Rotating electrical machine

Abstract

A rotating electric machine (10) includes a field element (20) including a magnet portion (22), and an armature (60) having a multiphase armature winding (61). The armature winding of each phase is formed by winding a conductor wire (CR), and has conductor wire portions (81) disposed at a prescribed interval in the circumferential direction at a position opposite the magnet portion. Each of the conductor wire portions is formed by arranging the conductor wire in one or more rows in the circumferential direction and in one or more rows in the radial direction. Each of the conductor wires is covered by an insulating film (602) in a state in which a plurality of wire members (601) are stacked in the circumferential direction. Each of the conductor wires is formed by connecting each of the wire members that constitute the conductor wire in parallel, and a cross section of each of the wire members is in a flat shape that is longer in the radial direction.

Description

[0001] Citation of relevant applications

[0002] This application is based on Japanese Patent Application No. 2019-209971, filed on November 20, 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, a rotary electric motor is known, comprising: an excitation element including a magnet portion having multiple magnetic poles with alternating polarities in the circumferential direction; and an armature having a multi-phase armature winding. In this rotary electric motor, a slotless structure is employed to eliminate the limitation caused by magnetic saturation in the pole teeth based on the stator core, and an anisotropic magnet is employed to increase the magnetic flux density. Thus, the output torque can be ideally increased while eliminating the limitation caused by magnetic saturation.

[0005] Existing technical documents

[0006] Patent documents

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

[0008] Furthermore, in the aforementioned rotating electric machine, there is a problem: if the cross-sectional area of ​​the conductor is increased to improve the duty cycle (which represents the proportion of the conductor carrying the current in the space housing the armature winding), then eddy current losses increase as magnetic flux from the magnet links with the conductor. In particular, this problem is particularly pronounced when a slotless structure is used and anisotropic magnets are employed.

[0009] This disclosure is made in view of the above circumstances, and its main purpose is to provide a rotating electric motor capable of reducing eddy current losses.

[0010] This specification discloses various methods that employ different technical means to achieve different objectives. The objectives, features, and effects disclosed in this specification will become clearer with reference to the following detailed description and accompanying drawings.

[0011] A first method for solving the above-described technical problem is a rotary electric machine including: an excitation element including a magnet portion having a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature having a plurality of phases of armature windings, either of the excitation element and the armature being a rotor, wherein each phase of the armature windings is configured by winding a wire, the armature windings have wire portions arranged at a prescribed interval in the circumferential direction at positions opposite the magnet portion, each of the wire portions is formed by arranging the wire in one or more rows in the circumferential direction and in one or more rows in a radial direction, each of the wires is configured by covering a plurality of wire members stacked in the circumferential direction with an insulating film, each of the wires is configured by connecting the wire members in parallel, and each of the wire members has a cross section in a flat shape that is longer in the radial direction.

[0012] In the above-described structure, since each of the wire members has a cross section in a flat shape that is longer in the radial direction, eddy current can be suppressed. In addition, by being in a flat shape that is longer in the radial direction, a gap in the radial direction within the wire, i.e., a gap between conductors or between the insulating film and the conductors, can be reduced, thereby improving a space factor of the conductors.

[0013] In addition, in the above-described structure, since each of the wire members has a cross section in a flat shape that is longer in the radial direction, a reduction effect of circulating current is improved. That is, a magnet flux varies depending on a circumferential position of the magnet portion. Therefore, the magnet flux that links each of the wire members of each wire varies with rotation of the rotor, and a difference occurs between electromotive forces generated in each of the wire members at a certain time. Here, in the first method, each of the wires has a cross section in a flat shape that is longer in the radial direction. Therefore, in each of the wires, a width dimension in the circumferential direction of the plurality of wire members arranged and arranged can be reduced. As a result, in each of the wires, the difference in the electromotive forces generated in each of the wire members at a certain time can be reduced. Thus, the difference in the electromotive forces generated in the wire members that configure the wire can be reduced, thereby reducing the circulating current.

[0014] A second method is based on the first method, the wire members have a cross section in a flat shape that is longer in the radial direction, and include a conductor through which a current flows and a fusion layer that covers a surface of the conductor, the fusion layer is configured to be thinner than the insulating film, and the fusion layers are caused to contact and fuse with each other in a state in which the plurality of wire members are stacked in the circumferential direction.

