion 153A to the vicinity of the coolant passage 85 of the stator holder 70.
- the fixing pin 191 is inserted into the concave portion 105 of the stator holder 70 so that 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.
- 18 insulating covers 161 and 163 are stacked inside and outside in the axial direction at the coil end CE, while the same number of insulating covers 161 and 163 as the insulating covers 161 and 163 are provided on the axial end surface of the stator holder 70 .
- Concave portions 105 are provided at 18 locations. Then, the 18 concave portions 105 are fixed by fixing pins 191 .
- the through hole 187 on the insulating cover 164 side is aligned with the through hole portion on the insulating cover 163 side and the concave portion 106 of the outer cylindrical member 71, and the concave portions 106 and 177 are aligned.
- the insulating covers 162 and 164 are integrally fixed to the outer cylindrical member 71 by inserting the fixing pin 191 into the through hole 187 .
- the coil modules 150A and 150B When assembling the coil modules 150A and 150B to the core assembly CA, first attach all the first coil modules 150A to the outer peripheral side of the core assembly CA, and then attach all the second coil modules 150B; It is preferable to perform fixing by a fixing pin 191 .
- the two first coil modules 150A and one second coil module 150B are first fixed to the core assembly CA with one fixing pin 191, and then the assembly of the first coil module 150A is performed. , the assembly of the second coil module 150B and the fixing by the fixing pin 191 may be repeated in this order.
- busbar module 200 Next, the busbar module 200 will be described.
- the busbar module 200 is electrically connected to the partial windings 151 of each coil module 150 in the stator winding 61, connects one end of the partial windings 151 of each phase in parallel, and 151 at the neutral point. 29 is a perspective view of the busbar module 200, and FIG. 30 is a cross-sectional view showing a part of the longitudinal section of the busbar module 200. As shown in FIG.
- the busbar module 200 has an annular portion 201 having an annular shape, 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 an insulating member such as resin.
- the annular portion 201 has a laminated plate 204 that has a substantially annular plate shape and is laminated in multiple layers (five layers in this embodiment) in the axial direction.
- bus bars 211 to 214 are provided sandwiched therebetween.
- Each of the busbars 211 to 214 has an annular shape, and includes a U-phase busbar 211, a V-phase busbar 212, a W-phase busbar 213, and a neutral point busbar 214. .
- These bus bars 211 to 214 are arranged side by side in the axial direction in the annular portion 201 so that their plate surfaces face each other.
- Each laminated plate 204 and each bus bar 211 to 214 are bonded to each other with an adhesive.
- connection terminal 202 is connected to each of the bus bars 211 to 214 so as to protrude radially outward from the annular portion 201 .
- a protrusion 201a extending annularly is provided on the upper surface of the annular portion 201, that is, on the upper surface of the laminate plate 204 on the outermost side of the laminate plates 204 provided in five layers.
- the busbar module 200 may be provided with the busbars 211 to 214 embedded in the annular portion 201, and the busbars 211 to 214 arranged at predetermined intervals are integrally insert-molded. can be anything. Further, the arrangement of the bus bars 211 to 214 is not limited to the configuration in which all the plate surfaces are aligned in the axial direction and all the plate surfaces face the same direction. A configuration in which the substrates are arranged in a row, a configuration in which the plate surfaces extend in different directions, or the like may be employed.
- connection terminals 202 are arranged in the circumferential direction of the annular portion 201 and extend axially on the radially outer side.
- the connection terminals 202 include 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. and a connection terminal connected to the bus bar 214 for.
- the connection terminals 202 are provided in the same number as the winding ends 154 and 155 of the partial windings 151 in the coil module 150.
- the connection terminals 202 have the winding ends 154 and 155 of the partial windings 151. 155 are connected one by one.
- the busbar 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 busbar material, and is provided so as to extend in the axial direction.
- Input/output terminals 203 include 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 respective bus bars 211 to 213 for each phase within the annular portion 201 . Through these input/output terminals 203 , power is input/output from an inverter (not shown) to each phase winding of the stator winding 61 .
- the busbar module 200 may be configured to be integrally provided with a current sensor for detecting the phase current of each phase.
- the busbar 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.
- annular portion 201 has a plurality of projecting portions 205 projecting inwardly as portions to be fixed to the stator holder 70, and through holes 206 extending in the axial direction are formed in the projecting portions 205. ing.
- FIG. 31 is a perspective view showing a state in which the busbar module 200 is attached to the stator holder 70
- FIG. 32 is a vertical cross-sectional view of a fixing portion where the busbar module 200 is fixed.
- the busbar 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 busbar module 200 is fixed to the stator holder 70 (inner cylinder member 81) by tightening fasteners 217 such as bolts in a state in which the busbar module 200 is positioned by being assembled to the strut portion 95 (see FIG. 12) of the inner cylinder member 81. ing.
- the end plate portion 91 of the inner cylinder member 81 is provided with a support portion 95 extending in the axial direction.
- the busbar module 200 is fixed to the strut portion 95 with fasteners 217 in a state in which the strut portion 95 is inserted through the through holes 206 provided in the plurality of projecting portions 205 .
- the busbar module 200 is fixed using a retainer plate 220 made of a metal material such as iron.
- the retainer plate 220 includes a fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted; and a bend portion 224 provided at the .
- the fastener 217 is screwed onto the strut portion 95 of the inner tubular member 81 while the fastener 217 is inserted through the insertion hole 221 of the retainer plate 220 .
- the pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200 .
- the retainer plate 220 is pushed downward in the drawing as the fastener 217 is screwed into the strut portion 95 , and the pressing portion 223 presses the annular portion 201 downward accordingly. Since the downward pressing force in the drawing generated by screwing the fastener 217 is transmitted to the pressing portion 223 through the bending portion 224, the pressing portion 223 presses in a state accompanied by the elastic force of the bending portion 224. ing.
- the annular projection 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 projection 201a.
- the pressing force of the retainer plate 220 downward in the figure is suppressed from escaping radially outward. In other words, the pressing force generated by screwing the fastener 217 is properly transmitted to the pressing portion 223 side.
- the input/output terminal 203 is positioned 180 degrees in the circumferential direction opposite to the inlet opening 86a and the outlet opening 87a leading to the coolant passage 85. It is set at a position where However, the input/output terminals 203 and the openings 86a and 87a may be collectively provided at the same position (ie close position).
- relay member 230 that electrically connects the input/output terminals 203 of the busbar module 200 to an external device of the rotating electric machine 10 will be described.
- Relay member 230 is a member that relays connection between input/output terminal 203 for each phase extending from busbar module 200 and a power line for each phase extending from an external device such as an inverter.
- FIG. 33 is a longitudinal 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.
- FIG. 33 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 inserted into the through hole 242 a of the housing cover 242 .
- the terminal insertion portion 232 has three insertion holes 233 into which the input/output terminals 203 of each phase are inserted. These three insertion holes 233 have elongated cross-sectional openings, and are formed side by side with their longitudinal directions substantially the same.
- the body portion 231 is attached with three relay bus bars 234 provided for each phase.
- the relay bus bar 234 is bent into a substantially L-shape, and is fixed to the main body 231 with fasteners 235 such as bolts. is fixed to the distal end portion thereof by fasteners 236 such as bolts and nuts.
- a power line for each phase extending from an external device can be connected to the relay member 230, so that power can be input/output to/from the input/output terminal 203 for each phase.
- FIG. 35 is an electric circuit diagram of the control system of rotating electric machine 10
- FIG. 36 is a functional block diagram showing control processing by control device 270. As shown in FIG.
- the stator winding 61 consists of U-phase winding, V-phase winding and W-phase winding, and an inverter 260 corresponding to a power converter is connected to the stator winding 61.
- the inverter 260 is composed of a full bridge circuit having the same number of upper and lower arms as the number of phases.
- Each of these switches 261 and 262 is turned on and off by a driver 263, and the phase winding of each phase is energized by the on and off.
- Each of the switches 261 and 262 is composed of a semiconductor switching element such as MOSFET or IGBT.
