Rotating electrical machine

Abstract

The magnet portion (22) has: a plurality of circular-arc-shaped magnets (710, 720) arranged in the circumferential direction, the magnets being oriented with their easy magnetization axes oriented in a circular-arc shape in a manner that the direction of the easy magnetization axis is more parallel to the d-axis on the d-axis side than on the q-axis side, and a magnet holding portion (31) for fixing the magnets. The magnets are divided at the d-axis and the q-axis, the q-axis side end surface (713b, 723b) in the circumferential direction of each of the magnets is arranged in surface contact with the q-axis side end surface of the circumferentially adjacent magnet, and a gap formed between the armature opposite side circumferential surface (712, 722) of each of the magnets and the fixing surface (31a) of the magnet holding portion is filled with a resin (801).

Description

[0001] Mutual citation of related applications

[0002] This application is based on Japanese Patent Application No. 2019-225365, filed on December 13, 2019, the contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a rotary electric motor. Background Technology

[0004] Conventionally, as described in Patent Document 1, rotary motors with oriented magnets have been proposed, wherein the oriented magnets form a generally arc-shaped magnetic circuit. By forming the aforementioned magnetic circuit, the magnetic flux density along the d-axis can be increased, thereby increasing the torque of the rotary motor.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2019-106864 Summary of the Invention

[0008] The high-torque rotary motors described above typically use sintered magnets as orientation magnets. To assemble the magnet units, composed of multiple magnets, into a ring shape along the circumference of the rotation axis, it is preferable that each magnet is arranged in an arc shape without gaps. However, when using sintered magnets, there are problems with large manufacturing errors and poor dimensional accuracy. Specifically, gaps easily form between magnets and between magnets and their holding components.

[0009] This disclosure is made in view of the above circumstances, and its main purpose is to provide a rotary motor that can suppress the effects of manufacturing errors of the magnet.

[0010] A first approach to solving the aforementioned technical problem is a rotating electric motor, comprising an excitation element and an armature. The excitation element has a magnet portion containing a plurality of magnetic poles with alternating polarities in the circumferential direction. The armature has a multi-phase armature winding. Either the excitation element or the armature is designated as a rotor. The magnet portion includes: a plurality of arc-shaped magnets arranged circumferentially; and a magnet holding portion for fixing the magnets. Among the magnets, [the following is a list of magnets, likely related to a specific configuration or structure]. Compared to the q-axis side, which serves as the magnetic pole boundary, the direction of the easy magnetization axis is made more parallel to the d-axis side, which serves as the magnetic pole center. The easy magnetization axis is oriented in an arc shape, and an arc-shaped magnetic circuit of the magnet is formed along the easy magnetization axis. The magnets are separated at the d-axis, which serves as the magnetic pole center, and the q-axis, which serves as the magnetic pole boundary. The circumferential q-axis side end face of each magnet is arranged to be in surface contact with the q-axis side end face of the circumferentially adjacent magnet. Resin is filled in the gap formed between the circumferential surface opposite to the armature side of each magnet and the fixing surface of the magnet holding part.

[0011] In a magnet with an arc-shaped magnetic circuit, if a gap exists between adjacent q-axis end faces, magnetic flux leakage will occur, resulting in a decrease in magnetic flux density at the d-axis, an effect caused by the gap between magnets. Therefore, the circumferentially adjacent q-axis end faces are arranged in face-to-face contact. This suppresses magnetic flux leakage from the q-axis end faces and reduces the effects caused by the gap between magnets.

[0012] Furthermore, resin is filled in the gap formed between the circumferential surface opposite to the armature of each magnet and the fixing surface of the magnet holding part, so that even if a gap is formed between the magnet and the magnet holding part, the magnet can be properly fixed to the magnet holding part.

[0013] The second method, based on the first method, involves forming a protrusion on the fixed surface near the d-axis, protruding radially toward the magnet portion. This allows the protrusion to easily engage with the magnet in the circumferential direction, thus preventing the magnet from rotating in that direction.

[0014] The third approach is a rotating electric motor, comprising an excitation element and an armature. The excitation element has a magnet portion containing multiple magnetic poles with alternating polarities in the circumferential direction. The armature has a multi-phase armature winding. Either the excitation element or the armature is designated as a rotor. The magnet portion includes: multiple arc-shaped magnets arranged circumferentially; and a magnet holding portion for fixing the magnets. The magnets are positioned such that the direction of the easily magnetized axis, compared to the q-axis side which serves as the magnetic pole boundary, is in the direction of the magnetic pole. The magnetizable axis is oriented in an arc shape on the d-axis side, which is more parallel to the d-axis. An arc-shaped magnetic circuit of the magnet is formed along the magnetizable axis. The magnet is separated at the d-axis, which is the center of the magnetic pole, and the q-axis, which is the boundary of the magnetic pole. The fixing surface of the magnet holding part for fixing the magnet is formed by a curved surface. The circumferential surface of the armature opposite side of each magnet is formed in a curved shape along the fixing surface and is arranged such that the circumferential surface of the armature opposite side abuts the fixing surface. The circumferential q-axis side end face of each magnet is filled with magnetic material in the gap formed between the q-axis side end faces of the circumferentially adjacent magnets.

[0015] If a gap is formed between the armature-opposite peripheral surface of the magnet and the fixed surface of the magnet holder, the armature-side peripheral surface of the magnet may protrude radially toward the armature side beyond the allowable value. In this case, the air gap between the armature and the magnet becomes excessively small, and there is a possibility of contact. Therefore, the armature-opposite peripheral surface of each magnet is formed as a curved surface along the fixed surface, and arranged so that the armature-opposite peripheral surface abuts against the fixed surface. As a result, the radial protrusion of the magnet toward the armature side can be suppressed, and the effect of the gap forming between the magnet and the magnet holder can be suppressed.

[0016] Furthermore, magnetic material is filled in the gap between the circumferentially adjacent q-axis end faces. This suppresses magnetic flux leakage from the q-axis end faces and reduces the impact of the gap between magnets. Attached Figure Description

[0017] The above-mentioned objects, other objects, features, and advantages of this disclosure will become clearer with reference to the accompanying drawings and the following detailed description. The accompanying drawings are described below.

[0018] Figure 1 This is a perspective view showing the overall rotary motor in the first embodiment.

[0019] Figure 2 This is a top view of a rotary electric motor.

[0020] Figure 3 This is a longitudinal sectional view of a rotary electric machine.

[0021] Figure 4 This is a cross-sectional view of a rotary electric machine.

[0022] Figure 5 This is an exploded view of a rotary electric motor.

[0023] Figure 6 This is a cross-sectional view of the rotor.

[0024] Figure 7 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit.

[0025] Figure 8 This is a graph showing the relationship between the electrical angle and magnetic flux density of the magnet in the embodiment.

[0026] Figure 9 This is a graph showing the relationship between the electric angle and magnetic flux density of the magnet in the comparative example.

[0027] Figure 10 This is a 3D view of the stator unit.

[0028] Figure 11 This is a longitudinal sectional view of the stator unit.

[0029] Figure 12 This is a three-dimensional view of the core assembly viewed from one axial side.

[0030] Figure 13 This is a three-dimensional view of the core assembly viewed from the other side of the axial direction.

[0031] Figure 14 This is a cross-sectional view of the iron core assembly.

[0032] Figure 15 This is an anatomical view of the iron core assembly.

[0033] Figure 16 It is a circuit diagram showing the connection status of some windings in each phase of a three-phase circuit.

[0034] Figure 17 It is a side view showing the first coil module and the second coil module arranged horizontally and compared.

[0035] Figure 18 It is a side view showing the first and second windings arranged laterally and compared.

[0036] Figure 19 This is a diagram showing the structure of the first coil module.

[0037] Figure 20 yes Figure 19 Sectional view of line 20-20 in (a).

[0038] Figure 21 This is a three-dimensional view showing the structure of the insulating cover.

[0039] Figure 22This is a diagram showing the structure of the second coil module.

[0040] Figure 23 yes Figure 22 Sectional view along line 23-23 in (a).

[0041] Figure 24 This is a three-dimensional view showing the structure of the insulating cover.

[0042] Figure 25 This is a diagram showing the overlapping positions of the thin film material when the coil modules are arranged circumferentially.

[0043] Figure 26 This is a top view showing the assembled state of the first coil module relative to the core assembly.

[0044] Figure 27 This is a top view showing the assembled state of the first and second coil modules relative to the core assembly.

[0045] Figure 28 This is a longitudinal sectional view showing the fixed state achieved by the fixing pin.

[0046] Figure 29 This is a 3D view of the busbar module.

[0047] Figure 30 This is a sectional view showing a portion of the longitudinal section of the busbar module.

[0048] Figure 31 This is a perspective view showing the busbar module assembled onto the stator retainer.

[0049] Figure 32 This is a longitudinal sectional view of the fixed part that secures the busbar module.

[0050] Figure 33 This is a longitudinal sectional view showing the relay components assembled in the housing.

[0051] Figure 34 This is a 3D diagram of the relay components.

[0052] Figure 35 This is a circuit diagram showing the control system of a rotating electric motor.

[0053] Figure 36 This is a functional block diagram illustrating the current feedback control processing of the control device.

[0054] Figure 37 This is a functional block diagram illustrating the torque feedback control processing of the control device.

[0055] Figure 38 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit in the modified example.

[0056] Figure 39 This is a diagram showing the structure of the stator unit with an internal rotor structure.

[0057] Figure 40 This is a top view showing the assembled state of the coil module relative to the core assembly.

[0058] Figure 41 This is a cross-sectional view of the rotor of variant example 2.

[0059] Figure 42 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit in Modified Example 2.

[0060] Figure 43 This is a diagram showing the magnetic circuit of the magnet in Modified Example 2.

[0061] Figure 44 This is a diagram showing the shape of the magnet in modified example 2.

[0062] Figure 45 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit in Modified Example 3.

[0063] Figure 46 This is a partial cross-sectional view showing the cross-sectional structure of another example of a magnet unit.

[0064] Figure 47 This is a partial cross-sectional view showing the cross-sectional structure of another example of a magnet unit.

[0065] Figure 48 This is a diagram showing another example of the shape of a magnet. Detailed Implementation

[0066] Hereinafter, several embodiments will be described with reference to the accompanying drawings. In several embodiments, sometimes functionally and / or structurally corresponding and / or related parts are labeled with the same reference numeral, or reference numerals differing by more than one hundred positions. For corresponding and / or related parts, please refer to the description of other embodiments.

[0067] The rotary motor in this embodiment is used as, for example, a vehicle power source. However, rotary motors can be widely used in industrial applications, vehicles, home appliances, office automation (OA) equipment, game consoles, and so on. Furthermore, in the following embodiments, the same or equivalent parts are labeled with the same symbols in the drawings, and descriptions of the parts with the same symbols are provided.

[0068] (First Implementation)

[0069] The rotary motor 10 in this embodiment is a synchronous multiphase AC motor with an external rotor structure (external rotation structure). Figures 1 to 5 An outline of the rotary motor 10 is shown. Figure 1 This is a perspective view showing the entire rotary motor 10. Figure 2 This is a top view of the rotary motor 10. Figure 3 This is a longitudinal sectional view of the rotary motor 10. Figure 2 (3-3 line section view), Figure 4 This is a cross-sectional view of the rotary motor 10. Figure 3 (4-4 line sectional view), Figure 5 This is an exploded view showing the components of the rotary electric machine 10. In the following description, in the rotary electric machine 10, the direction in which the rotation shaft 11 extends is defined as the axial direction, the direction in which it extends radially from the center of the rotation shaft 11 is defined as the radial direction, and the direction in which it extends circumferentially around the rotation shaft 11 is defined as the circumferential direction.

[0070] The rotary motor 10 generally includes: a 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 to surround the main body. All of the above components are coaxially arranged with respect to a rotating shaft 11 integrally provided on the rotor 20, and are assembled axially in a predetermined order to constitute the rotary motor 10. The rotating shaft 11 is supported by a pair of bearings 12 and 13 respectively provided on the stator unit 50 and the housing 241, and is rotatable in this state. Furthermore, the bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls disposed between the inner and outer rings. The rotation of the rotating shaft 11 causes, for example, the axle of a vehicle to rotate. The rotary motor 10 can be mounted in a vehicle by fixing the housing 241 to a vehicle body frame or the like.

[0071] In the rotary electric motor 10, a stator unit 50 is arranged to surround a rotating shaft 11, and a rotor 20 is disposed radially outside the stator unit 50. The stator unit 50 includes a stator 60 and a stator retainer 70 assembled radially inside it. The rotor 20 and the stator 60 are arranged radially opposite each other with an air gap between them, and the rotor 20 rotates integrally with the rotating shaft 11, thereby rotating radially outside the stator 60. The rotor 20 is equivalent to an "excitation element", and the stator 60 is equivalent to an "armature".

[0072] Figure 6 This is a longitudinal sectional view of rotor 20. (As shown) Figure 6As shown, the rotor 20 has a generally cylindrical rotor frame 21 and an annular magnet unit 22 fixed to the rotor frame 21. The rotor frame 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23. The rotor frame 21 is formed by integrating the cylindrical portion 23 and the end plate 24. The rotor frame 21 functions as a magnet holding member, and the magnet unit 22 is fixed annularly on the radially inner side of the cylindrical portion 23. A through hole 24a is formed in the end plate portion 24. With the through hole 24a inserted, the rotating shaft 11 is fixed to the end plate portion 24 by fasteners 25 such as bolts. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal) to the axial direction. With the flange 11a and the end plate portion 24 in a face-fitting state, the rotor frame 21 is fixed to the rotating shaft 11.