[0015] The conductors are insulated by the insulating film. On the other hand, although the conductors of the wire are covered with the fusion layer, since the insulating layer is not provided, the conductors sometimes contact each other and conduct. However, the potential difference between the conductors is small, and when the plurality of wires are bundled or the insulating film is covered, even if the fusion layer is broken, the area of the contact between the conductors is very small, and the contact resistance is very large. Therefore, even if not completely insulated, the eddy current flowing between the conductors can be suppressed.

[0016] Therefore, instead of providing the insulating layer on the surface of the conductor, the fusion layer is provided directly on the conductor and the fusion layers are fused to each other. Thereby, the work of providing the insulating layer is not required. In addition, by providing the fusion layer, the plurality of wires can be easily kept in a state of being bundled, and thus easily covered with the insulating film. By the above, the wire and the rotating electric machine can be easily manufactured, and since the insulating layer of the wire is omitted, the space factor of the conductor can be improved.

[0017] The third aspect is based on the first or second aspect, and in each of the above wires, the wire is arranged in one layer in the radial direction.

[0018] In each of the wires, the wire is arranged in one layer in the radial direction. Therefore, unlike a structure in which the wires of each wire are stacked in multiple layers in the radial direction, a difference in electromotive force caused by a difference in the arrangement position of the wire in the radial direction does not occur. Thereby, the difference in the electromotive force generated in the above wire constituting the wire can be reduced, and thus the circulating current flowing through the armature winding can be reduced.

[0019] In addition, by being provided in one layer, compared to the case of being provided in multiple layers, the gap between the conductors in the radial direction within the insulating film can be eliminated. That is, the space factor of the conductor can be improved.

[0020] The fourth aspect is based on any one of the first to third aspects, and the above magnets are respectively oriented such that the direction of the easy axis is more parallel to the d-axis on the d-axis side as the center of the magnetic pole than on the q-axis side as the boundary of the magnetic pole, and a magnetic path of the magnet is formed along the easy axis.

[0021] By being configured as described above, the closer to the d-axis, the easier the magnetic flux density is to be parallel to the radial direction. That is, the closer to the d-axis, the easier the radial component of the magnetic flux density is to be large, and on the other hand, the easier the circumferential component is to be small. Thereby, by making the thickness dimension of the circumferential direction thin, the eddy current loss can be more effectively suppressed.

[0022] The fifth aspect is any one of the first to third aspects, wherein the magnet portion includes a first magnet portion and a second magnet portion, a magnetic pole of the first magnet portion at the d-axis as the center of the magnetic poles is different from a magnetic pole of the second magnet portion opposite to the magnetic pole of the first magnet portion in the radial direction, the first magnet portion is disposed opposite to the wire portion on the inner side of the wire portion in the radial direction, and the second magnet portion is disposed opposite to the wire portion on the outer side of the wire portion in the radial direction.

[0023] By the above configuration, the magnetic flux density at the d-axis easily becomes parallel to the radial direction. That is, the radial component of the magnetic flux density easily becomes large, and on the other hand, the circumferential component easily becomes small. Thus, by making the thickness dimension in the circumferential direction thin, the eddy current loss can be more effectively suppressed. BRIEF DESCRIPTION OF DRAWINGS

[0024] The above objects, other objects, features, and advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0025] Figure 1 is a perspective view showing the entire rotating electric machine in the first embodiment.

[0026] Figure 2 is a plan view of the rotating electric machine.

[0027] Figure 3 is a longitudinal sectional view of the rotating electric machine.

[0028] Figure 4 is a transverse sectional view of the rotating electric machine.

[0029] Figure 5 is an exploded sectional view of the rotating electric machine.

[0030] Figure 6 is a sectional view of the rotor.

[0031] Figure 7 is a partial transverse sectional view showing the cross-sectional structure of the magnet unit.

[0032] Figure 8 is a graph showing the relationship between the electric angle and the magnetic flux density of the magnet of the embodiment.

[0033] Figure 9 is a graph showing the relationship between the electric angle and the magnetic flux density of the magnet of the comparative example.

[0034] Figure 10 is a perspective view of the stator unit.

[0035] Figure 11 is a longitudinal sectional view of the stator unit.

[0036] Figure 12is a perspective view of the core assembly as viewed from one axial side.

[0037] Figure 13 is a perspective view of the core assembly as viewed from the other axial side.

[0038] Figure 14 is a cross-sectional view of the core assembly.

[0039] Figure 15 is an exploded cross-sectional view of the core assembly.

[0040] Figure 16 is a circuit diagram showing the connection state of the partial windings in each phase winding of the three phases.