- a charge supply capacitor 264 is connected in parallel to the series connection body of the switches 261 and 262 to the upper and lower arms of each phase to supply the switches 261 and 262 with the charge required for switching.
- phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at a neutral point.
- the control device 270 includes a microcomputer including a CPU and various memories, and controls energization by turning on and off the switches 261 and 262 based on various detection information in the rotating electrical machine 10 and requests for power running and power generation.
- the detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 20 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, the current sensor contains the conducting current of each phase detected by
- the controller 270 performs ON/OFF control of the switches 261 and 262 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or rectangular wave control.
- Control device 270 may be a built-in control device built into rotating electrical machine 10 or an external control device provided outside rotating electrical machine 10 .
- the inductance of the stator 60 is reduced and the electrical time constant is reduced. Under low constant conditions, it is desirable to increase the switching frequency (carrier frequency) and increase the switching speed.
- the wiring inductance is reduced by connecting the charge supply capacitor 264 in parallel to the series connection of the switches 261 and 262 of each phase, and even with a configuration with a high switching speed, an appropriate surge can be prevented. Countermeasures are possible.
- a high potential side terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265, and a low potential side terminal is connected to the negative 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 cells are connected in series.
- 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 current feedback control processing for controlling each phase current of the U, V, and W phases.
- a current command value setting unit 271 uses a torque-dq map, and based on a powering torque command value or a power generation torque command value for the rotary electric machine 10 and an electrical angular velocity ⁇ obtained by differentiating the electrical angle ⁇ with time. , set the d-axis current command value and the q-axis current command value.
- the power generation torque command value is a regenerative torque command value, for example, when the rotary electric machine 10 is used as a vehicle power source.
- the dq transform unit 272 converts current detection values (three phase currents) by current sensors provided for each phase into orthogonal 2 It is converted into a d-axis current and a q-axis current, which are components of a dimensional rotating coordinate system.
- the d-axis current feedback control unit 273 calculates a d-axis command voltage as a manipulated variable for feedback-controlling the d-axis current to the d-axis current command value.
- the q-axis current feedback control unit 274 also calculates a q-axis command voltage as an operation amount for feedback-controlling the q-axis current to the q-axis current command value.
- a command voltage is calculated using the PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.
- the three-phase converter 275 converts the d-axis and q-axis command voltages into U-phase, V-phase and W-phase command voltages.
- the units 271 to 275 described above are feedback control units that perform feedback control of the fundamental wave current based on the dq conversion theory, and the command voltages of the U-phase, V-phase, and W-phase are feedback control values.
- the operation signal generator 276 uses a well-known triangular wave carrier comparison method to generate an operation signal for the inverter 260 based on the three-phase command voltages. Specifically, the operation signal generator 276 performs PWM control based on a magnitude comparison between a signal obtained by standardizing the three-phase command voltage by the power supply voltage and a carrier signal such as a triangular wave signal, thereby controlling the switch of the upper and lower arms in each phase. Generates an operation signal (duty signal). The switch operation signal generated by the operation signal generator 276 is output to the driver 263 of the inverter 260, and the driver 263 turns on/off the switches 261 and 262 of each phase.
- Control device 270 selects and executes either torque feedback control processing or current feedback control processing based on the operating conditions of 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 calculator 281 is a command value for the magnitude of the voltage vector based on the powering torque command value or the power generation torque command value for the rotary electric machine 10 and the electrical angular velocity ⁇ obtained by time differentiating the electrical angle ⁇ . Calculate the voltage amplitude command.
- the dq conversion unit 282 like the dq conversion unit 272, converts current detection values obtained by current sensors provided for each phase into d-axis current and q-axis current.
- Torque estimator 283 calculates torque estimated values corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. Note that the torque estimator 283 may calculate the voltage amplitude command based on map information in which the d-axis current, the q-axis current, and the voltage amplitude command are associated.
- the torque feedback control unit 284 calculates a voltage phase command, which is a command value for the phase of the voltage vector, as a manipulated variable for feedback-controlling the estimated torque value to the powering torque command value or the power generation torque command value.
- the torque feedback control unit 284 calculates a voltage phase command using the PI feedback technique based on the deviation of the estimated torque value from the powering torque command value or the power generation torque command value.
- the operation signal generator 285 generates an operation signal for the inverter 260 based on the voltage amplitude command, the voltage phase command and the electrical angle ⁇ . Specifically, the operation signal generator 285 calculates three-phase command voltages based on the voltage amplitude command, the voltage phase command, and the electrical angle ⁇ , and normalizes the calculated three-phase command voltages by the power supply voltage. , a switch operation signal for the upper and lower arms in each phase is generated by PWM control based on a magnitude comparison with a carrier signal such as a triangular wave signal. The switch operation signal generated by the operation signal generator 285 is output to the driver 263 of the inverter 260, and the driver 263 turns on/off the switches 261 and 262 of each phase.
- the operation signal generation unit 285 generates the voltage amplitude command, the voltage phase command, the electrical angle ⁇ , and the pulse pattern information, which is map information in which the switch operation signal is associated, the voltage amplitude command, the voltage phase command, and the electrical angle ⁇ . may be used to generate the switch operation signal.
- the configuration of the magnets in the magnet unit 22 may be changed as follows.
- the direction of the axis of easy magnetization in the magnet 32 is oblique to the radial direction, and a linear magnet magnetic path is formed along the direction of the axis of easy magnetization.
- the magnet magnetic path length of the magnet 32 can be made longer than the thickness dimension in the radial direction, and the permeance can be improved.
- the direction of bending of the transition portion 153 may be any of the radial direction inside and outside, and the first transition portion 153A is bent toward the core assembly CA in relation to the core assembly CA. Alternatively, the first transition portion 153A may be bent to the opposite side of the core assembly CA. Further, if the second transition portion 153B is in a state of straddling a part of the first transition portion 153A in the axial direction outside the first transition portion 153A in the circumferential direction, the second transition portion 153B may be radially inward or outward. It may be folded.
- the partial winding 151 may have one type of partial winding 151 instead of having two types of partial winding 151 (first partial winding 151A and second partial winding 151B).
- the partial winding 151 may be formed to have a substantially L shape or a substantially Z shape when viewed from the side.
- the transition portion 153 is bent radially inward or outward at one end in the axial direction, and the transition portion 153 is bent radially at the other end in the axial direction. It is configured to be provided without being bent.
- the connecting portion 153 is bent in opposite directions in the radial direction at one axial end and the other axial end. In either case, it is preferable that the coil module 150 is fixed to the core assembly CA by the insulating cover that covers the transition portion 153 as described above.
- all the partial windings 151 are connected in parallel for each phase winding, but this may be changed.
- all 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, the n partial windings 151 in each phase winding are divided into two groups of n/2 parallel connections, three groups of n/3 parallel connections, and the like. It is good also as a structure which connects.
- the stator winding 61 may have a configuration in which the plurality of partial windings 151 are all connected in series for each phase winding.
- the stator winding 61 in the rotating electrical machine 10 may be configured to have two phase windings (a U-phase winding and a V-phase winding).
- a pair of intermediate conductor portions 152 are provided separated by one coil pitch. may be arranged as long as one is arranged.
- FIGS. 39(a) and 39(b) are diagrams showing the configuration of the stator unit 300 when it has an inner rotor structure.
- FIG. 39(a) is a perspective view showing the coil modules 310A and 310B assembled to the core assembly CA
- FIG. 39(b) shows partial windings 311A and 311B included in each of the coil modules 310A and 310B. It is a perspective view showing the.
- a core assembly CA is configured by assembling a stator holder 70 to the radially outer side of the stator core 62 .
- a plurality of coil modules 310A and 310B are assembled inside the stator core 62 in the radial direction.
- the partial winding 311A has generally the same configuration as the above-described first partial winding 151A, and includes a pair of intermediate conductor portions 312 and axially opposite sides thereof bent toward the core assembly CA side (radially outward). It has a transition portion 313A formed thereon. Further, the partial winding 311B has substantially the same configuration as the second partial winding 151B described above, and includes a pair of intermediate conductor portions 312 and connecting portions 313A on both sides in the axial direction. and a bridging portion 313B provided so as to straddle the . An insulating cover 315 is attached to the transition portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the transition portion 313B of the partial winding 311B.