[0073] The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner circumferential surface of the magnet holder 31, and an end plate 33 fixed on one of the two axial sides opposite to the end plate portion 24 of the rotor frame 21. The magnet holder 31 has the same length dimension as the magnets 32 in the axial direction. The magnets 32 are arranged to be surrounded radially outward by the magnet holder 31. The magnet holder 31 and the magnets 32 are fixed at their axial ends in contact with the end plate 33. The magnet unit 22 is equivalent to a "magnet portion".

[0074] Figure 7 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. Figure 7 In the diagram, arrows indicate the direction of the easy magnetization axis of magnet 32.

[0075] In the magnet unit 22, the magnets 32 are arranged in such a way that their polarity changes alternately along the circumference of the rotor 20. Thus, the magnet unit 22 has multiple magnetic poles in the circumferential direction. The magnets 32 are permanent magnets with anisotropic polarity and are constructed using sintered neodymium magnets with an intrinsic coercivity of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more.

[0076] In magnet 32, the radially inner circumferential surface is the flux-acting surface 34 for transmitting magnetic flux. In magnet 32, the directions of the easy magnetization axis are different on the d-axis side (the portion near the d-axis) and the q-axis side (the portion near the q-axis). On the d-axis side, the direction of the easy magnetization axis is parallel to the d-axis, and on the q-axis side, the direction of the easy magnetization axis is orthogonal to the q-axis. In this case, an arc-shaped magnetic circuit is formed along the direction of the easy magnetization axis. In summary, magnet 32 ​​is configured such that, at the center of the magnetic pole, i.e., on the d-axis side, the direction of the easy magnetization axis is parallel to the d-axis compared to the magnetic pole boundary, i.e., on the q-axis side.

[0077] In magnet 32, since the magnetic circuit is formed in an arc shape, the length of the magnetic circuit is longer than the radial thickness of magnet 32. As a result, the magnetic permeability of magnet 32 ​​increases, enabling it to perform the same function as a magnet with a larger quantity of magnets with the same amount of magnets.

[0078] Magnets 32 are arranged in pairs along the circumferential direction to form a magnetic pole. That is, the multiple magnets 32 arranged circumferentially in magnet unit 22 each have a dividing surface along the d-axis and q-axis, and the magnets 32 are arranged in a state of contact or proximity to each other. As described above, the magnets 32 have an arc-shaped magnetic circuit, and at the q-axis, the N and S poles of the circumferentially adjacent magnets 32 face each other. Therefore, it is possible to improve the magnetic permeability near the q-axis. Furthermore, since the magnets 32 on both sides of the q-axis attract each other, the contact state between the magnets 32 can be maintained. Therefore, it still contributes to improving the magnetic permeability.

[0079] In magnet unit 22, since the magnetic flux flows in an arc shape between adjacent N and S poles through each magnet 32, the magnetic path is longer compared to, for example, a radially anisotropic magnet. Therefore, as Figure 8 As shown, the magnetic flux density distribution approximates a sine wave. The result is that, compared to... Figure 9 The radially anisotropic magnets shown as a comparative example have different magnetic flux density distributions, which can concentrate the magnetic flux on the central side of the magnetic poles and improve the torque of the rotary motor 10. Furthermore, in the magnet unit 22 of this embodiment, it can be confirmed that the magnetic flux density distribution differs from that of conventional Hellbeck array magnets. Additionally, in Figure 8 and Figure 9 In the diagram, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. Furthermore, in... Figure 8 and Figure 9 In the diagram, 90° on the horizontal axis represents the d-axis (i.e., the center of the magnetic pole), and 0° and 180° on the horizontal axis represent the q-axis.

[0080] That is, according to the above-described structure, the magnetic flux at the d-axis in the magnet unit 22 is enhanced, and the flux change near the q-axis is suppressed. Thus, it is possible to appropriately realize a magnet unit 22 with a gentle change in surface magnetic flux from the q-axis to the d-axis in each magnetic pole.

[0081] The sinusoidal matching ratio of the magnetic flux density distribution can be, for example, 40% or higher. This reliably increases the magnetic flux in the central portion of the waveform compared to using radially oriented magnets with a sinusoidal matching ratio of around 30% or using parallel-oriented magnets. Furthermore, if the sinusoidal matching ratio is set to 60% or higher, the magnetic flux in the central portion of the waveform can be reliably increased compared to flux-concentrated arrays such as the Hellbeck array.

[0082] exist Figure 9In the radially anisotropic magnet shown, the magnetic flux density changes drastically near the q-axis. The more drastic the change in magnetic flux density, the greater the increase in eddy currents in the stator winding 61 of the stator 60 (described later). Furthermore, the change in magnetic flux on the stator winding 61 side also becomes drastic. In contrast, in this embodiment, the magnetic flux density distribution is close to a sinusoidal magnetic flux waveform. Therefore, near the q-axis, the change in magnetic flux density is smaller than that of the radially anisotropic magnet. As a result, the generation of eddy currents can be suppressed.

[0083] Furthermore, in magnet 32, a recess 35 is formed on the outer peripheral surface in the radial direction, within a predetermined range including the d-axis, and a recess 36 is formed on the inner peripheral surface in the radial direction, within a predetermined range including the q-axis. In this case, depending on the direction of the easy magnetization axis of magnet 32, the magnetic circuit of magnet 32 ​​becomes shorter near the d-axis on the outer peripheral surface and shorter near the q-axis on the inner peripheral surface. Therefore, considering that it is difficult to generate sufficient magnetic flux in the parts of magnet 32 ​​where the magnetic circuit length is short, magnets are removed from the parts where the magnetic flux is weak.

[0084] Alternatively, the magnet unit 22 can be configured to use the same number of magnets 32 as the number of magnetic poles. For example, the magnets 32 can be arranged as a single magnet between the d-axis, where the d-axis is the center of each of two adjacent magnetic poles along the circumferential direction. In this case, the magnets 32 are configured with the circumferential center at the q-axis and have a dividing surface along the d-axis. Alternatively, instead of setting the circumferential center at the q-axis, the magnets 32 can also be configured with the circumferential center at the d-axis. Instead of using twice the number of magnets or the same number of magnets as the number of magnetic poles, the magnets 32 can also be configured as circularly connected toroidal magnets.

[0085] like Figure 3 As shown, a resolver 41, serving as a rotation sensor, is provided at the end opposite to the joint with the rotor frame 21 on one of the axial sides of the rotating shaft 11 (the upper end in the figure). The resolver 41 includes a resolver rotor fixed to the rotating shaft 11 and a resolver stator arranged radially outward from the resolver rotor. The resolver rotor is in the shape of a circular plate ring and is coaxially arranged on the rotating shaft 11 when the rotating shaft 11 is inserted. The resolver stator has a stator core and stator coils and is fixed to the housing 242.

[0086] Next, the structure of the stator unit 50 will be described. Figure 10 This is a 3D view of stator unit 50. Figure 11 This is a longitudinal sectional view of stator unit 50. Additionally, Figure 11 Is with Figure 3 Longitudinal sectional view at the same location.

[0087] In summary, the stator unit 50 has a stator 60 and a stator retainer 70 radially inward therefrom. The stator 60 also has a stator winding 61 and a stator core 62. Furthermore, the stator core 62 and the stator retainer 70 are integrated into a core assembly CA, and multiple partial windings 151 constituting the stator winding 61 are assembled to this core assembly CA. The stator winding 61 corresponds to an "armature winding," the stator core 62 corresponds to an "armature core," and the stator retainer 70 corresponds to an "armature retaining member." The core assembly CA corresponds to a "support member."

[0088] Here, we will first explain the core assembly CA. Figure 12 This is a three-dimensional view of the core assembly CA from one axial side. Figure 13 This is a three-dimensional view of the core assembly CA from the other side of the axial direction. Figure 14 This is a cross-sectional view of the core assembly CA. Figure 15 This is a anatomical view of the core assembly CA.

[0089] As described above, the core assembly CA has a stator core 62 and a stator retainer 70 assembled radially inward thereon. In other words, the stator core 62 is integrally assembled onto the outer peripheral surface of the stator retainer 70.

[0090] The stator core 62 is configured as a stack of iron chips 62a, which are made of electromagnetic steel plates as magnetic materials, stacked axially, and is cylindrical in 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, which is the rotor 20 side. The outer circumferential surface of the stator core 62 is a smooth, curved surface. The stator core 62 functions as a back yoke. The stator core 62 is, for example, constructed by stacking multiple iron chips 62a, which are punched into annular plates, axially. However, a stator core 62 with a helical core structure can also be used. In a helical core structure stator core 62, strip-shaped iron chips are used, which are formed by winding them in a ring shape and stacking them axially, thereby forming a cylindrical stator core 62 as a whole.

[0091] In this embodiment, the stator 60 is a slotless structure without pole teeth for forming slots, but its structure can also use any one of the following (A) to (C).

[0092] (A) In the stator 60, an inter-conductor member is provided between each circumferential conductor portion (the intermediate conductor portion 152 described later), and the inter-conductor member is a magnetic material that satisfies the relationship Wt×Bs≤Wm×Br when the circumferential width dimension of the inter-conductor member of a magnetic pole is set as Wt, the saturation magnetic flux density of the inter-conductor member is set as Bs, the circumferential width dimension of the magnet 32 ​​of a magnetic pole is set as Wm, and the residual magnetic flux density of the magnet 32 ​​is set as Br.

[0093] (B) In the stator 60, an inter-conductor member is provided between each circumferential conductor portion (intermediate conductor portion 152), and a non-magnetic material is used as the inter-conductor member.

[0094] (C) In the stator 60, there is no conductor inter-conductor member between the circumferential conductor portions (intermediate conductor portion 152).

[0095] In addition, such as Figure 15 As shown, the stator retainer 70 has an outer cylinder member 71 and an inner cylinder member 81, which are constructed by setting the outer cylinder member 71 to the radially outer side and the inner cylinder member 81 to the radially inner side, and assembling the above-mentioned members into one piece. The above-mentioned members 71 and 81 are made of metals such as aluminum and cast iron, or carbon fiber reinforced plastic (CFRP).

[0096] The outer cylindrical member 71 is a cylindrical member with both its outer and inner circumferential surfaces being perfectly circular curved surfaces. An annular flange 72 extending radially inward is formed at one axial end. On this flange 72, a plurality of protrusions 73 extending radially inward are formed at predetermined intervals along the circumferential direction (see reference). Figure 13 In addition, opposing surfaces 74 and 75, which are axially opposite to the inner cylinder member 81, are formed on one end side and the other end side of the outer cylinder member 71, respectively, and annular grooves 74a and 75a that extend in a ring shape are formed on the opposing surfaces 74 and 75.

[0097] Furthermore, the inner cylinder member 81 is a cylindrical member with an outer diameter smaller than that of the outer cylinder member 71, and its outer circumferential surface is a perfectly circular curved surface concentric with the outer cylinder member 71. An annular flange 82 extending radially outward is formed at one axial end of the inner cylinder member 81. The inner cylinder member 81 is assembled to the outer cylinder member 71 in a state where its opposing surfaces 74 and 75 are in axial contact. Figure 13 As shown, the outer cylinder component 71 and the inner cylinder component 81 are assembled together by fasteners 84 such as bolts. Specifically, on the inner circumferential side of the inner cylinder component 81, a plurality of protrusions 83 extending radially inward are formed at predetermined intervals along the circumferential direction. When the axial end face of the protrusions 83 overlaps with the protrusions 73 of the outer cylinder component 71, the protrusions 73 and 83 are fastened to each other by fasteners 84.

[0098] like Figure 14 As shown, when the outer cylinder member 71 and the inner cylinder member 81 are assembled together, an annular gap is formed between the inner circumferential surface of the outer cylinder member 71 and the outer circumferential surface of the inner cylinder member 81. This gap space serves as a refrigerant passage 85 for the flow of refrigerant such as cooling water. The refrigerant passage 85 is arranged annularly in the circumferential direction of the stator retainer 70. More specifically, a passage forming portion 88 is provided in the inner cylinder member 81. The passage forming portion 88 protrudes radially inward from the inner circumferential side of the inner cylinder member 81, and an inlet-side passage 86 and an outlet-side passage 87 are formed therein. Each passage 86 and 87 opens on the outer circumferential surface of the inner cylinder member 81. In addition, a partition portion 89 is provided on the outer circumferential surface of the inner cylinder member 81 to separate the refrigerant passage 85 into an inlet side and an outlet side. As a result, the refrigerant flowing in from the inlet-side passage 86 flows circumferentially in the refrigerant passage 85 and then flows out from the outlet-side passage 87.

[0099] The inlet side passage 86 and the outlet side passage 87 extend radially at one end and open on the outer peripheral surface of the inner cylinder member 81, and extend axially at the other end and open on the axial end face of the inner cylinder member 81. Figure 12 An inlet opening 86a leading to the inlet-side passage 86 and an outlet opening 87a leading to the outlet-side passage 87 are shown. Furthermore, the inlet-side passage 86 and the outlet-side passage 87 lead to an inlet port 244 and an outlet port 245 mounted on the housing 242 (see reference). Figure 1 The refrigerant flows out and in through the aforementioned ports 244 and 245.

[0100] A seal 101, 102 is provided at the joint between the outer cylinder component 71 and the inner cylinder component 81 to prevent refrigerant leakage in the refrigerant passage 85 (see reference). Figure 15 Specifically, the seals 101 and 102 are, for example, O-rings, which are received in the annular grooves 74a and 75a of the outer cylinder member 71 and are arranged in a compressed state by the outer cylinder member 71 and the inner cylinder member 81.