[0041] Figure 17 is a side view showing the first coil module and the second coil module arranged laterally and contrastively.

[0042] Figure 18 is a side view showing the first partial winding and the second partial winding arranged laterally and contrastively.

[0043] Figure 19 is a diagram showing the structure of the first coil module.

[0044] Figure 20 is a cross-sectional view of the 20-20 line in (a) of Figure 19

[0045] Figure 21 is a perspective view showing the structure of the insulating cover.

[0046] Figure 22 is a diagram showing the structure of the second coil module.

[0047] Figure 23 is a cross-sectional view of the 23-23 line in (a) of Figure 22

[0048] Figure 24 is a perspective view showing the structure of the insulating cover.

[0049] Figure 25 is a diagram showing the overlapping position of the film material in a state where the coil modules are arranged in the circumferential direction.

[0050] Figure 26 is a plan view showing the assembly state of the first coil module with respect to the core assembly.

[0051] Figure 27 is a plan view showing the assembly state of the first coil module and the second coil module with respect to the core assembly.

[0052] Figure 28 is a longitudinal cross-sectional view showing the fixing state achieved by the fixing pin.​​

[0053] Figure 29 is an external view of a busbar module.

[0054] Figure 30 is a sectional view showing a part of a longitudinal section of the busbar module.

[0055] Figure 31 is an external view showing a state in which the busbar module is assembled to a stator holder.

[0056] Figure 32 is a longitudinal sectional view of a fixing portion that fixes the busbar module.

[0057] Figure 33 is a longitudinal sectional view showing a state in which the relay member is assembled to the housing cover.

[0058] Figure 34 is an external view of a relay member.

[0059] Figure 35 is a circuit diagram showing a control system of a rotary electric machine.

[0060] Figure 36 is a functional block diagram showing a current feedback control process of a control device.

[0061] Figure 37 is a functional block diagram showing a torque feedback control process of a control device.

[0062] Figure 38 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modification example.

[0063] Figure 39 is a diagram showing a structure of a stator unit of an inner rotor structure.

[0064] Figure 40 is a plan view showing an assembled state of a coil module with respect to an iron core assembly.

[0065] Figure 41 is a diagram showing a structure of a first coil module of a modification example 2.

[0066] Figure 42 is a sectional view of a wire material of the modification example 2.

[0067] Figure 43 is a side view of the wire material of the modification example 2.

[0068] Figure 44 is a diagram showing a connection method of a wire material of the modification example 2.

[0069] Figure 45 is a flowchart showing a manufacturing method of a stator winding.

[0070] Figure 46 It is a schematic diagram showing the manufacturing process of stator windings.

[0071] Figure 47 This is a cross-sectional view of another example of a magnet unit.

[0072] Figure 48 This is a cross-sectional view of another example of a stator and magnet unit.

[0073] Figure 49 This is a flowchart illustrating a method for manufacturing a stator winding, as shown in another example. Detailed Implementation

[0074] 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.

[0075] 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.

[0076] (First Implementation)

[0077] 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 three-dimensional 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.

[0078] The rotary electric machine 10 generally includes a rotary electric machine main body including the rotor 20, the stator unit 50, and the busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotary electric machine main body. Each of the components is coaxially arranged with respect to the rotation axis 11 provided integrally to the rotor 20, and is assembled in a prescribed order in the axial direction, thereby constituting the rotary electric machine 10. The rotation axis 11 is supported by a pair of bearings 12, 13 provided to the stator unit 50 and the housing 241, respectively, and is rotatable in this state. The bearings 12, 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between the inner ring and the outer ring. The rotation axis 11 is rotated by, for example, a vehicle axle. The rotary electric machine 10 can be installed in a vehicle by fixing the housing 241 to a vehicle body frame or the like.

[0079] In the rotary electric machine 10, the stator unit 50 is provided so as to surround the rotation axis 11, and the rotor 20 is arranged on the radially outer side of the stator unit 50. The stator unit 50 has a stator 60, and a stator holder 70 assembled on the radially inner side thereof. The rotor 20 and the stator 60 are arranged in opposition to each other in the radial direction with an air gap interposed therebetween, and the rotor 20 rotates together with the rotation axis 11, whereby the rotor 20 rotates on the radially outer side of the stator 60. The rotor 20 corresponds to an "excitation element", and the stator 60 corresponds to an "armature".