- the insulating cover 315 is provided with semicircular concave portions 317 extending in the axial direction on both sides in the circumferential direction.
- the insulating cover 316 is provided with a protruding portion 318 that protrudes radially outward from the transition portion 313B, and a through hole 319 that extends in the axial direction is provided at the tip of the protruding portion 318 .
- FIG. 40 is a plan view showing a state in which the coil modules 310A and 310B are attached to the core assembly CA.
- a plurality of recesses 105 are formed in the axial end face of the stator holder 70 at regular intervals in the circumferential direction.
- the stator holder 70 has a cooling structure using a liquid refrigerant or air, and for example, it is preferable that a plurality of heat radiation fins be formed on the outer peripheral surface as an air cooling structure.
- the insulating covers 315 and 316 are arranged so as to overlap each other in the axial direction.
- a concave portion 317 provided in the side surface of the insulating cover 315, and a through hole 319 provided in a protruding portion 318 of the insulating cover 316 at a central position between one end and the other end of the insulating cover 316 in the circumferential direction. are connected in the axial direction, and are fixed by fixing pins 321 at each of them.
- the fixing positions of the insulating covers 315 and 316 by the fixing pins 321 are the axial end surfaces of the stator holder 70 radially outside the stator core 62. In contrast, it is configured to be fixed by a fixing pin 321 .
- the stator holder 70 is provided with a cooling structure, the heat generated in the partial windings 311A and 311B is easily conducted to the stator holder 70 . Thereby, the cooling performance of the stator winding 61 can be improved.
- the stator 60 used in the rotating electric machine 10 may have protrusions (eg, teeth) extending from the back yoke. Also in this case, it is sufficient that the coil module 150 and the like are attached to the stator core with respect to the back yoke.
- the rotating electric machine is not limited to star connection, but may be delta connection.
- a rotating armature type rotating electric machine having a field element as a rotor and an armature as a stator is replaced with a rotating field type rotating electric machine having an armature as a rotor and a field element as a stator. It is also possible to employ a rotating electrical machine.
- Modification 2 In the above embodiment or modification, the configuration may be changed as follows. Hereinafter, in Modified Example 2, differences from the configurations described in the above embodiments and modified examples will be mainly described. In addition, in Modification 2, the basic configuration of the rotating electric machine 10 will be described using the first embodiment as an example. In the following, the configuration of the magnet unit 1000 as the magnet portion in Modification 2 will be mainly described in detail.
- the magnet unit 1000 has a plurality of magnets 1001 and 1002 arranged side by side in the circumferential direction, and a magnet yoke 2000 holding these magnets 1001 and 1002. .
- Magnets 1001 and 1002 are fixed to magnet yoke 2000 via an adhesive or the like.
- the inner peripheral surface of the magnet yoke 2000 corresponds to the magnet fixing surface.
- each magnet 1001, 1002 is provided between the d-axis, which is the center of the magnetic pole, and the q-axis, which is the magnetic pole boundary circumferentially adjacent to the d-axis which is the center of the magnetic pole.
- the magnets 1001 and 1002 are provided symmetrically in the circumferential direction around the d-axis, which is the magnetic pole center, or the q-axis, which is the magnetic pole boundary. 41 and 42, the magnet on the left side of the d-axis, which is the magnetic pole center, is indicated as magnet 1001, and the magnet on the right side is indicated as magnet 1002.
- the magnet unit 1000 is provided in an annular shape by arranging the magnets 1001 and 1002 side by side in the circumferential direction.
- each of the magnets 1001 and 1002 has a stator-side peripheral surface 1003 (armature-side peripheral surface) on the radially inner side (the stator 60 side), and has a radially outer side (the magnet yoke 2000 side). It has an anti-stator-side peripheral surface 1004 (anti-armature-side peripheral surface) on the outer side, and has circumferential end surfaces 1005 that are planes along the radial direction at both ends in the circumferential direction.
- Each magnet 1001, 1002 is provided so as to have a predetermined height dimension in the axial direction.
- the cross-sectional shape of each magnet 1001, 1002 is the same at any point in the axial direction. Also, since the magnets 1001 and 1002 are bilaterally symmetrical, the magnet 1001 will be mainly described below.
- Each circumferential end surface 1005 is provided so as to connect the circumferential end of the stator-side circumferential surface 1003 and the circumferential end of the anti-stator-side circumferential surface 1004 .
- Each of the magnets 1001 and 1002 has a d-axis side end face 1005a that is a circumferential end face 1005 on the d-axis side that is the magnetic pole center, a q-axis side end face 1005b that is a circumferential end face 1005 on the q-axis side that is the magnetic pole boundary, have
- a stator-side peripheral surface 1003 of each magnet 1001 is formed in a substantially arcuate shape along the circumferential direction.
- the outermost surface in the radial direction is formed in a substantially arcuate shape along the circumferential direction, and is in contact with the inner peripheral surface of the magnet yoke 2000.
- an anti-stator side q-axis concave portion 1004b is provided at the q-axis side end portion which is the magnetic pole boundary. Due to the anti-stator side q-axis recess 1004b, the corner between the anti-stator side peripheral surface 1004 and the q-axis side end surface 1005b is recessed radially inward.
- the anti-stator-side q-axis recessed portion 1004b has a substantially trapezoidal shape in which the opening portion (outside portion in the radial direction) is wider than the bottom portion (inner portion in the radial direction). It is considered as an inclined surface. The range in which the anti-stator side q-axis recessed portion 1004b is provided will be described later.
- the anti-stator-side peripheral surface 1004 of each magnet 1001, 1002 has an uneven shape in the radial direction.
- the anti-stator side q-axis recess 1004b is formed on the q-axis side, which is the magnetic pole boundary, with the inner peripheral surface of the magnet yoke 2000 as a reference.
- the bottom of 1004b may be used as a reference.
- the magnet 1001 is formed with a d-axis side convex portion that radially protrudes toward the d-axis side, which is the center of the magnetic pole.
- the axes of easy magnetization of these magnets 1001 and 1002 are oriented parallel to the d-axis, which is the center of the magnetic pole, on the d-axis, which is the center of the magnetic pole, compared to the q-axis, which is the magnetic pole boundary.
- a magnet magnetic path is formed along the axis of easy magnetization. Specifically, in each of the magnets 1001 and 1002, as shown in FIG. 42, a plurality of arcuate magnet magnetic paths are formed around a central point (orientation center) set on the q-axis.
- the shape of the magnet magnetic path may be an arc that is a part of a perfect circle or an arc that is a part of an ellipse.
- the center of the arc is on the q-axis, it may not be on the q-axis as long as it is on the q-axis side of the d-axis.
- the center of the arc is located on the stator side peripheral surface 1003 of the plurality of magnets 1001 and 1002 in the radial direction, or the stator 60 (electric machine) rather than the stator side peripheral surface 1003 of the plurality of magnets 1001 and 1002. child) side.
- the axis of easy magnetization of each magnet 1001, 1002 is parallel to the d-axis, which is the center of the magnetic pole, or nearly parallel to the d-axis, which is the center of the magnetic pole, in the portion near the d-axis which is the center of the magnetic pole, and is at the magnetic pole boundary.
- the direction is orthogonal to the q-axis, which is the magnetic pole boundary, or nearly orthogonal to the q-axis, which is the magnetic pole boundary.
- the magnet magnetic path of the magnet 1001 is symmetrical in the circumferential direction about the d-axis, which is the center of the magnetic pole, with respect to the magnet magnetic path of the magnet 1002, which is adjacent in the circumferential direction about the d-axis, which is the center of the magnetic pole. It is Here, the magnet 1001 and the magnet 1002 adjacent to the magnet 1001 in the circumferential direction about the d-axis, which is the center of the magnetic poles, are referred to as a pair of magnets 1001 and 1002 .