[0101] In addition, such as Figure 12 As shown, the inner cylinder member 81 has an end plate portion 91 on one axial end side, in which a hollow cylindrical bushing portion 92 extending axially is provided. The bushing portion 92 is configured to surround an insertion hole 93 for inserting the rotating shaft 11. Multiple fastening portions 94 for fixing the outer casing 242 are provided on the bushing portion 92. Furthermore, multiple axially extending support portions 95 are provided on the radially outer side of the bushing portion 92 in the end plate portion 91. These support portions 95 serve as fixing portions for fixing the busbar module 200, and their details will be described later. Additionally, the bushing portion 92 is a bearing retaining member for holding the bearing 12, and the bearing 12 (see reference) is fixed in a bearing fixing portion 96 provided on its inner circumference. Figure 3 ).

[0102] In addition, such as Figure 12 , Figure 13 As shown, recesses 105 and 106 are formed in the outer cylinder member 71 and the inner cylinder member 81 for fixing the plurality of coil modules 150 described later.

[0103] Specifically, such as Figure 12 As shown, a plurality of recesses 105 are formed at equal intervals along the circumferential direction on the axial end face of the inner cylinder member 81, specifically on the outer axial end face of the end plate portion 91 surrounding the bushing portion 92. Furthermore, as... Figure 13 As shown, a plurality of recesses 106 are formed at equal intervals along the circumferential direction on the axial end face of the outer cylinder member 71, specifically on the axially outer end face of the flange 72. These recesses 105 and 106 are arranged on an imaginary circle concentric with the core assembly CA. The recesses 105 and 106 are respectively located at the same position in the circumferential direction, and their spacing and number are also the same.

[0104] Furthermore, to ensure assembly strength relative to the stator retainer 70, the stator core 62 is assembled in a state that generates radial compressive force relative to the stator retainer 70. Specifically, the stator core 62 is fitted and fixed to the stator retainer 70 with a specified interference fit by thermoforming or pressing. In this case, the stator core 62 and the stator retainer 70 are assembled in a state that generates radial stress from one to the other. Additionally, when increasing the torque of the rotating electric machine 10, for example, by increasing the diameter of the stator 60, the clamping force of the stator core 62 is increased to securely bond it to the stator retainer 70. However, if the compressive stress (in other words, residual stress) of the stator core 62 increases, the stator core 62 may break.

[0105] Therefore, in this embodiment, in the structure where the stator core 62 and the stator retainer 70 are fitted and fixed together with a predetermined interference fit, a limiting portion is provided in the radially opposite portions of the stator core 62 and the stator retainer 70. This limiting portion restricts the circumferential displacement of the stator core 62 through circumferential engagement. That is, as... Figures 12-14 As shown, in the radial direction, a plurality of engaging members 111, serving as limiting portions, are provided at predetermined intervals along the circumferential direction between the stator core 62 and the outer cylinder member 71 of the stator retainer 70. These engaging members 111 suppress circumferential positional displacement of the stator core 62 and the stator retainer 70. Furthermore, in this case, a recess may be provided in at least one of the stator core 62 and the outer cylinder member 71, and the engaging member 111 may engage with this recess. Alternatively, a protrusion may be provided in either the stator core 62 or the outer cylinder member 71, instead of the engaging member 111.

[0106] In the above structure, the stator core 62 and the stator retainer 70 (outer cylinder member 71) are not only fitted and fixed with a predetermined interference fit, but are also constrained by the locking member 111 to limit their circumferential displacement. Therefore, even assuming that the interference fit between the stator core 62 and the stator retainer 70 is relatively small, circumferential displacement of the stator core 62 can be suppressed. Furthermore, even with a relatively small interference fit, the desired displacement suppression effect can be obtained, thus preventing damage to the stator core 62 caused by excessive interference fit. As a result, displacement of the stator core 62 can be appropriately suppressed.

[0107] Alternatively, an annular internal space may be formed on the inner circumference of the inner cylinder member 81, surrounding the rotation axis 11. Electrical components constituting an inverter, acting as a power converter, may be disposed within this internal space. These electrical components are, for example, electrical modules encapsulated with semiconductor switching elements or capacitors. By arranging the electrical modules in contact with the inner circumferential surface of the inner cylinder member 81, the refrigerant flowing through the refrigerant passage 85 can be used to cool the electrical modules. Furthermore, the internal space on the inner circumferential side of the inner cylinder member 81 may be expanded by either not providing the multiple protrusions 83 or reducing the protrusion height of the protrusions 83.

[0108] Next, the structure of the stator winding 61 assembled into the core assembly CA will be described in detail. The state in which the stator winding 61 is assembled into the core assembly CA is as follows: Figure 10 and Figure 11 As shown, the multiple partial windings 151 constituting the stator winding 61 are assembled in a circumferential arrangement on the radial outer side of the core assembly CA, that is, on the radial outer side of the stator core 62.

[0109] The stator winding 61 has multiple phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction to form a cylindrical (ring-shaped) shape. In this embodiment, the stator winding 61 is configured to have a three-phase phase winding by using phase windings of phase U, phase V and phase W.

[0110] like Figure 11 As shown, the stator 60 has, in the axial direction, a portion corresponding to the coil side CS that is radially opposite to the magnet unit 22 of the rotor 20, and a portion corresponding to the axially outer side of the coil side CS, i.e., the coil edge end CE. In this case, the stator core 62 is arranged in the axial direction within the range corresponding to the coil side CS.

[0111] In the stator winding 61, each phase winding has multiple partial windings 151 (see reference). Figure 16Furthermore, this portion of the winding 151 is separately configured as a coil module 150. That is, the coil module 150 is constructed by integrating a portion of the phase winding 151 of each phase, and the stator winding 61 is constructed using a predetermined number of coil modules 150 corresponding to the number of poles. The coil modules 150 (partial windings 151) of each phase are arranged in a predetermined order along the circumference, thereby arranging the conductor portions of each phase in a predetermined order at the coil side CS of the stator winding 61. Figure 10 The diagram shows the arrangement of the U-phase, V-phase, and W-phase conductors on the coil side CS. In this embodiment, the number of magnetic poles is set to 24, but this number can be arbitrary.

[0112] In the stator winding 61, for each phase, some windings 151 of each coil module 150 are connected in parallel or in series, thereby forming the phase winding of each phase. Figure 16 This is a circuit diagram showing the connection state of some windings 151 in each phase of the three-phase windings. Figure 16 The diagram shows the state in which some windings 151 in each phase winding are connected in parallel.

[0113] like Figure 11 As shown, the coil module 150 is assembled radially outward of the stator core 62. In this case, the coil module 150 is assembled with its axially extending ends protruding axially outward from the stator core 62 (i.e., the coil edge end CE side). That is, the stator winding 61 has a portion corresponding to the coil edge end CE protruding axially outward from the stator core 62, and a portion corresponding to the coil side CS axially inward from the coil edge end CE.

[0114] The coil module 150 has two shapes: one where a portion of the winding 151 bends radially inward at the coil end CE, i.e., towards the stator core 62; and another where a portion of the winding 151 extends linearly axially without bending radially inward at the coil end CE. In the following description, for convenience, the portion of the winding 151 with the bent shape at both axial ends will be referred to as "first portion winding 151A," and the coil module 150 having this first portion winding 151A will be referred to as "first coil module 150A." Conversely, the portion of the winding 151 without the bent shape at both axial ends will be referred to as "second portion winding 151B," and the coil module 150 having this second portion winding 151B will be referred to as "second coil module 150B."

[0115] Figure 17 This is a side view showing the first coil module 150A and the second coil module 150B arranged horizontally and compared. Figure 18This is a side view showing the first winding 151A and the second winding 151B arranged laterally and compared. As shown in the figures above, the axial lengths of each coil module 150A, 150B and each winding 151A, 151B are different from each other, and the end shapes on both sides of the axial direction are different from each other. The first winding 151A is roughly C-shaped when viewed from the side, and the second winding 151B is roughly I-shaped when viewed from the side. In the first winding 151A, insulating covers 161 and 162, which serve as "first insulating covers," are installed on both sides of the axial direction. In the second winding 151B, insulating covers 163 and 164, which serve as "second insulating covers," are installed on both sides of the axial direction.

[0116] Next, the structure of coil modules 150A and 150B will be explained in detail.

[0117] Here, we will first describe the first coil module 150A in coil modules 150A and 150B. Figure 19 (a) is a perspective view showing the structure of the first coil module 150A. Figure 19 (b) is a perspective view showing the exploded components of the first coil module 150A. Additionally, Figure 20 yes Figure 19 Sectional view of line 20-20 in (a).

[0118] like Figure 19 As shown in (a) and (b), the first coil module 150A includes a first partial winding 151A and insulating covers 161 and 162. The first partial winding 151A is constructed by winding multiple layers of conductor material CR. The insulating covers 161 and 162 are assembled to one axial end and the other axial end of the first partial winding 151A. The insulating covers 161 and 162 are formed of insulating materials such as synthetic resin.

[0119] The first winding 151A includes a pair of intermediate conductor portions 152 arranged parallel to each other in a straight line, and a pair of overlapping portions 153A connecting the pair of intermediate conductor portions 152 at their respective axial ends, forming a ring shape through the pair of intermediate conductor portions 152 and the pair of overlapping portions 153A. The pair of intermediate conductor portions 152 are arranged apart by a predetermined coil spacing, and intermediate conductor portions 152 of other phase partial windings 151 can be arranged between the pair of intermediate conductor portions 152 in the circumferential direction. In this embodiment, the pair of intermediate conductor portions 152 are arranged apart by two coil spacings, and an intermediate conductor portion 152 of another two phase partial windings 151 is arranged between each pair of intermediate conductor portions 152.

[0120] The pair of overlapping portions 153A have the same shape on both sides in the axial direction, and are both configured to correspond to the coil edge end CE (see reference). Figure 11The overlapping portion 153A is configured to be bent in a direction orthogonal to the intermediate guide portion 152, that is, in a direction orthogonal to the axial direction.

[0121] like Figure 18 As shown, the first winding 151A has overlapping portions 153A on both sides of the axial direction, and the second winding 151B has overlapping portions 153B on both sides of the axial direction. The shapes of the overlapping portions 153A and 153B of the windings 151A and 151B are different from each other. To clarify their difference, the overlapping portion 153A of the first winding 151A is referred to as "first overlapping portion 153A", and the overlapping portion 153B of the second winding 151B is referred to as "second overlapping portion 153B".

[0122] In each winding 151A and 151B, the intermediate conductor portion 152 is provided as coil side conductor portions arranged one by one along the circumferential direction at the coil side portion CS. In addition, each overlapping portion 153A and 153B is provided as coil side end conductor portions that connect the intermediate conductor portions 152 of the same phase at two different positions in the circumferential direction at the coil side end portion CE.

[0123] like Figure 20 As shown, the first winding 151A is formed by winding the conductor material CR in multiple layers in such a way that the cross-section of the conductor assembly portion becomes a quadrilateral. Figure 20 A cross-section of the intermediate conductor portion 152 is shown, in which conductor material CR is wound in multiple layers in a manner arranged circumferentially and radially. That is, in the intermediate conductor portion 152, the first winding 151A has the conductor material CR arranged in multiple rows circumferentially and radially, thereby forming a generally rectangular cross-section. In addition, the conductor material CR is bent radially at the front end of the first overlap portion 153A, thereby winding the conductor material CR in multiple layers in a manner arranged axially and radially. In this embodiment, the first winding 151A is constructed by winding the conductor material CR in a concentric winding manner. However, the winding method of the conductor material CR is arbitrary; in addition to concentric winding, the conductor material CR can also be wound in multiple layers in an α winding manner.

[0124] In the first winding 151A, the end of the conductor material CR is connected from one of the first overlap portions 153A on both axial sides. Figure 19 The first overlapping portion 153A) on the upper side of (b) extends out, and its ends are winding ends 154 and 155. Winding ends 154 and 155 are respectively the starting and ending ends of winding the conductor material CR. 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.

[0125] In the first winding 151A, each intermediate conductor portion 152 is provided covered with a sheet-like insulating sheath 157. Furthermore, in Figure 19 In (a), the first coil module 150A is shown in a state where the intermediate conductor portion 152 is covered by an insulating cover 157 and the intermediate conductor portion 152 exists inside the insulating cover 157. However, for convenience, this part is referred to as the intermediate conductor portion 152 (described later). Figure 22 (b) is the same).

[0126] The insulating cover 157 uses a thin film material FM with an axial dimension at least having a length equal to the axial insulating cover range of the intermediate conductor portion 152, and is provided by winding the thin film material FM around the intermediate conductor portion 152. The thin film material FM is, for example, made of PEN (polyethylene naphthalate) film. More specifically, the thin film material FM includes a thin film substrate and a foamed adhesive layer disposed on one side of both sides of the thin film substrate. Moreover, the thin film material FM is wound relative to the intermediate conductor portion 152 in a state of being bonded by the adhesive layer. Alternatively, a non-foamed adhesive can also be used as the adhesive layer.

[0127] like Figure 20 As shown, the intermediate conductor portion 152 has a roughly rectangular cross-section due to the circumferential and radial arrangement of conductor materials CR. A thin film material FM covers the periphery of the intermediate conductor portion 152 with its circumferential ends overlapping, thereby providing an insulating cover 157. The thin film material FM is a rectangular sheet with a longitudinal dimension longer than the axial length of the intermediate conductor portion 152 and a transverse dimension longer than the circumference of the intermediate conductor portion 152. It is wound around the intermediate conductor portion 152 with folds corresponding to the cross-sectional shape of the intermediate conductor portion 152. With the thin film material FM wound around the intermediate conductor portion 152, the gap between the conductor materials CR and the thin film substrate is filled by foaming of the adhesive layer. Furthermore, in the overlapping portion OL of the thin film material FM, the circumferential ends of the thin film material FM are joined together by the adhesive layer.