[0080] Figure 6 is a longitudinal sectional view of the rotor 20. As shown in Figure 6 the rotor 20 has a substantially cylindrical rotor frame 21 and a ring-shaped magnet unit 22 fixed to the rotor frame 21. The rotor frame 21 is constituted by integrating a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23. 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, and the rotation axis 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt in a state of being inserted through the through hole 24a. The rotation axis 11 has a flange 11a extending in a direction intersecting (orthogonal to) the axial direction, and the rotor frame 21 is fixed to the rotation axis 11 in a state where the flange 11a and the end plate portion 24 are face-engaged.

[0081] 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 to the side opposite to the end plate portion 24 of the rotor frame 21 among the axial both sides. The magnet holder 31 has the same length dimension as the magnet 32 in the axial direction. The magnet 32 is provided in a state of being surrounded from the radial outer side by the magnet holder 31. The magnet holder 31 and the magnet 32 are fixed at the end portion on one side in the axial direction in a state of abutting against the end plate 33. The magnet unit 22 corresponds to the "magnet portion".

[0082] Figure 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. In Figure 7 , the direction of the easy magnetization axis of the magnet 32 is indicated by an arrow.

[0083] In the magnet unit 22, the magnets 32 are arranged in a manner of alternately changing the polarity along the circumferential direction of the rotor 20. Thus, the magnet unit 22 has a plurality of magnetic poles in the circumferential direction. The magnet 32 is a magnet of a polar anisotropy, and is constituted using a sintered neodymium magnet having an intrinsic coercive force of 400 [kA / m] or more and a residual magnetic flux density Br of 1.0 [T] or more.

[0084] In the magnet 32, the circumferential surface on the radial inner side is a magnetic flux acting surface 34 that performs the transfer of the magnetic flux. In the magnet 32, the directions of the easy magnetization axes of the d-axis side (the portion close to the d-axis) and the q-axis side (the portion close to the q-axis) are different, and in the d-axis side, the direction of the easy magnetization axis is a direction parallel to the d-axis, and in the q-axis side, the direction of the easy magnetization axis is a direction orthogonal to the q-axis. In this case, a circular arc-shaped magnet magnetic path is formed in accordance with the direction of the easy magnetization axis. In summary, the magnet 32 is constituted so as to be oriented so that the direction of the easy magnetization axis is more parallel to the d-axis at the magnetic pole center, i.e., the d-axis side, than at the magnetic pole boundary, i.e., the q-axis side.

[0085] In the magnet 32, since the magnet magnetic path is formed in a circular arc shape, the magnet magnetic path length is longer than the thickness dimension in the radial direction of the magnet 32. Thus, the permeance of the magnet 32 rises, and the same ability as a magnet having a larger amount of magnets can be exerted with the same amount of magnets.

[0086] The magnet 32 constitutes one magnetic pole as a group of two adjacent ones in the circumferential direction. That is, the plurality of magnets 32 arranged in the circumferential direction in the magnet unit 22 each has a division surface at the d-axis and the q-axis, and the above-described respective magnets 32 are disposed in a state of abutting against or approaching each other. As described above, the magnet 32 has a circular arc-shaped magnet magnetic path, and at the q-axis, the N-pole and the S-pole of the circumferentially adjacent magnets 32 are opposite to each other. Thus, the improvement of the permeance in the vicinity of the q-axis can be achieved. In addition, since the magnets 32 sandwiching the both sides of the q-axis attract each other, the contact state of the above-described respective magnets 32 with each other can be maintained. Thus, the improvement of the permeance is still facilitated.

[0087] In the magnet unit 22, since the magnetic flux flows in an arc shape between the adjacent N-pole and S-pole by each magnet 32, the magnet magnetic path is longer compared to, for example, a radial anisotropic magnet. Therefore, as shown in FIG. 6, the magnetic flux density distribution approaches a sine wave. As a result, compared to the radial anisotropic magnet shown in FIG. 5 as a comparative example, the torque of the rotating electric machine 10 can be improved. Figure 8 Figure 9 In the magnet unit 22 of the present embodiment, it is confirmed that there is a difference in the magnetic flux density distribution compared to the magnet of the conventional Halbach array. In addition, in the magnet unit 22 of the present embodiment, the magnetic flux is concentrated on the center side of the magnetic pole, and the torque of the rotating electric machine 10 can be improved compared to the radial anisotropic magnet shown in FIG. 5 as a comparative example. Figure 8 Figure 9 In FIGS. 6 and 7, the horizontal axis indicates the electric angle, and the vertical axis indicates the magnetic flux density. In addition, in FIGS. 6 and 7, the 90° of the horizontal axis indicates the d-axis (i.e., the center of the magnetic pole), and the 0° and 180° of the horizontal axis indicate the q-axis. Figure 8 Figure 9

[0088] That is, according to each magnet 32 of the above-described structure, the magnet flux at the d-axis in the magnet unit 22 is enhanced, and the change in the magnetic flux around the q-axis is suppressed. Thereby, the magnet unit 22 in which the surface magnetic flux change from the q-axis to the d-axis in each magnetic pole is moderated can be desirably realized.