- the magnetization directions (magnetization directions) of the magnets 1001 and 1002 are reversed for each of the paired magnets 1001 and 1002 so that the polarities of the d-axis, which is the magnetic pole center adjacent in the circumferential direction, are different. (Reverse). That is, as shown in FIG. 42, the magnetization direction (magnetization direction) of the magnets 1001 and 1002 paired around the d-axis, which is the center of the magnetic pole whose polarity is positive (N pole), is such that the magnetic flux line is at the center of the magnetic pole. It is set to converge toward a certain d-axis.
- the magnetization direction (magnetization direction) of the paired magnets 1001 and 1002 around the d-axis, which is the center of the magnetic pole whose polarity is negative (S pole), spreads in the opposite direction from the d-axis, which is the center of the magnetic pole. is set to
- Each magnet 1001, 1002 is a sintered magnet manufactured by a sintering method. That is, the produced raw materials such as neodymium, boron, and iron are melted and alloyed (first step). Next, the alloy obtained in the first step is pulverized into particles (second step). Then, the powder obtained in the second step is placed in a mold and pressure-molded in a magnetic field (third step). After pressure molding, the molded product is sintered (fourth step), and after sintering is completed, heat treated (fifth step). Heating and cooling are performed several times in the heat treatment. After machining such as grinding and surface processing (sixth step), the magnets 1001 and 1002 are completed by being magnetized (seventh step).
- the magnet yoke 2000 is made of a soft magnetic material and has a cylindrical shape. On the inner peripheral surface of the magnet yoke 2000, engaging portions 2001 protruding radially inward are provided at regular intervals in the circumferential direction. This engaging portion 2001 is formed integrally with the magnet yoke 2000 and is made of a soft magnetic material.
- the engaging portion 2001 is formed in the anti-stator side q-axis recessed portion in accordance with the shape of the anti-stator side q-axis recessed portion 1004b so as to be accommodated in the anti-stator side q-axis recessed portion 1004b of each of the magnets 1001 and 1002. It is formed to fill 1004b. That is, the engaging portion 2001 is formed in a substantially trapezoidal shape in which the bottom side (diameter direction outer portion) is wider than the upper side (diameter direction inner portion), and the gap between the magnets 1001 and 1002 is formed as little as possible, that is, they are configured to contact each other.
- the engaging portion 2001 engages on its side surface with the side surface of the anti-stator side q-axis recessed portion 1004b to restrict the movement of the magnets 1001 and 1002 in the circumferential direction. Therefore, it functions as a positioning member for the magnets 1001 and 1002 and as a detent.
- the easy magnetization axes of the magnets 1001 and 1002 are oriented parallel to the d-axis, which is the center of the magnetic pole, on the d-axis, which is the center of the magnetic pole, compared to the q-axis, which is the magnetic pole boundary. , and a magnet magnetic path is formed along the axis of easy magnetization.
- the magnets 1001 and 1002 should be arranged along the d-axis which is the magnetic pole center and the q-axis which is the magnetic pole boundary adjacent to the d-axis which is the magnetic pole center.
- the magnet it is preferable to manufacture the magnet by dividing it along the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary.
- the magnets 1001 and 1002 are provided between the d-axis that is the center of the magnetic pole and the q-axis that is the magnetic pole boundary adjacent to the d-axis that is the center of the magnetic pole, the magnetic flux density in the d-axis that is the center of the magnetic pole is improved.
- the magnets 1001 and 1002 due to the manufacturing method of the magnets 1001 and 1002, it is difficult to manufacture the magnets 1001 and 1002 according to the dimensions, resulting in a slight gap. Further, when the magnets 1001 and 1002 are provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary, the adjacent d-axis side end faces 1005a have the same polarity and tend to repel each other, so the q-axis side end face 1005b gaps are more likely to be formed compared to
- the gap between the engaging portions 2001 adjacent in the circumferential direction is set so that the gap between the d-axis side end faces 1005a of the magnets 1001 and 1002 is narrower than the gap between the q-axis side end faces 1005b.
- the distance L21 from the side surface of the anti-stator-side q-axis recessed portion 1004b (the position of engagement with the engaging portion 2001) to the d-axis, which is the center of the magnetic pole, is half the interval L20 of the engaging portion 2001. , or slightly smaller.
- the magnets 1001 and 1002 are arranged such that the distance L21 from the side surface of the anti-stator-side q-axis recessed portion 1004b to the d-axis, which is the magnetic pole center, is half the interval L20 of the engaging portion 2001 or slightly smaller. (anti-stator side q-axis concave portion 1004b or d-axis side end surface 1005a) is adjusted.
- the gap between the d-axis side end faces 1005a may be 1/4 or less of the gap between the q-axis side end faces 1005b.
- the interval between adjacent engaging portions 2001 is configured to become narrower toward the radially outer side. Therefore, when the rotary electric machine 10 rotates, part of the radially outward centrifugal force applied to the magnets 1001 and 1002 is converted by the engaging portion 2001 into stress in the circumferential direction d-axis. That is, the magnets 1001 and 1002 are applied with a force in the direction of approaching the d-axis side, which is the center of the magnetic pole, and it is possible to suppress the gap between the d-axis side end faces 1005a from widening.
- the axis of easy magnetization in each of the magnets 1001 and 1002 is oriented parallel to the d-axis, which is the center of the magnetic pole, on the side of the d-axis, which is the center of the magnetic pole, compared to the side of the q-axis, which is the magnetic pole boundary.
- a magnet magnetic path is formed along the axis of easy magnetization.
- the leakage magnetic flux between the magnet magnetic poles is reduced, and the surface magnetic flux density of the magnets 1001 and 1002 is sinusoidal (d can be approximated to a sinusoidal shape with extremes at the axis). That is, when the magnet magnetic path is formed in an arc shape as in this embodiment, the leakage magnetic flux between the magnet magnetic poles can be reduced, and the surface magnetic flux densities of the magnets 1001 and 1002 can be brought closer to a sinusoidal shape.
- the shapes of the magnets 1001 and 1002 are configured as follows. This will be explained below.
- the permeance coefficient Pc in the circumferential direction of the magnets 1001 and 1002 (more specifically, the stator-side circumferential surface 1003) is calculated, it is found to be proportional to the length of the magnet magnetic path.
- the permeance coefficient Pc is the ratio of the magnetic flux density to the magnetic field strength (magnetic field inside the magnet). If the material of the magnet is known, it can be calculated from the shape of the magnet (the length and cross-sectional area in the direction of magnetization). In general, it is known that the longer the length in the magnetization direction (the length of the magnet magnetic path), the larger the permeance coefficient Pc, the more difficult it is to self-demagnetize, and the easier it is to increase the magnetic flux density. .
- the magnets 1001 and 1002 are a collection of thin magnets along the magnet magnetic path, as shown in FIG. is approximately proportional to the length of the magnet magnetic path. Therefore, as shown in FIG. 43, in the magnets 1001 and 1002 in the state where the anti-stator-side q-axis recessed portion 1004b is not provided, in the circumferential direction, from the q-axis, which is the magnetic pole boundary, to the d-axis side, which is the magnetic pole center. The closer it gets, the larger the permeance coefficient Pc becomes.
- the magnets 1001 and 1002 are uniformly magnetized and have the same cross-sectional area (here, cross-sectional area in the axial direction) perpendicular to the magnetization direction (the direction of the magnet magnetic path). is assumed. Further, when calculating the permeance coefficient Pc, it is preferable to use the average value of the predetermined thicknesses (widths in the radial direction) of the magnets 1001 and 1002 .
- contour lines L11 to L13 of the permeance coefficient Pc can be drawn for the magnets 1001 and 1002 in which the anti-stator side q-axis recessed portion 1004b is not provided.
- the contour lines L11 to L13 of the permeance coefficient Pc are lines along which the permeance coefficient Pc has the same value. Due to the difference in the length of the magnet magnetic path, the contour line L13 closer to the anti-stator side has a higher permeance coefficient Pc than the contour line L11 closer to the stator side.
- the contour line L11 in FIG. 43 has the lowest permeance coefficient Pc, and the contour line L12 and the contour line L13 have higher permeance coefficients Pc in this order.