[0128] In the intermediate conductor section 152, the insulating cover 157 is provided in such a way that it covers all of the two circumferential sides and the two radial sides. In this case, in the insulating cover 157 surrounding the intermediate conductor section 152, an overlapping portion OL of thin film material FM is provided on the opposite portion of the intermediate conductor section 152 in the partial windings 151 of other phases, that is, on one of the two circumferential sides of the intermediate conductor section 152. In this embodiment, in a pair of intermediate conductor sections 152, the overlapping portion OL is provided on the same side in the circumferential direction.

[0129] In the first winding 151A, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portion covered by the insulating covers 161, 162 in the first overlapping portions 153A on both axial sides (i.e., the portion that becomes the inner side of the insulating covers 161, 162). Figure 17 In the first coil module 150A, the range of AX1 is the portion not covered by the insulating covers 161, 162, and an insulating cover 157 is provided in the range that expands vertically relative to the range of AX1.

[0130] Next, the structure of insulating covers 161 and 162 will be described.

[0131] An insulating cover 161 is installed on the first overlapping portion 153A on one axial side of the first winding 151A, and an insulating cover 162 is installed on the first overlapping portion 153A on the other axial side of the first winding 151A. Wherein, Figure 21 (a) and (b) show the structure of the insulating cover 161. Figure 21 (a) and (b) are perspective views of the insulating cover 161 viewed from two different directions.

[0132] like Figure 21 As shown in (a) and (b), the insulating cover 161 has a pair of side portions 171 forming circumferential sides, an outer surface portion 172 extending axially outward, an inner surface portion 173 extending axially inward, and a front surface portion 174 extending radially inward. Each of the portions 171 to 174 is formed in a plate shape and is three-dimensionally joined together with only radially outward opening. The pair of side portions 171 are respectively arranged in a direction extending toward the axis of the core assembly CA when assembled into the core assembly CA. Therefore, when the plurality of first coil modules 150A are arranged circumferentially, the side portions 171 of the insulating cover 161 are positioned in a contacting or near-contacting state relative to each other in adjacent first coil modules 150A. Thus, mutual insulation can be achieved in the circumferentially adjacent first coil modules 150A, and they can be appropriately arranged in a ring shape.

[0133] In the insulating cover 161, an opening 175a is provided in the outer surface portion 172 for leading out the winding end 154 of the first partial winding 151A, and an opening 175b is provided in the front surface portion 174 for leading out the winding end 155 of the first partial winding 151A. In this configuration, one winding end 154 is led out axially from the outer surface portion 172, while the other winding end 155 is led out radially from the front surface portion 174.

[0134] Furthermore, in the insulating cover 161, in each of the pair of side portions 171, a semi-circular recess 177 extending axially is provided at both ends of the front surface portion 174, that is, at the intersection of each side portion 171 and the front surface portion 174. In addition, in the outer surface portion 172, a pair of protrusions 178 extending axially are provided at symmetrical positions along both sides of the circumference with reference to the center line of the insulating cover 161 in the circumferential direction.

[0135] Supplementary description of the recess 177 of the insulating cover 161. For example... Figure 20 As shown, the first overlapping portion 153A of the first winding 151A is curved, protruding radially inward, i.e., towards the CA side of the core assembly. In this structure, a gap is formed between adjacent first overlapping portions 153A in the circumferential direction, with the gap widening as it approaches the front end of the first overlapping portion 153A. Therefore, in this embodiment, a recess 177 is provided in the side portion 171 of the insulating cover 161 at a position outside the curved portion of the first overlapping portion 153A, utilizing the gap between the circumferentially arranged first overlapping portions 153A.

[0136] Alternatively, a temperature sensing unit (thermostat) can be provided in the first winding 151A. In this configuration, an opening for leading out a signal line extending from the temperature sensing unit can be provided in the insulating cover 161. In this case, the temperature sensing unit can be appropriately housed within the insulating cover 161.

[0137] Although detailed descriptions of the illustrations are omitted, the insulating cover 162 on the other axial side has a structure substantially the same as that of the insulating cover 161. Similar to the insulating cover 161, the insulating cover 162 has a pair of side portions 171, an axially outer outer surface portion 172, an axially inner inner surface portion 173, and a radially inner front surface portion 174. Furthermore, in the insulating cover 162, semi-circular recesses 177 are provided at the circumferential ends of the front surface portion 174 in the pair of side portions 171, and a pair of protrusions 178 are provided in the outer surface portion 172. As a difference from the insulating cover 161, the insulating cover 162 is configured not to have openings for leading out the winding ends 154, 155 of the first partial winding 151A.

[0138] In the insulating covers 161 and 162, the axial height dimension (i.e., the axial width dimension of the pair of side portions 171 and the front surface portion 174) is different. Specifically, as Figure 17As shown, the axial height dimension W11 of insulating cover 161 and the axial height dimension W12 of insulating cover 162 are both greater than W11. That is, when the conductor material CR is wound in multiple layers, it is necessary to switch the winding layers of conductor material CR (track change) in a direction orthogonal to the winding direction (circumferential direction). Due to this switching, the winding width may increase. As a supplement, insulating cover 161 of insulating covers 161 and 162 is the portion that covers the first overlap portion 153A on the side including the winding start end and winding end end of conductor material CR. Since it includes the winding start end and winding end end of conductor material CR, the amount of winding (layer overlap) of conductor material CR is greater than other portions, resulting in a larger winding width. Taking this into consideration, the axial height dimension W11 of insulating cover 161 is greater than the axial height dimension W12 of insulating cover 162. Thus, unlike the case where the height dimensions W11 and W12 of the insulating covers 161 and 162 are the same, the undesirable situation where the number of turns of the conductor material CR is limited by the insulating covers 161 and 162 is suppressed.

[0139] Next, the second coil module 150B will be described.

[0140] Figure 22 (a) is a perspective view showing the structure of the second coil module 150B. Figure 22 (b) is a perspective view showing the exploded components of the second coil module 150B. Additionally, Figure 23 yes Figure 22 Sectional view along line 23-23 in (a).

[0141] like Figure 22 As shown in (a) and (b), the second coil module 150B includes a second partial winding 151B and insulating covers 163 and 164. The second partial winding 151B, like the first partial winding 151A, is constructed by winding multiple layers of conductor material CR. The insulating covers 163 and 164 are mounted on one axial end and the other axial end of the second partial winding 151B. The insulating covers 163 and 164 are formed of insulating materials such as synthetic resin.

[0142] The second winding 151B has a pair of intermediate conductor portions 152 arranged parallel to each other in a straight line; and a pair of second overlapping portions 153B connecting the pair of intermediate conductor portions 152 at their respective axial ends, forming a ring shape through the pair of intermediate conductor portions 152 and the pair of second overlapping portions 153B. In the second winding 151B, the pair of intermediate conductor portions 152 has the same structure as the intermediate conductor portions 152 of the first winding 151A. In contrast, the structure of the pair of second overlapping portions 153B is different from the structure of the first overlapping portion 153A of the first winding 151A. The second overlapping portions 153B of the second winding 151B are configured to extend axially in a straight line from the intermediate conductor portions 152 without bending radially. Figure 18 The differences between some windings 151A and 151B are compared and clearly stated.

[0143] In the second winding 151B, the end of the conductor material CR is connected from one of the second overlaps 153B on both axial sides. Figure 22 The second overlapping portion 153B on the upper side of (b) is led out, and its ends become winding ends 154 and 155. Moreover, similar to the first part of the winding 151A, in the second part of the winding 151B, 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.

[0144] Similar to the first winding 151A, the second winding 151B is configured such that each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157. The insulating cover 157 is made of a thin film material FM with an axial dimension having a length of at least the axial insulating coverage range of the intermediate conductor portion 152, and is configured by winding the thin film material FM around the intermediate conductor portion 152.

[0145] The structure of the insulating sheath 157 is roughly the same in the various windings 151A and 151B. That is, as... Figure 23 As shown, the thin film material FM covers the periphery of the intermediate conductor portion 152 in a state where the circumferential ends overlap. In the intermediate conductor portion 152, the insulating cover 157 is provided in such a way that it covers all of the two circumferential sides and two radial sides. In this case, on the insulating cover 157 surrounding the intermediate conductor portion 152, an overlapping portion OL of the thin film material FM is provided on one of the two circumferential sides of the intermediate conductor portion 152, opposite to the intermediate conductor portion 152 in the partial windings 151 of other phases. In this embodiment, in a pair of intermediate conductor portions 152, overlapping portions OL are provided on the same circumferential side.

[0146] In the second winding 151B, an insulating covering 157 is provided in the area from the intermediate conductor portion 152 to the portion of the second overlapping portions 153B on both axial sides covered by insulating covers 163, 164 (i.e., the portion that becomes the inner side of insulating covers 163, 164). Figure 17 In the second coil module 150B, the range of AX2 is the portion not covered by the insulating covers 163 and 164, and an insulating cover 157 is provided in the range that expands vertically relative to this range AX2.

[0147] In each of the windings 151A and 151B, the insulating cover 157 is provided within a range including a portion of the overlap portions 153A and 153B. That is, in each of the windings 151A and 151B, the insulating cover 157 is provided in the portion of the intermediate conductor portion 152 and the overlap portions 153A and 153B that extends linearly from the intermediate conductor portion 152. However, since the axial lengths of the windings 151A and 151B are different, the axial range of the insulating cover 157 is also different.

[0148] Next, the structure of insulating covers 163 and 164 will be explained.

[0149] An insulating cover 163 is installed on the second overlapping portion 153B on one axial side of the second winding 151B, and an insulating cover 164 is installed on the second overlapping portion 153B on the other axial side of the second winding 151B. Figure 24 (a) and (b) show the structure of the insulating cover 163. Figure 24 (a) and (b) are perspective views of the insulating cover 163 viewed from two different directions.

[0150] like Figure 24 As shown in (a) and (b), the insulating cover 163 has a pair of side portions 181 that form circumferential sides, an outer surface portion 182 that is axially outward, a front surface portion 183 that is radially inward, and a rear surface portion 184 that is radially outward. Each of the portions 181 to 184 is formed in a plate shape and is three-dimensionally joined together with only its axially inward side open. The pair of side portions 181 are respectively arranged in a direction extending toward the axis of the core assembly CA when assembled into the core assembly CA. Therefore, when the plurality of second coil modules 150B are arranged circumferentially, the side portions 181 of the insulating cover 163 are positioned in a contacting or near-contacting state relative to each other in adjacent second coil modules 150B. Thus, mutual insulation can be achieved in the circumferentially adjacent second coil modules 150B, and they can be appropriately arranged in a ring shape.

[0151] In the insulating cover 163, an opening 185a is provided on the front surface portion 183 for leading out the winding end 154 of the second partial winding 151B, and an opening 185b is provided on the outer surface portion 182 for leading out the winding end 155 of the second partial winding 151B.

[0152] A protrusion 186 protruding radially inward is provided on the front surface portion 183 of the insulating cover 163. The protrusion 186 is positioned at the center of the insulating cover 163 from one circumferential end to the other, protruding further radially inward than the second overlapping portion 153B. When viewed from above, the protrusion 186 has a tapered shape that tapers towards the radially inward front end, and a through hole 187 extending axially is provided at its front end. Furthermore, the structure of the protrusion 186 can be arbitrary, as long as it protrudes further radially inward than the second overlapping portion 153B and has a through hole 187 at the center of the insulating cover 163 from one circumferential end to the other. However, considering the overlap with the axially inward insulating cover 161, it is desirable to form a narrower circumferential width to avoid interference with the winding ends 154 and 155.

[0153] The axial thickness of the protrusion 186 thins in a stepped manner at the radially inner front end, and a through hole 187 is provided in the lower step 186a where the thickness is reduced. This lower step 186a corresponds to the portion where the height from the axial end face of the inner cylinder member 81 is lower than the height of the second overlap 153B when the second coil module 150B is assembled to the core assembly CA.

[0154] In addition, such as Figure 23 As shown, a through hole 188 extending axially is provided in the protrusion 186. Therefore, when the insulating covers 161 and 163 overlap axially, adhesive can be filled between the insulating covers 161 and 163 through the through hole 188.

[0155] Although detailed descriptions of the illustrations are omitted, the insulating cover 164 on the other axial side has a structure substantially the same as that of the insulating cover 163. Similar to the insulating cover 163, the insulating cover 164 has a pair of side portions 181, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184, and has a through hole 187 provided at the front end of the protrusion 186. Furthermore, unlike the insulating cover 163, the insulating cover 164 is configured not to have openings for leading out the winding ends 154, 155 of the second partial winding 151B.

[0156] In insulating covers 163 and 164, the radial width dimensions of a pair of side portions 181 are different. Specifically, as shown... Figure 17As shown, the radial width dimension W21 of the side portion 181 in insulating cover 163 and the radial width dimension W22 of the side portion 181 in insulating cover 164 are both greater than W21. That is, insulating cover 163 in insulating covers 163 and 164 is the portion that covers the second overlap portion 153B, which includes the winding start end and winding end end of the conductor material CR. Since it includes the winding start end and winding end end of the conductor material CR, the amount of winding (layering) of the conductor material CR is greater than that of other portions, which may result in a larger winding width. Considering this, the radial width dimension W21 of insulating cover 163 is greater than the radial width dimension W22 of insulating cover 164. Thus, unlike the case where the width dimensions W21 and W22 of insulating covers 163 and 164 are the same, the undesirable situation of limiting the number of turns of the conductor material CR due to insulating covers 163 and 164 is suppressed.