[0089] The sine wave matching rate of the magnetic flux density distribution is preferably, for example, a value of 40% or more. In this way, compared to the case where a radial orientation magnet having a sine wave matching rate of about 30% is used or a parallel orientation magnet is used, the magnetic flux of the deformed central portion can be reliably increased. In addition, if the sine wave matching rate is set to 60% or more, the magnetic flux of the deformed central portion can be reliably increased compared to the magnetic flux concentration array like the Halbach array.

[0090] In the radial anisotropic magnet shown in FIG. 5, the magnetic flux density sharply changes around the q-axis. The more sharply the magnetic flux density changes, the more the eddy current in the stator winding 61 of the stator 60 described later increases. In addition, the change in the magnetic flux on the stator winding 61 side also becomes sharp. In contrast, in the present embodiment, the magnetic flux deformation is the magnetic flux density distribution that approaches a sine wave. Therefore, around the q-axis, the change in the magnetic flux density is smaller than the change in the magnetic flux density of the radial anisotropic magnet. Thereby, the generation of the eddy current can be suppressed. Figure 9

[0091] ​​​​​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 path near the d-axis on the outer peripheral surface of magnet 32 ​​becomes shorter, and the magnetic path near the q-axis on the inner peripheral surface of magnet 32 ​​becomes shorter. Therefore, considering that it is difficult to generate sufficient magnetic flux in the parts of magnet 32 ​​where the magnetic path length is short, magnets are removed from the parts where the magnetic flux is weaker.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] As an outline thereof, the stator unit 50 has the stator 60 and the stator holder 70 on the radially inner side thereof. In addition, the stator 60 has the stator winding 61 and the stator core 62. Also, the stator core 62 and the stator holder 70 are integrated to be provided as a core assembly CA, and a plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. Further, the stator winding 61 corresponds to an "armature winding", the stator core 62 corresponds to an "armature core", and the stator holder 70 corresponds to an "armature holding member". In addition, the core assembly CA corresponds to a "support member".

[0096] Here, first, the core assembly CA will be described. Figure 12 is a perspective view of the core assembly CA as viewed from the one axial side, Figure 13 is a perspective view of the core assembly CA as viewed from the other axial side, Figure 14 is a cross-sectional view of the core assembly CA, Figure 15 is an exploded cross-sectional view of the core assembly CA.

[0097] As described above, the core assembly CA has the stator core 62 and the stator holder 70 assembled on the radially inner side thereof. In other words, the stator core 62 is integrally assembled to the outer peripheral surface of the stator holder 70.

[0098] The stator core 62 is configured as a core laminated body in which core pieces 62a made of an electromagnetic steel sheet as a magnetic body are laminated in the axial direction, and is in the shape of a cylinder having a prescribed thickness in the radial direction. The stator winding 61 is assembled on the radially outer side in the stator core 62 on the side of the rotor 20. The outer peripheral surface of the stator core 62 is in the shape of a curved surface without irregularities. The stator core 62 functions as a back yoke. The stator core 62 is configured, for example, by a plurality of core pieces 62a punched into the shape of a circular ring plate and laminated in the axial direction. However, a stator core 62 having a spiral core structure can also be used. In the stator core 62 having a spiral core structure, a core piece in the shape of a band is used, and the stator core 62 is formed as a whole in the shape of a cylinder by winding the core piece into a ring shape and laminating it in the axial direction.

[0099] In the present embodiment, the stator 60 is of a slotless structure that does not have pole teeth for forming a slot, but its structure can also use any one of the following structures of (A) to (C).

[0100] (A) In the stator 60, inter-conductor members are provided between the respective conductor portions (intermediate conductor portions 152) in the circumferential direction, and as the inter-conductor members, a magnetic material that satisfies the relationship Wt x Bs ≤ Wm x Br when the width dimension in the circumferential direction of the inter-conductor member of one magnetic pole is set to Wt, the saturation magnetic flux density of the inter-conductor member is set to Bs, the width dimension in the circumferential direction of the magnet 32 of one magnetic pole is set to Wm, and the residual magnetic flux density of the magnet 32 is set to Br is used.