- the thickness dimension of the magnets 1001 and 1002 in the radial direction is d It can be seen that while it is necessary to increase the thickness on the axis side, the thickness may be reduced on the q-axis side, which is the magnetic pole boundary.
- the surface magnetic flux density of the magnet unit 1000 approaches a sinusoidal shape
- the magnetic pole center it is necessary to increase the thickness on the d-axis side, which is the magnetic pole center, by further reducing the thickness on the q-axis side, which is the magnetic pole boundary, the magnetic pole center It can be seen that the permeance coefficient Pc can be increased as it approaches the d-axis side.
- the permeance coefficient Pc of each of the magnets 1001 and 1002 calculated based on the length of the magnet magnetic path is the q-axis, which is the magnetic pole boundary, in the circumferential direction.
- An anti-stator-side q-axis recess 1004b is provided on the anti-stator-side circumferential surface 1004 on the q-axis side, which is the magnetic pole boundary, so that it becomes larger as it approaches the d-axis, which is the center of the magnetic pole. That is, along the dashed line in FIG.
- unevenness is provided on the anti-stator side peripheral surface 1004 to adjust the length of the magnet magnetic path, and the permeance coefficient Pc of each magnet 1001, 1002 is aligned with the q axis, which is the magnetic pole boundary. It is assumed that the distance from the d-axis, which is the center of the magnetic pole, increases. Although it is desirable to provide the anti-stator side q-axis recess 1004b so as to completely match the broken line in FIG. A q-axis recess 1004b is provided.
- the maximum dimension of the thickness in the radial direction of the magnets 1001 and 1002 is defined as dimension Ta (see FIG. 41).
- This dimension Ta corresponds to the dimension from the radially innermost portion of the stator-side peripheral surface 1003 to the radially outermost portion of the anti-stator-side peripheral surface 1004 . Note that this corresponds to the thickness dimension on the d-axis side, which is the center of the magnetic poles of the magnets 1001 and 1002, when the anti-stator side d-axis concave portion 1004a is not provided.
- the thickness dimension on the q-axis side which is the magnetic pole boundary, is defined as dimension Tb (see FIG. 41).
- This dimension Tb corresponds to the dimension from the radially innermost portion of the stator-side peripheral surface 1003 to the bottom of the anti-stator-side q-axis recess 1004b.
- a magnet 3000 having a shape as shown in FIG. 45 is assumed as a comparative example. It is assumed that the magnet magnetic path of the magnet 3000 shown in FIG. 45 is arc-shaped as in the present embodiment. It is also assumed that the shape of the stator-side peripheral surface 1003 is the same. On the other hand, it is assumed that the anti-stator-side q-axis recess 1004b is not provided on the anti-stator-side circumferential surface on the q-axis side, which is the magnetic pole boundary. That is, the description will be made assuming that the magnet 3000 has a uniform thickness in the radial direction.
- the radial thickness of the magnet 3000 is thinner than the dimension Ta on the d-axis side, which is the magnetic pole center of the magnets 1001 and 1002, and is thicker than the dimension Tb on the q-axis side, which is the magnetic pole boundary.
- the surface magnetic flux density of the magnet unit composed of the magnets 3000 formed in this way is as indicated by the solid line in FIG. It can be seen that there is room for improvement, although the waveform is closer to a sinusoidal waveform than a magnet provided with a linear magnet magnetic path along the radial direction.
- the surface magnetic flux density can be lowered to make it closer to a sinusoidal wave (indicated by a dashed line).
- the arrow Y2 shown in FIG. by increasing the dimension Ta on the d-axis side, which is the magnetic pole center, compared to the dimension Tb on the q-axis side, which is the magnetic pole boundary, the arrow Y2 shown in FIG. , it is possible to improve the surface magnetic flux density near the d-axis side, which is the center of the magnetic pole, and to make it closer to a sine wave.
- the permeance coefficient Pc of the plurality of magnets 1001 and 1002 calculated based on the length of the magnet magnetic path varies from the q-axis, which is the magnetic pole boundary, to the magnetic pole in the circumferential direction.
- Anti-stator-side q-axis recesses 1004b are provided on the anti-stator-side circumferential surface 1004 on the q-axis side, which is the magnetic pole boundary, so that the recesses 1004b become larger as they approach the d-axis, which is the center.
- the length of the magnet magnetic path is adjusted by providing unevenness on the peripheral surface 1004 opposite to the stator, and the permeance coefficient Pc increases in the circumferential direction as it approaches the d-axis, which is the center of the magnetic pole, from the q-axis, which is the magnetic pole boundary. I decided to become This makes it possible to easily bring the surface magnetic flux density of the magnet unit 1000 closer to a sinusoidal wave than when adjusting the direction and length of the axis of easy magnetization.
- the anti-stator side q-axis concave portion of the non-stator side peripheral surface 1004 is provided on the q-axis side which is the magnetic pole boundary.
- An engaging portion 2001 made of a soft magnetic material is provided to engage with 1004b in the circumferential direction and exchange magnetic flux between the magnetic poles of the magnets 1001 and 1002 having different polarities.
- magnetic flux leakage between magnets of different polarities between magnet magnetic poles
- the magnets 1001 and 1002 can be properly fixed and prevented from rotating.
- the magnets 1001 and 1002 have their easy magnetization axes oriented in an arc, and the orientation center of the arc-oriented easy magnetization axes is the magnetic pole center in the circumferential direction.
- leakage of magnetic flux between the magnetic poles of the magnet can be suppressed, and the magnetic flux density can be improved while making it closer to a sine wave.
- the average thickness of the magnets 1001 and 1002 can be suppressed, and the amount of magnets used can be reduced.
- the d-axis side end face 1005a has the same polarity and repulsion occurs. Therefore, a gap is easily formed compared to the q-axis side end surface 1005b. Therefore, the interval L20 between the engaging portions 2001 adjacent in the circumferential direction is set so that the gap between the d-axis side end faces 1005a of the magnets 1001 and 1002 is narrower than the gap between the q-axis side end faces 1005b.
- the gap L20 between the engaging portions 2001 that engage with the magnets 1001 and 1002 in the circumferential direction is adjusted so that the gap between the d-axis side end faces 1005a of the magnets 1001 and 1002 in the circumferential direction is the gap between the q-axis side end faces 1005b. narrower than This makes it possible to easily position the magnets 1001 and 1002 with high accuracy. Since the gap between the d-axis side end faces 1005a can be suppressed, a rapid change in magnetic flux density caused by the gap can be suppressed, and torque pulsation and cogging torque can be suppressed.
- the easy magnetization axes of the magnets 1001 and 1002 are oriented parallel to the d-axis, which is the center of the magnetic pole, on the d-axis, which is the center of the magnetic pole, compared to the q-axis, which is the magnetic pole boundary.
- a magnet magnetic path is formed along the axis of easy magnetization. Therefore, it is possible to make the surface magnetic flux density closer to a sine wave while improving the magnetic flux density in the d-axis, which is the center of the magnetic pole.
- a magnetic pole center d-axis and the magnetic pole boundary q-axis adjacent to the magnetic pole center d-axis should be provided.
- magnets 1001, 1002 are provided.
- the magnets 1001 and 1002 are provided between the d-axis that is the center of the magnetic pole and the q-axis that is the magnetic pole boundary adjacent to the d-axis that is the center of the magnetic pole, the magnetic flux density in the d-axis that is the center of the magnetic pole is improved.
- the radially oriented magnets when the radially oriented magnets are arranged in the circumferential direction without gaps, the magnetic flux density changes sharply near the q-axis, which is the magnetic pole boundary, as shown in FIG. For this reason, when adopting radially oriented magnets, they are usually arranged at predetermined intervals.
- the magnets 1001 and 1002 are formed with irregularities on their peripheral surfaces 1004 opposite to the stator, and the inner peripheral surface of the magnet yoke 2000 serving as the magnet fixing surface is provided with a peripheral surface 1004 opposite to the stator. and has an engaging portion 2001 that engages with the peripheral surface 1004 on the opposite side of the stator.