[0157] Figure 25 This diagram shows the overlapping positions of the thin film material FM with each coil module 150A, 150B arranged circumferentially. As described above, in each coil module 150A, 150B, the thin film material FM is covered around the intermediate conductor portion 152 in such a way that it overlaps with the circumferential side surface of the intermediate conductor portion 152 in the opposite portions of the partial windings 151 of other phases. Figure 20 and Figure 23 Furthermore, with the coil modules 150A and 150B arranged circumferentially, the overlapping portions OL of the thin film material FM are all positioned on the same side on both circumferentially (the right side of the circumferential direction in the figure). This configuration ensures that in the intermediate conductor portions 152 of adjacent circumferentially adjacent phase windings 151A and 151B, the overlapping portions OL of the thin film material FM do not overlap each other circumferentially. In this configuration, a maximum of three sheets of thin film material FM overlap between each of the circumferentially arranged intermediate conductor portions 152.

[0158] Next, the structure related to the assembly of each coil module 150A, 150B relative to the core assembly CA will be described.

[0159] The axial lengths of each coil module 150A and 150B are different from each other, and the shapes of the overlapping portions 153A and 153B of some windings 151A and 151B are different from each other. They are installed on the core assembly CA with the first overlapping portion 153A of the first coil module 150A positioned axially inside and the second overlapping portion 153B of the second coil module 150B positioned axially outside. Regarding the insulating covers 161 to 164, the insulating covers 161 and 163 overlap axially at one axial end of each coil module 150A and 150B, and the insulating covers 162 and 164 overlap axially at the other axial end. The insulating covers 161 to 164 are fixed relative to the core assembly CA.

[0160] Figure 26 This is a top view showing the multiple insulating covers 161 arranged circumferentially with the first coil module 150A assembled into the core assembly CA. Figure 27 This is a top view showing the multiple insulating covers 161, 163 arranged circumferentially with the first coil module 150A and the second coil module 150B assembled into the core assembly CA. Furthermore, Figure 28 (a) is a longitudinal sectional view showing the state before the coil modules 150A and 150B are fixed by the retaining pin 191 after being assembled into the core assembly CA. Figure 28 (b) is a longitudinal sectional view showing the state after the coil modules 150A and 150B are assembled into the core assembly CA and secured by the retaining pin 191.

[0161] like Figure 26 As shown, with multiple first coil modules 150A assembled into the core assembly CA, multiple insulating covers 161 are respectively configured such that their side faces 171 are in contact or close to each other. Each insulating cover 161 is configured such that the boundary line LB of the side faces 171 aligns with the recess 105 on the axial end face of the inner cylinder member 81. In this case, since the side faces 171 of the circumferentially adjacent insulating covers 161 are in contact or close to each other, the following state is achieved: through the recesses 177 of the insulating covers 161, axially extending through holes are formed, and the positions of these through holes and recesses 105 are aligned.

[0162] In addition, such as Figure 27As shown, a second coil module 150B is also assembled relative to the integral core assembly CA and the first coil module 150A. Along with this assembly, multiple insulating covers 163 are respectively configured such that the side portions 181 are in contact or close to each other. In this state, the overlapping portions 153A, 153B are configured to intersect each other on a circle on which the intermediate conductor portions 153 are arranged circumferentially. Each insulating cover 163 is configured such that the protrusion 186 overlaps the insulating cover 161 axially, and the through hole 187 of the protrusion 186 communicates axially with the through hole portion formed by each recess 177 of the insulating cover 161.

[0163] At this time, the protrusion 186 of the insulating cover 163 is guided to a predetermined position by a pair of protrusions 178 provided on the insulating cover 161, so that the position of the through hole 187 on the insulating cover 163 side coincides with the through hole portion on the insulating cover 161 side and the recess 105 of the inner cylinder member 81. That is, when each coil module 150A, 150B is assembled into the core assembly CA, the recess 177 of the insulating cover 161 is located on the inner side of the insulating cover 163, so it may be difficult to align the position of the through hole 187 of the protrusion 186 relative to the recess 177 of the insulating cover 161. In this regard, the protrusion 186 of the insulating cover 163 is guided by a pair of protrusions 178 of the insulating cover 161, thereby making it easier to align the position of the insulating cover 163 relative to the insulating cover 161.

[0164] Moreover, such as Figure 28 As shown in (a) and (b), in the overlapping portion where the protrusions 186 of insulating cover 161 and insulating cover 163 overlap, fixation is achieved by a fixing pin 191 as a fixing member while they are engaged. More specifically, with the recesses 105 of the inner cylinder member 81, the recesses 177 of the insulating cover 161, and the through holes 187 of the insulating cover 163 aligned, the fixing pin 191 is inserted into the recesses 105, 177, and the through holes 187. Thus, the insulating covers 161 and 163 are integrally fixed relative to the inner cylinder member 81. According to this structure, each circumferentially adjacent coil module 150A and 150B is fixed to the core assembly CA at the coil edge end CE using a common fixing pin 191. The fixing pin 191 is preferably made of a material with good thermal conductivity, such as a metal pin.

[0165] like Figure 28As shown in (b), the retaining pin 191 is assembled to the lower step 186a in the protrusion 186 of the insulating cover 163. In this state, the upper end of the retaining pin 191 protrudes upward above the lower step 186a, but does not protrude upward beyond the upper surface (outer surface 182) of the insulating cover 163. In this case, the retaining pin 191 is longer in axial height than the overlapping portion of the insulating cover 161 and the protrusion 186 (lower step 186a) of the insulating cover 163, and has a margin for upward protrusion. Therefore, it is believed that the retaining pin 191 can be easily inserted into the recesses 105, 177 and the through hole 187 (i.e., during the fixing operation of the retaining pin 191). In addition, since the upper end of the retaining pin 191 does not protrude upward beyond the upper surface (outer surface 182) of the insulating cover 163, the undesirable situation of the stator 60 becoming longer due to the protrusion of the retaining pin 191 can be suppressed.

[0166] After securing the insulating covers 161 and 163 with the retaining pins 191, adhesive is filled through the through holes 188 provided in the insulating cover 163. Thus, the axially overlapping insulating covers 161 and 163 are firmly bonded together. Furthermore, in Figure 28 In (a) and (b), for convenience, the through hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163, but in reality, the through hole 188 is provided in the thin plate portion formed by reducing the wall or the like.

[0167] like Figure 28 As shown in (b), the insulating covers 161, 163, fixed by the fixing pin 191, are positioned radially inward (on the left side of the figure) on the axial end face of the stator retainer 70, and are fixed relative to the stator retainer 70 by the fixing pin 191. That is, the first overlap portion 153A is fixed relative to the axial end face of the stator retainer 70. In this case, since a refrigerant passage 85 is provided in the stator retainer 70, the heat generated in the first part of the winding 151A is directly transferred from the first overlap portion 153A to the vicinity of the refrigerant passage 85 in the stator retainer 70. Furthermore, the fixing pin 191 is inserted into the recess 105 of the stator retainer 70, thereby promoting the transfer of heat to the stator retainer 70 side. With this structure, the cooling performance of the stator winding 61 can be improved.

[0168] In this embodiment, 18 insulating covers 161 and 163 are arranged overlappingly in the axial direction at the coil end CE. On the axial end face of the stator retainer 70, recesses 105 are provided at 18 locations, the same number as the insulating covers 161 and 163. Then, the 18 locations are fixed by retaining pins 191 at the recesses 105.

[0169] Although not shown, the insulating covers 162 and 164 on opposite axial sides are also the same. That is, firstly, when assembling the first coil module 150A, since the side portions 171 of the circumferentially adjacent insulating covers 162 are in abutting or close to each other, the following state is achieved: through-hole portions extending axially are formed by the recesses 177 of the insulating covers 162, and the position of these through-hole portions coincides with the position of the recess 106 on the axial end face of the outer cylinder member 71. Then, when assembling the second coil module 150B, the position of the through-hole 187 on the insulating cover 164 side coincides with the through-hole portion on the insulating cover 163 side and the recess 106 of the outer cylinder member 71, and the insulating covers 162 and 164 are integrally fixed relative to the outer cylinder member 71 by inserting the fixing pin 191 into the recesses 106, 177 and the through-hole 187.

[0170] When assembling the coil modules 150A and 150B into the core assembly CA, all the first coil modules 150A can be pre-installed onto the outer periphery of the core assembly CA. Then, all the second coil modules 150B are assembled and secured using the fixing pin 191. Alternatively, first, two first coil modules 150A and one second coil module 150B are secured to the core assembly CA using a fixing pin 191. Then, the assembly of the first coil modules 150A, the assembly of the second coil modules 150B, and the securing using the fixing pin 191 are repeated in this order.

[0171] Next, the bus module 200 will be described.

[0172] The bus module 200 is a winding connection component that is electrically connected to a portion of the winding 151 of each coil module 150 in the stator winding 61. For each phase, one end of the portion of the winding 151 of each phase is connected in parallel, and the other end of each portion of the winding 151 is connected at the neutral point. Figure 29 This is a 3D view of busbar module 200. Figure 30 This is a sectional view showing a portion of the longitudinal section of the busbar module 200.

[0173] The bus module 200 has: an annular portion 201 in the shape of a ring; 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 into an annular shape, for example, by means of an insulating member such as resin.

[0174] like Figure 30As shown, the annular portion 201 has a multi-layered plate 204 that is generally circular and stacked axially in multiple layers (five layers in this example), and four busbars 211 to 214 are arranged between the multi-layered plates 204. Each busbar 211 to 214 is annular and includes a busbar 211 for the U phase, a busbar 212 for the V phase, a busbar 213 for the W phase, and a busbar 214 for the neutral point. The busbars 211 to 214 are arranged axially with their surfaces facing each other within the annular portion 201. The multi-layered plates 204 and the busbars 211 to 214 are joined together by an adhesive. An adhesive sheet is preferred as the adhesive. However, a liquid or semi-liquid adhesive may also be used. Furthermore, the connecting terminals 202 are connected to each busbar 211 to 214 in a manner that protrudes radially outward from the annular portion 201.

[0175] On the upper surface of the annular portion 201, that is, on the upper surface of the outermost layer of the five-layer laminate 204, an annularly extending protrusion 201a is provided.

[0176] Furthermore, the busbar module 200 can be configured such that each busbar 211 to 214 is embedded within the annular portion 201, or the busbars 211 to 214 can be integrally embedded with each busbar at a predetermined interval. Additionally, the arrangement of the busbars 211 to 214 is not limited to a structure in which all are arranged axially and all plate surfaces face the same direction; it can also be a structure arranged radially, a structure arranged in two rows axially and two rows radially, or a structure including busbars with different extension directions of the plate surfaces, etc.

[0177] exist Figure 29 In this configuration, each connection terminal 202 is arranged circumferentially along the annular portion 201 and extends axially at its radially outer side. The connection terminals 202 include terminals connected to the busbar 211 for the U phase, the busbar 212 for the V phase, the busbar 213 for the W phase, and the busbar 214 for the neutral point. The connection terminals 202 are provided in the same number as the winding ends 154 and 155 of each partial winding 151 in the coil module 150, and each connection terminal 202 is connected to one winding end 154 or 155 of each partial winding 151. Thus, the busbar module 200 is connected to the partial windings 151 of the U phase, the V phase, and the W phase, respectively.

[0178] The input / output terminals 203 are, for example, constructed from busbar components and arranged in an axially extending direction. The input / output terminals 203 include an input / output terminal 203U for the U-phase, an input / output terminal 203V for the V-phase, and an input / output terminal 203W for the W-phase. These input / output terminals 203 are connected to each busbar 211-213 for each phase within the annular portion 201. Through these input / output terminals 203, power is input and output to each phase winding of the stator winding 61 via an inverter (not shown).

[0179] Alternatively, the bus module 200 can be configured to integrate current sensors that detect the phase current of each phase. In this case, current detection terminals can be provided in the bus module 200, and the detection results of the current sensors can be output to a control device (not shown) via the current detection terminals.

[0180] In addition, as the fixed part relative to the stator retainer 70, the annular part 201 has a plurality of protrusions 205 protruding inward to the circumferential side, and through holes 206 extending axially are formed in the protrusions 205.

[0181] Figure 31 This is a perspective view showing the busbar module 200 assembled on the stator retainer 70. Figure 32 This is a longitudinal sectional view of the fixed portion of the fixed busbar module 200. Additionally, the structure of the stator retainer 70 before assembling the busbar module 200 is shown in reference. Figure 12 .

[0182] exist Figure 31 In this configuration, the busbar module 200 is mounted on the end plate portion 91 in such a way that it surrounds the bushing portion 92 of the inner cylinder member 81. The busbar module 200 is further mounted on the support portion 95 (see reference 81) of the inner cylinder member 81. Figure 12 In the positioned state, it is fixed to the stator retainer 70 (inner cylinder component 81) by fastening with bolts or other fasteners 217.

[0183] More in detail, such as Figure 32 As shown, an axially extending support portion 95 is provided on the end plate portion 91 of the inner cylinder component 81. Then, the busbar module 200 is fixed to the support portion 95 by fasteners 217 with the support portion 95 inserted into the through holes 206 provided in the plurality of protrusions 205. In this embodiment, a stop plate 220 made of a metal material such as iron is used to fix the busbar module 200. The stop plate 220 includes: a fastening portion 222 having an insertion hole 221 through which the fastener 217 is inserted; a pressing portion 223 pressing against the upper surface of the annular portion 201 of the busbar module 200; and a bending portion 224 disposed between the fastening portion 222 and the pressing portion 223.