[0101] (B) In the stator 60, inter-conductor members are provided between the respective conductor portions (intermediate conductor portions 152) in the circumferential direction, and a non-magnetic material is used as the inter-conductor members.

[0102] (C) In the stator 60, no inter-conductor members are provided between the respective conductor portions (intermediate conductor portions 152) in the circumferential direction.

[0103] Further, as shown in Figure 15 , the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, and is configured 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 members into one body. The respective members 71, 81 are, for example, made of a metal such as aluminum or cast iron or a carbon fiber reinforced plastic (CFRP).

[0104] The outer cylinder member 71 is a cylindrical member in which both the outer peripheral surface and the inner peripheral surface are set to a circular curved surface, and a ring-shaped flange 72 extending toward the radially inner side is formed on the one end side in the axial direction. A plurality of protrusions 73 extending toward the radially inner side at a prescribed interval in the circumferential direction are formed on the flange 72 (see FIG. 6). Figure 13 Further, the opposite surfaces 74, 75 of the outer cylinder member 71 on the one end side and the other end side in the axial direction are formed so as to be opposed to the inner cylinder member 81 in the axial direction, and a ring-shaped groove 74a, 75a extending in a ring shape is formed on the opposite surfaces 74, 75.

[0105] Further, the inner cylinder member 81 is a cylindrical member having an outer diameter dimension smaller than the inner diameter dimension of the outer cylinder member 71, and the outer peripheral surface thereof is a circular curved surface concentric with the outer cylinder member 71. A ring-shaped flange 82 extending toward the radially outer side is formed on the one end side in the axial direction of the inner cylinder member 81. The inner cylinder member 81 is assembled to the outer cylinder member 71 in a state of abutting against the opposite surfaces 74, 75 of the outer cylinder member 71 in the axial direction. As shown in Figure 13 , the outer cylinder member 71 and the inner cylinder member 81 are assembled to each other by fastening members 84 such as bolts. Specifically, a plurality of protrusions 83 extending toward the radially inner side at a prescribed interval in the circumferential direction are formed on the inner peripheral side of the inner cylinder member 81, and the protrusions 73, 83 are fastened to each other by the fastening members 84 in a state of overlapping the axial end surfaces of the protrusions 83 and the protrusions 73 of the outer cylinder member 71.

[0106] AsFigure 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 88, and an inlet-side passage 86 and an outlet-side passage 87 are formed therein. Each passage 86 and 87 opens onto 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.

[0107] One end of the inlet passage 86 and the outlet passage 87 extends radially and opens onto the outer peripheral surface of the inner cylinder member 81, while the other end extends axially and opens onto 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.

[0108] 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 state of compression by the outer cylinder member 71 and the inner cylinder member 81.

[0109] 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 ).

[0110] Further, as shown in Figure 12 , Figure 13 , recesses 105, 106 for fixing a plurality of coil modules 150 to be described later are formed in the outer cylinder member 71 and the inner cylinder member 81.

[0111] Specifically, as shown in Figure 12 , a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end surface of the inner cylinder member 81, in detail, the end surface of the shaft sleeve portion 92, which is the axial outer side end surface of the end plate portion 91. Further, as shown in Figure 13 , a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end surface of the outer cylinder member 71, in detail, the end surface of the flange 72, which is the axial outer side end surface. The recesses 105, 106 described above are arranged on an imaginary circle concentric with the core assembly CA. The recesses 105, 106 are respectively provided at the same position in the circumferential direction, and have the same interval and number.

[0112] Further, in order to ensure the assembly strength with respect to the stator holder 70, the stator core 62 is assembled in a state in which a compressive force in the radial direction with respect to the stator holder 70 is generated. Specifically, the stator core 62 is fixedly fitted to the stator holder 70 with a prescribed amount of interference by thermal press-fitting or press-fitting. In this case, the stator core 62 and the stator holder 70 can be said to be assembled in a state in which a radial stress from one to the other is generated. Further, in the case of increasing the torque of the rotary electric machine 10, for example, it is considered to increase the diameter of the stator 60, in which case, in order to firmly bond the stator core 62 with respect to the stator holder 70, the fastening force of the stator core 62 can be increased. However, if the compressive stress (in other words, the residual stress) of the stator core 62 is increased, the stator core 62 can be damaged.