- the peripheral surfaces 1004 of the magnets 1001 and 1002 on the side opposite to the stator engage with the engaging portion 2001 in the circumferential direction, so that rotation can be properly prevented.
- the interval between adjacent engaging portions 2001 is configured so as to become narrower toward the outer side in the radial direction. Therefore, when the rotating electric machine 10 rotates, part of the radially outward centrifugal force applied to the magnets 1001 and 1002 is converted by the engaging portion 2001 into stress toward the d-axis side, which is the magnetic pole center in the circumferential direction. be. That is, the magnets 1001 and 1002 are applied with a force in the direction of approaching the d-axis side, which is the center of the magnetic pole, and it is possible to suppress the gap between the d-axis side end faces 1005a from widening.
- an outer rotor type rotor is used in Modified Example 2
- an inner rotor type rotor may be used as shown in FIG. The rotor will be described in detail below.
- Magnet unit 1000 shown in FIG. is doing. Magnets 1011 and 1012 are fixed to the outer peripheral surface of magnet yoke 2010 via an adhesive or the like.
- each of the magnets 1011 and 1012 has a d-axis that is the center of the magnetic pole and a q-axis that is the magnetic pole boundary circumferentially adjacent to the d-axis that is the center of the magnetic pole. are provided between each.
- the magnets 1011 and 1012 are provided symmetrically in the circumferential direction around the d-axis, which is the magnetic pole center, or the q-axis, which is the magnetic pole boundary.
- Magnet unit 1000 shown in FIG. 47 is provided in an annular shape by arranging magnets 1011 and 1012 side by side in the circumferential direction.
- each of the magnets 1011 and 1012 has a stator-side peripheral surface 1003 (armature-side peripheral surface) on the radially outer side (the stator 60 side), and has a radially inner side (the magnet yoke 2010 side). It has an anti-stator-side peripheral surface 1004 (anti-armature-side peripheral surface) on the outer side, and has circumferential end surfaces 1005 that are planes along the radial direction at both ends in the circumferential direction.
- a stator-side peripheral surface 1003 of each magnet 1011, 1012 is formed in a substantially arc shape along the circumferential direction.
- the innermost surfaces in the radial direction are formed in a substantially arcuate shape along the circumferential direction and are in contact with the outer peripheral surface of the magnet yoke 2010.
- anti-stator-side q-axis recesses 1004b are provided on the anti-stator-side peripheral surfaces 1004 of the magnets 1011 and 1012 at the ends on the q-axis side, which are magnetic pole boundaries.
- the easy magnetization axes of the magnets 1011 and 1012 are oriented parallel to the d-axis, which is the magnetic pole center, on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.
- a magnet magnetic path is formed along the axis of easy magnetization. Specifically, in each of the magnets 1001 and 1002, a plurality of arcuate magnet magnetic paths are formed around a central point (orientation center) set on the q-axis, which is the magnetic pole boundary.
- the magnet yoke 2010 is made of a soft magnetic material and has a cylindrical shape. On the outer peripheral surface of the magnet yoke 2010, engaging portions 2011 protruding radially outward are provided at regular intervals in the circumferential direction.
- the engaging portion 2011 is integrally formed with the magnet yoke 2010 and is made of a soft magnetic material.
- This engaging portion 2011 is fitted in the anti-stator side q-axis recessed portion 1004b so as to be accommodated in the anti-stator side q-axis recessed portion 1004b of each of the magnets 1011 and 1012. is formed to fill the
- the gap between the engaging portions 2011 adjacent in the circumferential direction is adjusted such that the gap between the d-axis side end surfaces 1005a of the magnets 1011 and 1012 is narrower than the gap between the q-axis side end surfaces 1005b. is set.
- the permeance coefficient Pc of the magnets 1011 and 1012 is increased in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the center of the magnetic pole.
- a cover member 2100 is provided to cover the stator-side peripheral surface 1003 (outer peripheral surface) of the magnets 1011 and 1012 in order to prevent the magnets 1011 and 1012 from coming off. .
- the inner rotor type rotor has less leakage flux between the magnetic poles of the magnets due to the geometrical difference in the magnet arrangement. Therefore, as shown in FIG. 47, the q-axis side end face 1005b, which is the magnetic pole boundary of each magnet 1011, 1012, may be slightly separated from the q-axis. That is, a predetermined circumferential gap may be provided on the q-axis side of the magnets 1011 and 1012 having different polarities. As a result, even if the amount of magnets is reduced, there is little effect on torque reduction, and there is an effect of saving magnets.
- the shape of the anti-stator side q-axis recessed portion 1004b of the magnets 1001 and 1002 may be changed arbitrarily. It may be recessed in an arc shape, or it may be formed in a stepped shape.
- the side surfaces of the anti-stator-side q-axis concave portions 1004b of the magnets 1001 and 1002 are inclined surfaces, but they may be changed arbitrarily.
- the side surface of the anti-stator side q-axis recess 1004b may be a curved surface, or may be a side surface along the radial direction and configured stepwise.
- the direction and shape of the magnet magnetic path may be changed.
- the axes of easy magnetization of the magnets 1001 and 1002 may be oriented in parallel so that their orientations are linear with a constant inclination angle with respect to the radial direction. That is, a plurality of magnetization easy axes are oriented parallel to each other so as to be oblique to the radial direction, and a plurality of magnet magnetic paths are formed in parallel so as to be oblique to the radial direction along the magnetization easy axes.
- the magnetization easy axes of the magnets 1001 and 1002 are linear easy magnetization axes having an inclination angle with respect to the radial direction, and the inclination angle changes gradually depending on the position in the circumferential direction. can be anything.
- the linear easy axis of magnetization becomes parallel to the d-axis, which is the center of the magnetic pole, as it approaches the d-axis, which is the center of the magnetic pole, from the q-axis side which is the magnetic pole boundary.
- the inclination angle of each of the linear easy magnetization axes is set to be small with respect to the radial direction. That is, the axes of easy magnetization may be oriented radially around the d-axis, which is the center of the magnetic pole, and the magnet magnetic paths may be formed radially along the axes of easy magnetization.
- the permeance coefficient Pc of the magnets 1001 and 1002 which is calculated based on the length of the magnet magnetic path, increases in the circumferential direction as it approaches the d-axis, which is the center of the magnetic pole, from the q-axis, which is the magnetic pole boundary.
- a concave portion is provided on the q-axis side, which is the magnetic pole boundary, or a convex portion is provided on the d-axis side, which is the magnetic pole center, or a convex portion is provided on the q-axis side, which is the magnetic pole boundary. It is desirable that a concave portion is provided and a convex portion is provided on the d-axis side, which is the center of the magnetic pole.
- the engaging portion 2001 may be provided separately from the magnet yoke 2000 and fixed to the magnet yoke 2000 with an adhesive, screws, or the like.
- the magnet yoke 2000 can be made of a material different from that of the engaging portion 2001, such as resin, to reduce the weight.
- the magnet yoke of the present disclosure connects a magnet of a certain magnetic pole and a magnet of an adjacent magnetic pole, and the material is not limited to iron as a magnetic material.
- a helical core 2200 configured in a cylindrical shape by spirally winding and stacking elongated thin plate-like band members may be used as the magnet yoke.
- the yield of materials can be improved.
- the engaging portion 2001 may be integrally formed on the inner peripheral surface or the outer peripheral surface of the helical core 2200 .
- helical core 2200 is also made of a soft magnetic material.
- a bending step is performed to form a cylindrical helical core 2200 in which an elongated thin plate-like band member is spirally wound and laminated by bending an elongated linear plate member (step S101). and a fixing step of fixing the magnets 1001 and 1002 to the helical core 2200 (step S102).
- the plate member is preformed so that the engaging portion 2001 protrudes in the width direction before the bending step is performed. must be integrated.
- the magnets 1001 and 1002 may not be in proper contact. .
- the engaging portion 2001 is integrally formed on the inner peripheral surface or the outer peripheral surface of the helical core 2200, as shown in FIG. 2001 is integrally formed in advance so as to protrude in the width direction thereof, and unevenness 4002 is provided in the engaging portion 2001 before working to absorb deformation due to bending.