[0184] With the stop plate 220 installed, and the fastener 217 inserted into the through hole 221 of the stop plate 220, the fastener 217 is screwed onto the support portion 95 of the inner cylinder member 81. Additionally, the pressing portion 223 of the stop plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200. In this situation, as the fastener 217 is screwed into the support portion 95, the stop plate 220 is pressed downwards, and correspondingly, the annular portion 201 is pressed downwards by the pressing portion 223. The downward pressing force generated by the screwing of the fastener 217 is transmitted to the pressing portion 223 through the bending portion 224; therefore, the pressing portion 223 is pressed down by the elastic force of the bending portion 224.

[0185] As described above, an annular protrusion 201a is provided on the upper surface of the annular portion 201, and the front end of the pressing portion 223 side of the stop plate 220 can abut against the protrusion 201a. This suppresses the downward pressing force of the stop plate 220 from escaping radially outward. That is, the pressing force generated by the screwing of the fastener 217 is appropriately transmitted to the pressing portion 223 side.

[0186] In addition, such as Figure 31 As shown, with the bus module 200 assembled relative to the stator retainer 70, the input / output terminals 203 are positioned on the opposite side of the inlet opening 86a and outlet opening 87a leading to the refrigerant passage 85, circumferentially 180 degrees apart. However, the input / output terminals 203 and the openings 86a and 87a may also be concentrated in the same position (i.e., close to each other).

[0187] Next, the relay member 230 that electrically connects the input / output terminals 203 of the bus module 200 to the external device of the rotary motor 10 will be described.

[0188] like Figure 1 As shown, in the rotating electric motor 10, the input / output terminals 203 of the bus module 200 are configured to protrude outward from the housing 242, and are connected to the relay member 230 on the outside of the housing 242. The relay member 230 is a member that relays the connection between the input / output terminals 203 for each phase extending from the bus module 200 and the power lines for each phase extending from external devices such as inverters.

[0189] Figure 33 This is a longitudinal sectional view showing the relay component 230 installed on the housing 242. Figure 34 This is a 3D view of relay component 230. (For example...) Figure 33As shown, a through hole 242a is formed in the outer casing 242, through which the input / output terminal 203 can be led out.

[0190] The relay component 230 has a main body 231 fixed to the housing 242 and a terminal insertion portion 232 inserted into a through hole 242a in the housing 242. The terminal insertion portion 232 has three insertion holes 233 for each phase's input / output terminal 203 to be inserted one by one. The cross-sectional opening of the three insertion holes 233 is elongated, and the three insertion holes 233 are arranged in a direction that is approximately the same along their long sides.

[0191] Three relay buses 234, each for each phase, are installed on the main body 231. The relay buses 234 are bent into a roughly L-shape and fixed to the main body 231 by fasteners 235 such as bolts, and fixed to the front end of the input / output terminals 203, which are inserted into the insertion holes 233 of the terminal insertion section 232, by fasteners 236 such as bolts and nuts.

[0192] Additionally, although the illustration is omitted, it is possible to connect the power lines for each phase extending from the external device to the relay member 230, and to input or output power for each phase relative to the input / output terminals 203.

[0193] Next, the structure of the control system for controlling the rotary motor 10 will be described. Figure 35 This is the circuit diagram of the control system for the rotary motor 10. Figure 36 This is a functional block diagram showing the control processing of the control device 270.

[0194] like Figure 35 As shown, the stator winding 61 consists of a U-phase winding, a V-phase winding, and a W-phase winding. An inverter 260, which is equivalent to a power converter, is connected to the stator winding 61. The inverter 260 is a full-bridge circuit with the same number of upper and lower arms as the number of phases. Each phase has a series connection including an upper arm switch 261 and a lower arm switch 262. Each switch 261 and 262 is switched on and off by a driver 263, energizing the phase winding of each phase. Each switch 261 and 262 is composed of semiconductor switching elements such as MOSFETs and IGBTs. Furthermore, in the upper and lower arms of each phase, a capacitor 264 is connected in parallel with the series connection of the switches 261 and 262 to supply the charge required for switching to each switch 261 and 262.

[0195] One end of the U-phase winding, V-phase winding, and W-phase winding are respectively connected to the intermediate connection point between switches 261 and 262 in the upper and lower arms. The above-mentioned phase windings are star-connected (Y-connected), and the other ends of the phase windings are interconnected at the neutral point.

[0196] The control device 270 includes a microcomputer with a CPU and various memories. Based on various detection information from the rotating electric motor 10, requests for power operation and power generation, it implements power control by switching on and off various switches 261 and 262. The detection information of the rotating electric motor 10 includes, for example, the rotation angle of the rotor 20 (electrical angle information) detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the current flowing through each phase detected by a current sensor. The control device 270 implements the switching on and off control of each switch 261 and 262 through, for example, PWM control or rectangular wave control at a predetermined switching frequency (carrier frequency). The control device 270 can be a built-in control device integrated into the rotating electric motor 10, or an external control device located outside the rotating electric motor 10.

[0197] Since the rotary motor 10 of this embodiment has a slotless structure (poleless tooth structure), the inductance of the stator 60 is reduced, resulting in a smaller electrical time constant. With this smaller electrical time constant, it is desirable to increase the switching frequency (carrier frequency) and accelerate the switching speed. In this regard, since a capacitor 264 for charge supply is connected in parallel with the series connection of the switches 261 and 262 of each phase, the wiring inductance is reduced, and even in a structure with accelerated switching speed, appropriate surge countermeasures can be taken.

[0198] The high-potential side terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265, and the 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, a battery pack of multiple individual cells connected in series. In addition, a smoothing capacitor 266 is connected in parallel with the DC power supply 265 at both the high-potential side terminal and the low-potential side terminal of the inverter 260.

[0199] Figure 36 This is a block diagram illustrating the current feedback control process for controlling the current of each phase (U, V, and W).

[0200] exist Figure 36 In this configuration, the current command value setting unit 271 uses torque-dq mapping to set the current command values ​​for the d-axis and q-axis based on the power operating torque command value or generator torque command value for the rotary motor 10 and the electrical angular velocity ω obtained by time differentiation of the electrical angle θ. Furthermore, for example, when the rotary motor 10 is used as a power source for a vehicle, the generator torque command value is the regenerative torque command value.

[0201] The dq conversion unit 272 converts the current detection values ​​(three phase currents) of the current sensors set for each phase into components of an orthogonal two-dimensional rotating coordinate system with the excitation direction (direction of an axis of a magnetic field, or field direction) as the d-axis, namely the d-axis current and the q-axis current.

[0202] The d-axis current feedback control unit 273 calculates the command voltage for the d-axis as an operational quantity for controlling the d-axis current feedback to the current command value for the d-axis. Similarly, the q-axis current feedback control unit 274 calculates the command voltage for the q-axis as an operational quantity for controlling the q-axis current feedback to the current command value for the q-axis. In each of the feedback control units 273 and 274, the command voltage is calculated using a PI feedback method based on the deviations of the d-axis and q-axis currents from the current command values.

[0203] The three-phase conversion unit 275 converts the command voltages of the d-axis and q-axis into command voltages for the U-phase, V-phase, and W-phase. Furthermore, each of the aforementioned units 271 to 275 is a feedback control unit that implements feedback control of the fundamental current based on the dq conversion theory, and the command voltages of the U-phase, V-phase, and W-phase are feedback control values.

[0204] The operation signal generation unit 276 uses a well-known triangular wave carrier comparison method to generate operation signals for the inverter 260 based on the three-phase command voltages. Specifically, the operation signal generation unit 276 generates switching operation signals (duty cycle signals) for the upper and lower arms of each phase by comparing the magnitudes of a signal that normalizes the three-phase command voltages using the power supply voltage and a carrier signal such as a triangular wave signal using PWM control. The switching operation signals generated by the operation signal generation unit 276 are output to the driver 263 of the inverter 260, and the driver 263 turns the switches 261 and 262 of each phase on and off.

[0205] Next, the torque feedback control process will be explained. Under operating conditions where the output voltage of each inverter 260 increases, such as in high-rotation and high-output regions, the above-mentioned process is primarily used to maximize the output of the rotating motor 10 and reduce losses. Based on the operating conditions of the rotating motor 10, the control device 270 selects and executes either the torque feedback control process or the current feedback control process.

[0206] Figure 37 This is a block diagram showing the torque feedback control process corresponding to phases U, V, and W.

[0207] The voltage amplitude calculation unit 281 calculates the voltage vector magnitude command value, i.e., the voltage amplitude command, based on the power operating torque command value or generator torque command value of the rotating motor 10 and the electric angular velocity ω obtained by time differentiation of the electric angle θ.

[0208] Similar to the dq conversion unit 272, the dq conversion unit 282 converts the current detection values ​​of the current sensors provided for each phase into d-axis current and q-axis current. The torque estimation unit 283 calculates the torque estimation values ​​corresponding to phases U, V, and W based on the d-axis current and q-axis current. Furthermore, the torque estimation unit 283 calculates the voltage amplitude command based on mapping information that sets the relationship between the d-axis current, q-axis current, and voltage amplitude command.

[0209] The torque feedback control unit 284 calculates the command value of the voltage vector phase, i.e., the voltage phase command, as an operating quantity for feeding back the torque estimate value to the power operating torque command value or the generator torque command value. In the torque feedback control unit 284, the voltage phase command is calculated using a PI feedback method based on the deviation of the torque estimate value from the power operating torque command value or the generator torque command value.

[0210] The operation signal generation unit 285 generates operation signals for the inverter 260 based on voltage amplitude commands, voltage phase commands, and electrical angle θ. Specifically, the operation signal generation unit 285 calculates the command voltages for the three phases based on the voltage amplitude commands, voltage phase commands, and electrical angle θ. It then generates switching operation signals for the upper and lower arms of each phase through PWM control based on a signal that normalizes the calculated three-phase command voltages using the power supply voltage and a carrier signal such as a triangular wave signal. The switching operation signals generated by the operation signal generation unit 285 are output to the driver 263 of the inverter 260, and the driver 263 turns the switches 261 and 262 of each phase on and off.

[0211] Alternatively, the operation signal generation unit 285 can also generate a switching operation signal based on the mapping information of the relationship between the set voltage amplitude command, voltage phase command, electrical angle θ and the switching operation signal, namely pulse mode information, voltage amplitude command, voltage phase command and electrical angle θ.

[0212] (Modified Example)

[0213] Hereinafter, variations related to the above embodiments will be described.

[0214] The structure of the magnet in magnet unit 22 can also be changed as described below. Figure 38In the magnet unit 22 shown, the direction of the easy magnetization axis in the magnet 32 ​​is inclined relative to the radial direction, and a straight magnetic circuit is formed along the direction of the easy magnetization axis. In this structure, the length of the magnetic circuit of the magnet 32 ​​can be longer than the radial thickness dimension, and the magnetic permeability can be improved.

[0215] • A Hellbeck array magnet can also be used in magnet unit 22.

[0216] In each winding 151, the bending direction of the overlapping portion 153 can be either radially inward or outward. In relation to the core assembly CA, the first overlapping portion 153A can be bent towards the core assembly CA, or it can be bent towards the opposite side of the core assembly CA. Furthermore, the second overlapping portion 153B only needs to be in a state where it circumferentially crosses a portion of the first overlapping portion 153A on its axially outer side; the second overlapping portion 153B can be bent in either radially inward or outward.

[0217] • As a partial winding 151, it is also possible to have only one partial winding 151 instead of two partial windings 151 (first partial winding 151A and second partial winding 151B). Specifically, the partial winding 151 can be formed into a generally L-shaped or generally Z-shaped form when viewed from the side. When the partial winding 151 is formed into a generally L-shaped form when viewed from the side, the overlapping portion 153 is configured to be bent in either radially inward or outward at one axial end, and the overlapping portion 153 is configured not to be bent radially at the other axial end. Alternatively, when the partial winding 151 is formed into a generally Z-shaped form when viewed from the side, the overlapping portion 153 is configured to be bent radially in opposite directions at one axial end and the other axial end. In either case, as described above, the coil module 150 can be fixed to the core assembly CA by an insulating cover covering the overlapping portion 153.

[0218] The above structure describes the parallel connection of all partial windings 151 for each phase winding in the stator winding 61, but this can be modified. For example, it can be configured such that all partial windings 151 for each phase winding are divided into multiple parallel connection groups, and these multiple parallel connection groups are connected in series. That is, it can also be configured such that all n partial windings 151 in each phase winding are divided into two parallel connection groups of n / 2 each, three parallel connection groups of n / 3 each, etc., and connected in series. Alternatively, it can be configured such that all partial windings 151 in the stator winding 61 are connected in series for each phase winding.

[0219] • Alternatively, the stator winding 61 in the rotary motor 10 can be configured to have two phase windings (U-phase winding and V-phase winding). In this case, it is sufficient to configure, for example, in a partial winding 151, a pair of intermediate conductor portions 152 are separated by a coil spacing, and an intermediate conductor portion 152 of another phase partial winding 151 is arranged between the pair of intermediate conductor portions 152.