[0113] Therefore, in the present embodiment, in a structure in which the stator core 62 and the stator holder 70 are fixedly fitted to each other with a prescribed amount of interference, a restriction portion that restricts the circumferential displacement of the stator core 62 by engagement in the circumferential direction is provided to the portion of the stator core 62 and the stator holder 70 that oppose each other in the radial direction. That is, as shown in Figures 12 to 14 , a plurality of engagement members 111 as the restriction portion are provided at prescribed intervals in the circumferential direction in the radial direction between the stator core 62 and the outer cylinder member 71 of the stator holder 70, and by the engagement members 111, the positional displacement in the circumferential direction of the stator core 62 and the stator holder 70 is suppressed. Further, in this case, it is preferable to be configured so that a recess is provided in at least either one of the stator core 62 and the outer cylinder member 71, and the engagement member 111 is engaged with the recess. Instead of the engagement member 111, it can also be configured so that a protrusion is provided in either one of the stator core 62 and the outer cylinder member 71.

[0114] In the above structure, the stator core 62 and the stator holder 70 (the outer cylinder member 71) are disposed in a state where the circumferential displacement of each other is restricted, in addition to being fitted and fixed with a prescribed amount of interference, by the restriction of the engagement member 111. Therefore, even if the amount of interference of the stator core 62 and the stator holder 70 is relatively small, the circumferential displacement of the stator core 62 can be suppressed. Also, the desired displacement suppression effect can be obtained even if the amount of interference is relatively small, and thus, the breakage of the stator core 62 due to the amount of interference being too large can be suppressed. As a result, the displacement of the stator core 62 can be appropriately suppressed.

[0115] It can also be configured so that an annular inner space that surrounds the rotating shaft 11 is formed on the inner peripheral side of the inner cylinder member 81, and, for example, an electrical component that constitutes an inverter as a power converter is disposed in the inner space. The electrical component is, for example, an electrical module in which a semiconductor switching element or a capacitor is packaged. By disposing the electrical module in a state of abutting against the inner peripheral surface of the inner cylinder member 81, the electrical module can be cooled by the refrigerant flowing through the refrigerant passage 85. In addition, a plurality of protruding portions 83 can not be provided on the inner peripheral side of the inner cylinder member 81, or the protruding height of the protruding portion 83 can be reduced, and thus, the inner space on the inner peripheral side of the inner cylinder member 81 can be expanded.

[0116] Next, the structure of the stator winding 61 assembled to the core assembly CA will be described in detail. As shown in Figs. 1 and 2, the stator winding 61 is assembled to the core assembly CA in a state where a plurality of partial windings 151 that constitute the stator winding 62 are assembled to the radially outer side of the core assembly CA, that is, the radially outer side of the stator core 61, in a state of being arranged in the circumferential direction. Figure 10 and Figure 11 As shown in Figs. 1 and 2, the stator winding 61 is assembled to the core assembly CA in a state where a plurality of partial windings 151 that constitute the stator winding 62 are assembled to the radially outer side of the core assembly CA, that is, the radially outer side of the stator core 61, in a state of being arranged in the circumferential direction.

[0117] The stator winding 61 has a plurality of phase windings, and the phase windings of each phase are arranged in a prescribed order in the circumferential direction, thereby being formed in a cylindrical shape (annular shape). In the present embodiment, the stator winding 61 is provided with phase windings of three phases by using phase windings of a U phase, a V phase, and a W phase.

[0118] As shown in Figs. 1 and 2, the stator winding 61 is assembled to the core assembly CA in a state where a plurality of partial windings 151 that constitute the stator winding 62 are assembled to the radially outer side of the core assembly CA, that is, the radially outer side of the stator core 61, in a state of being arranged in the circumferential direction. Figure 11 As shown in Figs. 1 and 2, the stator winding 61 is assembled to the core assembly CA in a state where a plurality of partial windings 151 that constitute the stator winding 62 are assembled to the radially outer side of the core assembly CA, that is, the radially outer side of the stator core 61, in a state of being arranged in the circumferential direction.

[0119] In the stator winding 61, the phase windings of each phase respectively have a plurality of partial windings 151 (refer to Figs. 1 and 2). The plurality of partial windings 151 of each phase are arranged in the circumferential direction in a prescribed order, and are formed in a cylindrical shape (annular shape). Figure 16), and the partial winding 151 is provided as a coil module 150 individually. That is, the coil module 150 is configured by providing the partial winding 151 of each phase winding of each phase as one body, and the stator winding 61 is configured by using a prescribed 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 prescribed order in the circumferential direction, and thus the wire portions of each phase are arranged in a prescribed order at the coil side portion CS of the stator winding 61. In Figure 10 , the arrangement order of the wire portions of the U phase, the V phase, and the W phase of the coil side portion CS is shown. In the present embodiment, the number of magnetic poles is set to 24, but the number can be arbitrary.