- the inverse shape is obtained by incorporating the amount of deformation due to bending from the shape after being bent into an annular shape.
- deformation due to bending is absorbed by the unevenness 4002, and the shape accuracy of the engaging portion 2001 can be stabilized. As a result, it is possible to reliably engage the magnet and improve the positioning accuracy of the magnet.
- the second modification may be configured as follows.
- the magnet unit comprises a plurality of magnets (1001, 1002) arranged side by side in the circumferential direction, and a magnet yoke (2000) to which the plurality of magnets are fixed on the inner or outer peripheral surface, each of the magnets is provided between a d-axis and a q-axis that are adjacent in the circumferential direction, and end surfaces are formed on the d-axis and the q-axis, respectively;
- a recess (1004b) is provided on the q-axis side, or a protrusion is provided on the d-axis side, or a recess is provided on the q-axis side, on the anti-arma
- the controller and techniques described in this disclosure constitute a processor and memory programmed to perform one or more functions embodied by the computer program.
- the controls and techniques described in this disclosure may be implemented by a dedicated computer provided by configuring the processor with one or more dedicated hardware logic circuits.
- the control units and techniques described in this disclosure can be implemented by a combination of a processor and memory programmed to perform one or more functions and a processor configured by one or more hardware logic circuits. It may also be implemented by one or more dedicated computers configured.
- the computer program may also be stored as computer-executable instructions on a computer-readable non-transitional tangible recording medium.
- the disclosure in this specification is not limited to the illustrated embodiments.
- the disclosure encompasses the illustrated embodiments and variations thereon by those skilled in the art.
- the disclosure is not limited to the combinations of parts and/or elements shown in the embodiments.
- the disclosure can be implemented in various combinations.
- the disclosure can have additional parts that can be added to the embodiments.
- the disclosure encompasses omitting parts and/or elements of the embodiments.
- the disclosure encompasses permutations or combinations of parts and/or elements between one embodiment and another.
- the disclosed technical scope is not limited to the description of the embodiments.
- the disclosed technical scope is indicated by the description of the claims, and should be understood to include all modifications within the meaning and range of equivalents to the description of the claims.
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Permanent Field Magnets Of Synchronous Machinery (AREA)
Abstract
Description
本実施形態に係る回転電機10は、同期式多相交流モータであり、アウタロータ構造(外転構造)のものとなっている。回転電機10の概要を図1~図5に示す。図1は、回転電機10の全体を示す斜視図であり、図2は、回転電機10の平面図であり、図3は、回転電機10の縦断面図(図2の3-3線断面図)であり、図4は、回転電機10の横断面図(図3の4-4線断面図)であり、図5は、回転電機10の構成要素を分解して示す分解断面図である。以下の記載では、回転電機10において、回転軸11が延びる方向を軸方向とし、回転軸11の中心から放射状に延びる方向を径方向とし、回転軸11を中心として円周状に延びる方向を周方向としている。
(A)固定子60において、周方向における各導線部(後述する中間導線部152)の間に導線間部材を設け、かつその導線間部材として、1磁極における導線間部材の周方向の幅寸法をWt、導線間部材の飽和磁束密度をBs、1磁極における磁石32の周方向の幅寸法をWm、磁石32の残留磁束密度をBrとした場合に、Wt×Bs≦Wm×Brの関係となる磁性材料を用いている。
(B)固定子60において、周方向における各導線部(中間導線部152)の間に導線間部材を設け、かつその導線間部材として、非磁性材料を用いている。
(C)固定子60において、周方向における各導線部(中間導線部152)の間に導線間部材を設けていない構成となっている。
以下に、上記実施形態に関する変形例を説明する。
上記実施形態又は上記変形例において、次のように構成を変更してもよい。以下、本変形例2では、主に、上記各実施形態及び各変形例等で説明した構成に対する相違部分について説明する。また、本変形例2では、回転電機10の基本構成として、第1実施形態のものを例に説明する。以下、この変形例2における磁石部としての磁石ユニット1000の構成を中心に詳しく説明する。
上記変形例2における磁石ユニット1000を、以下に説明するように変更してもよい。
前記磁石部は、周方向に並べて配置されている複数の磁石(1001,1002)と、複数の前記磁石が内周面又は外周面に固定される磁石ヨーク(2000)と、を備え、
各々の前記磁石は、周方向において隣り合うd軸とq軸との間に設けられ、d軸及びq軸において端面がそれぞれ形成されており、
前記磁石の反電機子側周面(1004)には、q軸側に凹部(1004b)が設けられており、又はd軸側に凸部が設けられており、若しくは、q軸側に凹部が設けられるとともにd軸側に凸部が設けられており、
前記磁石の反電機子側周面において、q軸側には、前記反電機子側周面の前記凹部又は前記凸部に対して周方向に係合する係合部(2001)が設けられており、
周方向における前記磁石のd軸側端面同士の隙間が、q軸側端面同士の隙間よりも狭くなるように、周方向において隣り合う前記係合部の間隔が設定されている回転電機。
Claims (8)
- 周方向に極性が交互となる複数の磁極を含む磁石部(1000)を有する界磁子(20)と、径方向において前記磁石部に対向して配置される電機子(60)と、を備え、前記界磁子及び前記電機子のうちいずれかを回転子とする回転電機(10)において、
前記磁石部は、周方向に並べて配置されている複数の磁石(1001,1002)と、複数の前記磁石が内周面又は外周面に固定される磁石ヨーク(2000)と、を備え、
前記複数の磁石における磁化容易軸は、その向きが磁極境界であるq軸の側に比べて磁極中心であるd軸の側において、磁極中心であるd軸に平行となるように配向され、当該磁化容易軸に沿って磁石磁路が形成されており、
当該磁石磁路の長さに基づいて算出される前記複数の磁石のパーミアンス係数が、周方向において、磁極境界であるq軸から磁極中心であるd軸に近づくほど大きくなるように、前記複数の磁石の反電機子側周面(1004)において、磁極境界であるq軸側に凹部(1004b)が設けられており、又は磁極中心であるd軸側に凸部が設けられており、若しくは、磁極境界であるq軸側に凹部が設けられるとともに磁極中心であるd軸側に凸部が設けられており、
前記複数の磁石の反電機子側周面において、磁極境界であるq軸側には、前記反電機子側周面の前記凹部又は前記凸部に対して周方向に係合するとともに、前記複数の磁石の極性の異なる磁極間で磁束を授受するための軟磁性材からなる係合部(2001)が設けられた回転電機。 - 前記複数の磁石は、磁化容易軸が円弧状に配向され、
当該円弧状に配向された磁化容易軸の配向中心は、周方向において磁極境界であるq軸側であって、径方向において、当該複数の磁石の電機子側周面(1003)、または、当該複数の磁石の電機子側周面よりも前記電機子の側に設定されている請求項1に記載の回転電機。 - 前記複数の磁石における磁化容易軸は、径方向に対する傾斜角度を有する直線状磁化容易軸であって、周方向の位置により当該傾斜角度が徐変するものであり、