[0220] • Instead of an external rotor type surface magnet type rotary motor, the rotary motor 10 can also be embodied as an internal rotor type surface magnet type rotary motor. Figure 39 Figures (a) and (b) are diagrams illustrating the structure of the stator unit 300 when it is configured as an internal rotor structure. Figure 39 (a) is a perspective view showing the coil modules 310A and 310B assembled in the core assembly CA. Figure 39 (b) is a perspective view showing the partial windings 311A ​​and 311B included in each coil module 310A and 310B. In this example, the stator retainer 70 is assembled to the radially outer side of the stator core 62, thereby forming the core assembly CA. Alternatively, multiple coil modules 310A and 310B are configured to be assembled to the radially inner side of the stator core 62.

[0221] Partial winding 311A ​​has a structure substantially the same as the first partial winding 151A described above, having a pair of intermediate conductor portions 312 and overlapping portions 313A formed by bending on both axial sides toward the core assembly CA side (radially outward). Partial winding 311B has a structure substantially the same as the second partial winding 151B described above, having a pair of intermediate conductor portions 312 and overlapping portions 313B arranged on both axial sides such that they circumferentially span the overlapping portions 313A on the axial outward. An insulating cover 315 is installed on the overlapping portion 313A of partial winding 311A, and an insulating cover 316 is installed on the overlapping portion 313B of partial winding 311B.

[0222] In the insulating cover 315, semi-circular recesses 317 extending axially are provided on the side portions on both circumferential sides. In addition, the insulating cover 316 is provided with a protrusion 318 that protrudes radially outward more than the overlapping portion 313B, and a through hole 319 extending axially is provided at the front end of the protrusion 318.

[0223] Figure 40 This is a top view showing the coil modules 310A and 310B assembled in the core assembly CA. Additionally, in Figure 40 In this structure, a plurality of recesses 105 are formed at equal intervals along the circumferential direction on the axial end face of the stator retainer 70. Furthermore, the stator retainer 70 has a cooling structure achieved by liquid refrigerant or air, and as an air-cooled structure, for example, a plurality of heat dissipation fins are formed on the outer peripheral surface.

[0224] exist Figure 40 In this configuration, insulating covers 315 and 316 are arranged in an axially overlapping state. Furthermore, the recess 317 provided on the side of the insulating cover 315 and the through hole 319 provided in the protrusion 318 of the insulating cover 316, which is located at the center between one end of the insulating cover 316 and the other end, are axially connected, and are fixed by fixing pins 321 in each of the above-mentioned parts.

[0225] In addition, Figure 40 In this configuration, the insulating covers 315 and 316, secured by the fixing pins 321, are located on the axial end face of the stator retainer 70, which is radially outer than the stator core 62, and are fixed relative to the stator retainer 70 using the fixing pins 321. In this case, since a cooling structure is provided in the stator retainer 70, some of the heat generated in the windings 311A ​​and 311B is easily transferred to the stator retainer 70. This improves the cooling performance of the stator windings 61.

[0226] The stator 60 used in the rotary motor 10 may also have protrusions (e.g., pole teeth) extending from the back yoke. In this case, it is sufficient to assemble the back yoke with coil modules 150 and the like relative to the stator core.

[0227] • As a rotary motor, it is not limited to a rotary motor with a star connection, but can also be a rotary motor with a delta connection.

[0228] • As a rotary motor 10, it can also replace the rotary excitation type rotary motor with the excitation element as the rotor and the armature as the stator, and adopt the rotary armature type rotary motor with the armature as the rotor and the excitation element as the stator.

[0229] (Variation Example 2)

[0230] In the above-described embodiments or modifications, the structure of the magnet unit can be changed as described below. Hereinafter, the structure of the magnet unit 700 in this modification will be described in detail. Furthermore, in this modification, the parts that differ from the structures described in the above-described embodiments and modifications will be mainly described. In addition, in this modification, the structure of the first embodiment will be used as an example to describe the basic structure of the rotary electric machine.

[0231] like Figure 41As shown, the magnet unit 700 includes a cylindrical magnet holder 31, a plurality of magnets 710 and 720 fixed to the inner circumferential surface of the magnet holder 31, and an end plate 33 fixed on one of the two axial sides opposite to the end plate portion 24 of the rotor frame 21. The magnet holder 31 has the same length dimension as the magnets 710 and 720 in the axial direction. The magnets 710 and 720 are arranged to be surrounded radially outward by the magnet holder 31. The magnet holder 31 and the magnets 710 and 720 are fixed at their axial ends in contact with the end plate 33. The magnet unit 700 is equivalent to a "magnet portion".

[0232] like Figure 42 As shown, magnets 710 and 720 are fixed to the inner circumferential surface 31a of magnet holder 31 via resin adhesive 801. In this modified example, magnet holder 31 corresponds to magnet holding portion, and inner circumferential surface 31a corresponds to fixing surface of magnet holder 31. Multiple magnets 710 and 720 are provided and are arranged alternately along the circumferential direction.

[0233] First, the shapes of each magnet 710 and 720 will be described. Each magnet 710 and 720 is configured with a cross-sectional shape that is approximately arc-shaped, and if they are arranged circumferentially, they form a ring.

[0234] That is, each magnet 710 has a stator-side peripheral surface 711 (armature-side peripheral surface) formed in a generally arc shape on the radially inner side (stator side), and a stator-opposite peripheral surface 712 (armature-opposite peripheral surface) formed in a generally arc shape on the radially outer side (magnet holder side). Furthermore, each magnet 710 has circumferential end faces that are planes at both circumferential ends. Additionally, in each magnet 710, the circumferential end face on the d-axis side is sometimes referred to as the d-axis end face 713a, and the circumferential end face on the q-axis side is referred to as the q-axis end face 713b.

[0235] Similarly, each magnet 720 has a stator-side peripheral surface 721 (armature-side peripheral surface) formed in a generally arc shape on the radially inner side (stator side), and a stator-side peripheral surface 722 (armature-side peripheral surface) formed in a generally arc shape on the radially outer side (magnet holder side). Furthermore, each magnet 720 has circumferential end faces that are planes at both circumferential ends. Additionally, in each magnet 720, the circumferential end face on the d-axis side is sometimes referred to as the d-axis end face 723a, and the circumferential end face on the q-axis side is referred to as the q-axis end face 723b.

[0236] Each magnet 710 and 720 is separated at the d-axis and q-axis. In addition, magnets 710 and 720 are arranged symmetrically about the q-axis (or d-axis) in the circumferential direction.

[0237] Next, based on Figure 43The magnetic circuits of each magnet 710 and 720 will be described. The magnets 710 and 720 are respectively oriented such that, compared to the q-axis side which serves as the magnetic pole boundary, the direction of the easy magnetization axis is more parallel to the d-axis side which serves as the magnetic pole center, and a magnetic circuit is formed along the easy magnetization axis. Specifically, the easy magnetization axes of the magnets 710 and 720 are arranged such that the easy magnetization axes are parallel to or nearly parallel to the d-axis in the portion near the d-axis, and orthogonal to or nearly orthogonal to the q-axis in the portion near the q-axis.

[0238] More specifically, such as Figure 43 As shown, in magnets 710 and 720, multiple easily magnetized axes are arranged in an arc shape around an orientation center point C10 set on the q-axis. Furthermore, the shape of the magnetic circuit of the magnet can be an arc shape of a portion of a perfect circle or an arc shape of a portion of an ellipse. Moreover, although the orientation center point C10 is on the q-axis, it may not be on the q-axis. However, it is more ideal for the orientation center point C10 to be on the q-axis side compared to the d-axis. In this modified example 2, the orientation center point C10 is set between the magnet unit 700 and the stator winding 61.

[0239] Furthermore, the magnetic circuit of magnet 710 is formed symmetrically about the d-axis in the circumferential direction relative to the magnetic circuit of magnet 720 which is circumferentially adjacent to magnet 710 about the d-axis. Here, magnet 710 and magnet 720 which are circumferentially adjacent to magnet 710 about the d-axis are referred to as a pair of magnets 710 and 720.

[0240] Furthermore, in the magnet unit 700, the magnetization directions (magnetizing directions) of the magnets 710 and 720 are opposite (reverse) for each pair of magnets 710 and 720, so that the polarities of adjacent d-axis along the circumferential direction are different. That is, as Figure 43 As shown, the magnetization direction (magnetization initiation direction) of the pair of magnets 710 and 720 centered on the d-axis with positive polarity (N pole) is set such that the magnetic flux lines face the d-axis. On the other hand, the magnetization direction (magnetization initiation direction) of the pair of magnets 710 and 720 centered on the d-axis with negative polarity (S pole) is set such that the magnetic flux lines diffuse outward from the d-axis.

[0241] Next, a general description of the manufacturing methods for rotors 710 and 720 will be given. Each magnet 710 and 720 is a sintered magnet manufactured by a sintering method. Specifically, 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 granules (second step). Then, the powder obtained in the second step is placed in a mold and pressed and shaped under a magnetic field (third step). By shaping in this mold, the cross-sectional shape of magnets 710 and 720 becomes approximately arc-shaped. After pressing and shaping, the shaped material is sintered (fourth step), and after sintering, it undergoes heat treatment (fifth step). During heat treatment, several heating and cooling cycles are performed. Then, machining and surface finishing, such as grinding, are performed (sixth step). Finally, magnetization is performed (seventh step), completing each magnet 710 and 720.

[0242] Since magnets 710 and 720 are sintered magnets, their corners are prone to rounding, sometimes leading to manufacturing errors and suboptimal dimensional accuracy. For example, the range of the stator-side peripheral surfaces 712 and 722 formed on magnets 710 and 720 sometimes differs from the range of the stator-side peripheral surfaces 711 and 721 formed on magnets 710 and 720. Specifically, such as... Figure 44 As shown, the angular range (θa1+θa2) between the circumferential ends of the opposite stator circumferential surface 712 is sometimes greater than the angular range (θb1+θb2) between the circumferential ends of the stator side circumferential surface 711. Furthermore, sometimes the d-axis side end face 713a of the magnet 710 is not orthogonal to the stator side circumferential surface 711 and the opposite stator side circumferential surface 712, but rather inclined. The same applies to the q-axis side end face 713b of the magnet 710. Figure 44 In the example shown, magnet 710 is illustrated, but magnet 720 is the same. In addition, the curvature of the stator side circumferential surfaces 711, 712 and the stator opposite side circumferential surfaces 712, 722 may sometimes deviate from the curvature of the inner circumferential surface 31a of the magnet holder 31.

[0243] In this case, even if the magnets 710 and 720 are arranged circumferentially in an arc shape, gaps will still occur between the magnets 710 and 720 and between the magnet holder 31 and the magnets 710 and 720. Alternatively, the magnets 710 and 720 can be made larger, and the dimensions of each circumferential surface can be adjusted to good precision through machining such as grinding and surface finishing, but this would be time-consuming and costly.

[0244] Therefore, as Figures 42-43As shown, the q-axis side end faces 713b and 723b of magnets 710 and 720 are formed as planes. Furthermore, the aforementioned q-axis side end faces 713b and 723b are formed to be inclined circumferentially inward toward the center of the circumference of magnets 710 and 720 compared to a plane along the radial direction of magnets 710 and 720. That is, the q-axis side end faces 713b and 723b are configured to be inclined circumferentially inward toward the center of the circumference of magnets 710 and 720 compared to a plane orthogonal to the stator side circumferential surfaces 711 and 721 (or the opposite stator side circumferential surfaces 712 and 722). In other words, as... Figure 44 As shown, the angular range θa2 from the circumferential center to the q-axis end of the stator's opposite circumferential surface 712 is greater than the angular range θb2 from the circumferential center to the q-axis end of the stator's side circumferential surface 711. Figure 44 In the example shown, magnet 710 is illustrated, but magnet 720 is the same.

[0245] Furthermore, the q-axis side end faces 713b and 723b of circumferentially adjacent magnets 710 and 720 are made to contact each other without gap (abut). At this time, the q-axis side end faces 713b and 723b of circumferentially adjacent magnets 710 and 720 are magnetic flux action surfaces, and because they have different magnetic poles, they can easily make gapless surface contact through magnetic force. Moreover, when magnets 710 and 720 are disposed in magnet holder 31, the q-axis side end faces 713b and 723b are arranged to be parallel to the radial direction. In addition, at least the q-axis side ends of the stator opposite side circumferential surfaces 712 and 722 of magnets 710 and 720 are arranged to abut against the inner circumferential surface 31a of magnet holder 31.

[0246] Furthermore, the curvature of the stator-side peripheral surfaces 711, 721 and the stator-opposite peripheral surfaces 712, 722 of the magnets 710, 720 is preferably the same as the curvature of the inner peripheral surface 31a of the magnet holder 31, but it may be different. Specifically, when the magnets 710, 720 are arranged in the magnet holder 31 as described above, if a gap is formed between the stator-opposite peripheral surfaces 712, 722 of the magnets 710, 720 and the inner peripheral surface 31a of the magnet holder 31, the stator-opposite peripheral surfaces 712, 722 may be formed arbitrarily.

[0247] Furthermore, resin adhesive 801 is filled in the gap between the stator opposite peripheral surfaces 712 and 722 of magnets 710 and 720 and the inner peripheral surface 31a of magnet holder 31 to fill the gap, and the stator opposite peripheral surfaces 712 and 722 are fixed to the inner peripheral surface 31a via the resin adhesive 801.

[0248] Furthermore, when magnets 710 and 720 are positioned on magnet holding member 31, it is sufficient that the d-axis side end faces 713a and 723a of circumferentially adjacent magnets 710 and 720 do not contact each other and interfere. Figure 43As shown, it is permissible for a gap to form between the d-axis side end faces 713a and 723a. Furthermore, it is permissible for the d-axis side end faces 713a and 723a to be formed arbitrarily, as long as they do not contact each other and interfere. That is, the d-axis side end faces 713a and 723a can also be curved surfaces, and they can also be arbitrarily inclined relative to the radial direction.

[0249] The advantageous effects of the modified example 2 constructed as described above will be explained.

[0250] In magnets 710 and 720 with arc-shaped magnetic circuits, if a gap exists between adjacent q-axis side end faces 713b and 723b, magnetic flux leakage will occur, resulting in a decrease in magnetic flux density at the d-axis due to the gap between magnets. Therefore, the q-axis side end faces 713b and 723b are formed as planes and arranged such that circumferentially adjacent q-axis side end faces 713b and 723b are in surface contact with each other. This suppresses magnetic flux leakage from the q-axis side end faces 713b and 723b and reduces the impact of the gap formed between magnets 710 and 720.

[0251] Furthermore, resin adhesive 801 is filled in the gaps formed between the stator opposite peripheral surfaces 712 and 722 of each magnet 710 and 720 and the inner peripheral surface 31a of the magnet holder 31. Therefore, even if there are gaps between the magnets 710 and 720 and the magnet holder 31, the magnets 710 and 720 can be properly fixed to the magnet holder 31.

[0252] In addition, such as Figure 43 As shown, on the opposite stator peripheral surfaces 712 and 722 of each magnet 710 and 720, the magnetic path near the q-axis end tends to become longer. Therefore, by making the q-axis end of the opposite stator peripheral surfaces 712 and 722 of each magnet 710 and 720 abut against the inner peripheral surface 31a of the magnet holder 31, a long magnetic path can be formed, which can increase the magnetic flux density at the d-axis.

[0253] Furthermore, in the gap formed between the stator-opposite peripheral surfaces 712 and 722 of magnets 710 and 720 and the inner peripheral surface 31a of magnet holder 31, the radial dimension is larger closer to the d-axis. Therefore, by filling this gap with resin adhesive 801, the resin adhesive 801 is configured to protrude radially from the inner peripheral surface 31a. As a result, the stator-opposite peripheral surfaces 712 and 722 of each magnet 710 and 720 engage circumferentially with respect to the resin adhesive 801. Therefore, compared to the case where the radial thickness of the resin adhesive 801 is uniform, it is possible to properly prevent rotation of each magnet 710 and 720.

[0254] (Variation Example 3)

[0255] The configuration of magnets 710 and 720 in Modification 2 above is changed as follows. Furthermore, in this modification, the parts that differ in structure from those described in Modification 2 will be explained.

[0256] In the case where magnets 710 and 720 are arranged in magnet holding member 31 as in Modified Example 2 above, such as Figure 42 As shown, the d-axis end of the stator-side peripheral surfaces 711 and 721 of magnets 710 and 720 protrudes radially toward the stator winding 61. That is, in the stator-side peripheral surfaces 711 and 721 of magnets 710 and 720, the d-axis end is closer to the stator winding 61 than the q-axis end, and the air gap between the d-axis end and the stator winding 61 becomes smaller. When the air gap becomes smaller, it has the advantage of reduced magnetic flux leakage; on the other hand, the possibility of contact with the stator winding 61 and the stator 60 increases.

[0257] Therefore, in variation example 3, such as Figure 45 As shown, the stator-opposite peripheral surfaces 712 and 722 of magnets 710 and 720 are fixed to abut against the inner peripheral surface 31a of magnet holder 31. At this time, magnets 710 and 720 are fixed to magnet holder 31 by a resin adhesive (not shown). Thus, an appropriate distance (air gap) can be maintained between magnets 710 and 720 and stator winding 61.

[0258] Furthermore, under the above configuration, such as Figure 45 As shown, on the q-axis side, a gap is formed between the q-axis side end faces 713b and 723b of circumferentially adjacent magnets 710 and 720, which may lead to magnetic flux leakage. Therefore, this gap is filled with a magnetic material 810 with a higher permeability than air. For example, a resin containing magnetic powder or a conductive metal such as iron or copper can be considered as the magnetic material 810. This suppresses magnetic flux leakage on the q-axis side.

[0259] Furthermore, in this modified example 3, among the circumferentially adjacent magnets 710 and 720, the circumferential separation distance of the q-axis side end faces 713b and 723b is formed such that the radially inner side (stator side) is longer than the radially outer side (opposite stator side). That is, in the gap formed between the q-axis side end faces 713b and 723b, the circumferential width is formed such that the radially inner side (stator side) is wider than the radially outer side (opposite stator side). Therefore, it can be said that in the q-axis side end faces 713b and 723b of magnets 710 and 720, the radially inner side (stator side) is more prone to increased magnetic flux leakage compared to the radially outer side (opposite stator side).

[0260] However, at the q-axis side portion of magnets 710 and 720, such as Figure 45As shown, the magnetic circuit of the magnet tends to be longer on the radially outer side (opposite to the stator) compared to the inner side (stator side). That is, the magnetic circuit of the magnet tends to be shorter on the radially inner side (stator side) compared to the outer side (opposite to the stator). Therefore, at the q-axis side portion of magnets 710 and 720, the radially inner side (stator side) becomes the more easily demagnetized portion compared to the outer side (opposite to the stator). Therefore, according to... Figure 45 In the structure shown, although the possibility of magnetic flux leakage is more likely on the radially inner side compared to the outer side in the q-axis side end faces 713b and 723b, the impact on the magnetic flux density on the d-axis is less because the possibility of demagnetization is also greater to begin with. That is, on the q-axis side of magnets 710 and 720, by making the gap in the radially outer (opposite stator side) portion where the possibility of non-demagnetization is higher, the decrease in magnetic flux density on the d-axis can be appropriately suppressed.

[0261] Therefore, as Figure 45 As shown, compared with the outer side, the circumferential separation distance of the q-axis side end faces 713b and 723b is increased, which can reduce the impact caused by the formation of gap.

[0262] Furthermore, in Modification 3, the curvature of the stator-opposite peripheral surfaces 712 and 722 of magnets 710 and 720 is the same as the curvature of the inner peripheral surface 31a. However, as long as the stator-opposite peripheral surfaces 712 and 722 and the inner peripheral surface 31a are configured as curved surfaces in the same circumferential direction, the curvatures can be different. In this case, the air gap between magnets 710 and 720 and stator winding 61 can be adjusted to an appropriate distance. As a result, if a gap is formed between the stator-opposite peripheral surfaces 712 and 722 of magnets 710 and 720 and the inner peripheral surface 31a of magnet holder 31, the gap can be filled by resin adhesive 801.

[0263] (Another example of variations 2 and 3)

[0264] The structures in the above-described variations 2 and 3 can also be modified as described below. Furthermore, in this other example, the parts that differ from the structures described in the above-described variations 2 and 3 will be explained primarily.

[0265] • In the above variation example 2, such as Figure 46 As shown, a protrusion 901 may also be provided on the inner circumferential surface 31a of the magnet holder 31, the protrusion protruding radially toward the magnets 710 and 720. The protrusion 901 is positioned circumferentially closer to the d-axis than the q-axis side. Furthermore, the protrusion 901 is mechanically fixed to the magnet holder 31, for example, by being integrally formed or by welding. Additionally, the protrusion 901 has an inclined surface that slopes radially outward, and its cross-section is approximately triangular.

[0266] With the above configuration, the magnets 710 and 720 are engaged with the protrusion 901 in the circumferential direction via the resin adhesive 801, which reliably prevents rotation compared to the case where only the resin adhesive 801 is used. Furthermore, the gap formed between the stator-opposite circumferential surfaces 712 and 722 of each magnet 710 and 720 and the inner circumferential surface 31a of the magnet holder 31 can be reduced, making it easier to fill with the resin adhesive 801.

[0267] • In the above variation example 2, such as Figure 48 As shown, the q-axis side end faces 713b and 723b of magnets 710 and 720 can also be configured to be inclined outward from the circumferential center of magnets 710 and 720 compared to the plane along the radial direction. That is, the angle range θa2 from the circumferential center of the stator side circumferential faces 712 and 722 to the q-axis side end face is smaller than the angle range θb2 from the circumferential center of the stator side circumferential faces 711 and 721 to the q-axis side end face.

[0268] Furthermore, similar to variation 2, such as Figure 47 As shown, the q-axis side end faces 713b and 723b of circumferentially adjacent magnets 710 and 720 are in close contact (abutting) with each other without gaps. In this case, it may be impossible to make the q-axis side ends of the stator opposite circumferential surfaces 712 and 722 of magnets 710 and 720 abut against the inner circumferential surface 31a of the magnet holder 31. In this case, any part of the stator opposite circumferential surfaces 712 and 722 abuts. Furthermore, in this case, a gap is also formed on the q-axis side between the stator opposite circumferential surfaces 712 and 722 of each magnet 710 and 720 and the inner circumferential surface 31a of the magnet holder 31. Therefore, it is preferable to fill this gap with resin adhesive 801.

[0269] Furthermore, when magnets 710 and 720 are positioned on magnet holding member 31, it is sufficient that the d-axis side end faces 713a and 723a of circumferentially adjacent magnets 710 and 720 do not contact each other and interfere. Figure 47 As shown, it is permissible for a gap to form between the d-axis side end faces 713a and 723a.

[0270] In the above-described modifications 2 and 3 and another example, the curvature of the stator-side peripheral surfaces 711 and 721 and the opposite-side peripheral surfaces 712 and 722 of the magnets 710 and 720 is preferably the same as the curvature of the inner peripheral surface 31a of the magnet holder 31, but it may also be different. In this case, if a gap is formed between the opposite-side peripheral surfaces 712 and 722 of the stator and the inner peripheral surface 31a of the magnet holder 31, it can be filled by a resin adhesive 801 or the like.

[0271] Although an external rotor type rotor was used in the above variations 2 and 3, an internal rotor type rotor can also be used.

[0272] • In the above variations 2 and 3, magnets 710 and 720 may also be without a gap on the d-axis side. For example, the d-axis side end faces 713a and 723a may be made to abut against each other.

[0273] The disclosure of this specification is not limited to the illustrated embodiments. This disclosure includes illustrated embodiments and modifications made by those skilled in the art based thereon. For example, this disclosure is not limited to combinations of components and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. This disclosure may have additional portions that can be added to the embodiments. This disclosure includes embodiments in which components and / or elements of the embodiments are omitted. This disclosure includes substitutions or combinations of components and / or elements between one embodiment and another. The scope of the disclosed technology is not limited to the description of the embodiments. Several technical scopes of the disclosure should be understood to be expressed by the description of the claims, and also include all modifications within the meaning and scope of equivalence to the description of the claims.

[0274] Although this disclosure has been described based on embodiments, it should be understood that this disclosure is not limited to the above embodiments and structures. This disclosure also includes various modifications and equivalent variations. In addition, various combinations and methods, and further including only one element, one or more other combinations and methods, also fall within the scope and spirit of this disclosure.

Claims

1. A rotating electric motor, the rotating electric motor comprising an excitation element and an armature, the excitation element having a magnet portion comprising a plurality of magnetic poles with alternating polarities in the circumferential direction, the armature having a multi-phase armature winding, wherein either the excitation element or the armature is designated as a rotor. The magnet section includes: a plurality of arc-shaped magnets arranged circumferentially; and a magnet holding section for fixing the magnets. In the magnet, the easy magnetization axis is oriented in an arc shape, such that its direction is more parallel to the d-axis on the d-axis side, which is the center of the magnetic poles, compared to the q-axis side, which serves as the boundary of the magnetic poles. An arc-shaped magnetic circuit is formed along the easy magnetization axis. The magnet is separated at the d-axis, which serves as the center of the magnetic poles, and the q-axis, which serves as the boundary of the magnetic poles. The q-axis side end face of each of the magnets is configured to make surface contact with the q-axis side end face of the magnets adjacent in the circumferential direction. Resin is filled in the gap formed between the circumferential surface of the armature opposite to that of each magnet and the fixing surface of the magnet holding part. The d-axis side end face of each magnet in the circumferential direction is separated from the d-axis side end face of the adjacent magnet in the circumferential direction, and a gap is formed between the d-axis side end faces.

2. The rotary motor according to claim 1, characterized in that, A protrusion that projects radially toward the magnet portion is formed on the fixed surface near the d-axis.

3. A rotating electric motor, the rotating electric motor comprising an excitation element and an armature, the excitation element having a magnet portion comprising a plurality of magnetic poles with alternating polarities in the circumferential direction, the armature having a multi-phase armature winding, wherein either the excitation element or the armature is designated as a rotor. The magnet section includes: a plurality of arc-shaped magnets arranged circumferentially; and a magnet holding section for fixing the magnets. In the magnet, the easy magnetization axis is oriented in an arc shape, such that its direction is more parallel to the d-axis on the d-axis side, which is the center of the magnetic poles, compared to the q-axis side, which serves as the boundary of the magnetic poles. An arc-shaped magnetic circuit is formed along the easy magnetization axis. The magnet is separated at the d-axis, which serves as the center of the magnetic poles, and the q-axis, which serves as the boundary of the magnetic poles. The fixing surface of the magnet holding part for fixing the magnet is composed of a curved surface. The opposite peripheral surfaces of the armatures of each magnet are formed into curved surfaces along the fixed surface, and are configured such that the opposite peripheral surfaces of the armatures abut against the fixed surface. The q-axis end face of each magnet in the circumferential direction is filled with magnetic material in the gap formed between the q-axis end faces of the magnets adjacent in the circumferential direction. The d-axis side end face of each of the magnets is separated from the d-axis side end face of the adjacent magnets in the circumferential direction, forming a gap between the d-axis side end faces. The gap formed between the end faces on the q-axis is smaller than the gap formed between the end faces on the d-axis.

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