周方向において、磁極境界であるq軸側から磁極中心であるd軸側に近づくにつれて、前記直線状磁化容易軸が磁極中心であるd軸に平行となるように、各々の当該直線状磁化容易軸の傾斜角度が径方向に対して小さくなるように設定されている請求項1に記載の回転電機。 - 周方向に極性が交互となる複数の磁極を含む磁石部(1000)を有する界磁子(20)と、径方向において前記磁石部に対向して配置される電機子(60)と、を備え、前記界磁子及び前記電機子のうちいずれかを回転子とする回転電機(10)において、
前記磁石部は、周方向に並べて配置されている複数の磁石(1001,1002)と、複数の前記磁石が内周面又は外周面に固定される磁石ヨーク(2000)と、を備え、
前記複数の磁石における磁化容易軸は、その向きが径方向に対して一定の傾斜角度を有して直線状となるようにパラレル配向され、当該磁化容易軸に沿って磁石磁路が形成されており、
当該磁石磁路の長さに基づいて算出される前記複数の磁石のパーミアンス係数が、周方向において、磁極境界であるq軸から磁極中心であるd軸に近づくほど大きくなるように、前記複数の磁石の反電機子側周面(1004)において、磁極境界であるq軸側に凹部(1004b)が設けられており、又は磁極中心であるd軸側に凸部が設けられており、若しくは、磁極境界であるq軸側に凹部が設けられるとともに磁極中心であるd軸側に凸部が設けられており、
前記複数の磁石の反電機子側周面において、磁極境界であるq軸側には、前記反電機子側周面の前記凹部又は前記凸部に対して周方向に係合するとともに、前記複数の磁石の極性の異なる磁極間で磁束を授受するための軟磁性材からなる係合部(2001)が設けられた回転電機。 - 前記係合部は、前記磁石ヨークの内周面又は外周面から突出するように前記磁石ヨークに一体形成されている請求項1~4のうちいずれか1項に記載の回転電機。
- 前記磁石ヨークは、細長い薄板状の帯部材が螺旋状に巻回されて積層されることにより筒状に構成されたヘリカルコア(2200)である請求項1~5のうちいずれか1項に記載の回転電機。
- 各々の前記磁石(1001,1002)は、周方向において隣り合う磁極中心であるd軸と磁極境界であるq軸との間に設けられ、磁極境界であるd軸及び磁極境界であるq軸において端面(1005)がそれぞれ形成されており、
周方向における前記磁石のd軸側端面(1005a)同士の隙間が、q軸側端面(1005b)同士の隙間よりも狭くなるように、周方向において隣り合う前記係合部の間隔が設定されている請求項1~6のうちいずれか1項に記載の回転電機。 - 周方向に極性が交互となる複数の磁極を含む磁石部(1000)を有する界磁子(20)と、径方向において前記磁石部に対向して配置される電機子(60)と、を備え、前記界磁子及び前記電機子のうちいずれかを回転子とする回転電機(10)の製造方法であって、
前記磁石部は、周方向に並べて配置されている複数の磁石(1001,1002)を備え、
前記複数の磁石における磁化容易軸は、その向きが磁極境界であるq軸の側に比べて磁極中心であるd軸の側において、d軸に平行となるように配向され、又は、磁化容易軸が、径方向に対して一定の傾斜角度を有して直線状になるようにパラレル配向され、当該磁化容易軸に沿って磁石磁路が形成されており、
当該磁石磁路の長さに基づいて算出される前記複数の磁石のパーミアンス係数が、周方向において、磁極境界であるq軸から磁極中心であるd軸に近づくほど大きくなるように、反電機子側周面(1004)において、磁極境界であるq軸側に凹部(1004b)が設けられており、又は磁極中心であるd軸側に凸部が設けられており、若しくは、磁極境界であるq軸側に凹部が設けられるとともに磁極中心であるd軸側に凸部が設けられており、
前記磁石の反電機子側周面において、磁極境界であるq軸側には、前記反電機子側周面の前記凹部又は前記凸部に対して周方向に係合するとともに、前記複数の磁石の極性の異なる磁極間で磁束を授受するための軟磁性材からなる係合部(2001)が設けられた回転電機の製造方法において、
細長い直線状の板部材(4001)に対して曲げ加工を行うことにより、細長い薄板状の帯部材を螺旋状に巻回して積層された筒状の磁石ヨーク(2200)を形成する曲げ加工ステップと、
前記磁石ヨークに前記複数の磁石を固定する固定ステップと、を有し、
前記曲げ加工ステップの実行前において、前記板部材には、前記係合部がその幅方向に突出するように予め一体形成されているとともに、当該係合部には、前記曲げ加工による変形を吸収する凹凸(4002)が設けられている回転電機の製造方法。
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN202280007689.3A CN116547888A (zh) | 2021-02-24 | 2022-02-18 | 旋转电机以及旋转电机的制造方法 |
JP2023502347A JPWO2022181473A1 (ja) | 2021-02-24 | 2022-02-18 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2021027628 | 2021-02-24 | ||
JP2021-027628 | 2021-02-24 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2022181473A1 true WO2022181473A1 (ja) | 2022-09-01 |
Family
ID=83048970
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2022/006600 WO2022181473A1 (ja) | 2021-02-24 | 2022-02-18 | 回転電機及び回転電機の製造方法 |
Country Status (3)
Country | Link |
---|---|
JP (1) | JPWO2022181473A1 (ja) |
CN (1) | CN116547888A (ja) |
WO (1) | WO2022181473A1 (ja) |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6399748A (ja) * | 1986-10-14 | 1988-05-02 | Inoue Japax Res Inc | 磁石 |
JP2009177919A (ja) * | 2008-01-23 | 2009-08-06 | Mitsui High Tec Inc | 回転子積層鉄心 |
JP2011045156A (ja) * | 2009-08-19 | 2011-03-03 | Jtekt Corp | 電動モータおよびロータ |
JP2015228762A (ja) * | 2014-06-02 | 2015-12-17 | 日東電工株式会社 | 永久磁石、永久磁石の製造方法、回転電機及び回転電機の製造方法 |
JP2019140368A (ja) * | 2017-08-01 | 2019-08-22 | 株式会社デンソー | 磁石の製造方法 |
JP2020141527A (ja) * | 2019-02-28 | 2020-09-03 | 株式会社デンソー | 回転電機 |
-
2022
- 2022-02-18 JP JP2023502347A patent/JPWO2022181473A1/ja active Pending
- 2022-02-18 CN CN202280007689.3A patent/CN116547888A/zh active Pending
- 2022-02-18 WO PCT/JP2022/006600 patent/WO2022181473A1/ja active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS6399748A (ja) * | 1986-10-14 | 1988-05-02 | Inoue Japax Res Inc | 磁石 |
JP2009177919A (ja) * | 2008-01-23 | 2009-08-06 | Mitsui High Tec Inc | 回転子積層鉄心 |
JP2011045156A (ja) * | 2009-08-19 | 2011-03-03 | Jtekt Corp | 電動モータおよびロータ |
JP2015228762A (ja) * | 2014-06-02 | 2015-12-17 | 日東電工株式会社 | 永久磁石、永久磁石の製造方法、回転電機及び回転電機の製造方法 |
JP2019140368A (ja) * | 2017-08-01 | 2019-08-22 | 株式会社デンソー | 磁石の製造方法 |
JP2020141527A (ja) * | 2019-02-28 | 2020-09-03 | 株式会社デンソー | 回転電機 |
Also Published As
Publication number | Publication date |
---|---|
JPWO2022181473A1 (ja) | 2022-09-01 |
CN116547888A (zh) | 2023-08-04 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20230283137A1 (en) | Rotary electric machine | |
JP7472630B2 (ja) | 回転電機 | |
JP7424513B2 (ja) | 回転電機 | |
JP7404794B2 (ja) | 回転電機 | |
JP7452019B2 (ja) | 電機子、及び電機子の製造方法 | |
WO2022181473A1 (ja) | 回転電機及び回転電機の製造方法 | |
JP2022151073A (ja) | 回転電機 | |
JP7354847B2 (ja) | 電機子 | |
JP7211340B2 (ja) | 回転電機 | |
JP7404841B2 (ja) | 回転電機 | |
WO2022186057A1 (ja) | 回転電機及び回転電機の制御方法 | |
JP7268589B2 (ja) | 回転電機 | |
WO2022186056A1 (ja) | 回転電機 | |
JP7400361B2 (ja) | 回転電機 | |
JP7392437B2 (ja) | 回転電機 | |
JP7487511B2 (ja) | 回転電機 | |
JP7463707B2 (ja) | 回転電機 | |
WO2022113935A1 (ja) | 回転電機 | |
WO2021220761A1 (ja) | 回転電機及びその製造方法 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 22759509 Country of ref document: EP Kind code of ref document: A1 |
|
ENP | Entry into the national phase |
Ref document number: 2023502347 Country of ref document: JP Kind code of ref document: A |
|
WWE | Wipo information: entry into national phase |
Ref document number: 202280007689.3 Country of ref document: CN |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 22759509 Country of ref document: EP Kind code of ref document: A1 |