[0120] In the stator winding 61, the partial windings 151 of each coil module 150 for each phase are connected in parallel or in series, thereby configuring the phase winding of each phase. Figure 16 is a circuit diagram showing the connection state of the partial winding 151 in each phase winding of three phases. In Figure 16 , the state in which the partial windings 151 in the phase winding of each phase are connected in parallel, respectively, is shown.

[0121] As shown in Figure 11 , the coil module 150 is assembled to the radially outer side of the stator core 62. In this case, the coil module 150 is assembled in a state in which the both end portions in the axial direction thereof protrude to the axial outer side (i.e., the coil end portion CE side) of the stator core 62. That is, the stator winding 61 has a portion corresponding to the coil end portion CE protruding to the axial outer side of the stator core 62, and a portion corresponding to the coil side portion CS on the axial inner side than the coil end portion CE.

[0122] The coil module 150 has two shapes, one in which the partial winding 151 is bent to the radially inner side, i.e., the stator core 62 side, at the coil end portion CE, and the other in which the partial winding 151 extends linearly in the axial direction without being bent to the radially inner side at the coil end portion CE. In the following description, for convenience, the partial winding 151 having a bent shape at both end portions in the axial direction will be referred to as a "first partial winding 151A", and the coil module 150 having the first partial winding 151A will be referred to as a "first coil module 150A". In addition, the partial winding 151 not having a bent shape at both end portions in the axial direction will be referred to as a "second partial winding 151B", and the coil module 150 having the second partial winding 151B will be referred to as a "second coil module 150B".

[0123] Figure 17 is a side view showing the first coil module 150A and the second coil module 150B arranged side by side and in comparison, 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.

[0124] Next, the structure of coil modules 150A and 150B will be explained in detail.

[0125] 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).

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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".

[0130] 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.

[0131] 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.

[0132] In the first winding 151A, the end of the conductor material CR is connected from one of the first overlaps 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.

[0133] 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).

[0134] The insulating cover 157 uses a thin film material FM with an axial dimension of at least the length of 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] Next, the structure of insulating covers 161 and 162 will be described.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] In addition, in the insulating cover 161, in the pair of side surface portions 171, at positions of the circumferential both ends of the front surface portion 174, that is, at positions where the side surface portions 171 and the front surface portion 174 intersect, semicircular concave portions 177 extending in the axial direction are provided. Further, in the outer surface portion 172, a pair of protruding portions 178 extending in the axial direction are provided at positions symmetrical to each other in the circumferential direction with the center line of the insulating cover 161 as a reference.

[0143] The insulating cover 161 will be further described with reference to the concave portions 177. As shown in FIG. 6, the first lap portion 153A of the first partial winding 151A has a curved shape protruding toward the radially inner side of the radially inner and outer sides, that is, the core assembly CA side. In this structure, a gap having a width wider toward the front end side of the first lap portion 153A is formed between the circumferentially adjacent first lap portions 153A. Therefore, in the present embodiment, the concave portions 177 are provided at positions outside the curved portions of the first lap portions 153A in the side surface portions 171 of the insulating cover 161 using the gaps between the circumferentially arranged first lap portions 153A. Figure 20

[0144] In addition, it is also possible to provide a temperature detecting portion (thermistor) in the first partial winding 151A, and in this structure, it is preferable to provide an opening portion for leading out a signal line extending from the temperature detecting portion in the insulating cover 161. In this case, the temperature detecting portion can be desirably housed in the insulating cover 161.

[0145] Although detailed description of illustration is omitted, the insulating cover 162 on the other axial side has substantially the same structure as the insulating cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side surface portions 171, an outer surface portion 172 on the axial outer side, an inner surface portion 173 on the axial inner side, and a front surface portion 174 on the radially inner side. In addition, in the insulating cover 162, in the pair of side surface portions 171, the semicircular concave portions 177 are provided at positions of the circumferential both ends of the front surface portion 174, and the pair of protruding portions 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 an opening portion for leading out the winding end portions 154, 155 of the first partial winding 151A.

[0146] In the insulating covers 161, 162, the height dimension in the axial direction (that is, the width dimension in the axial direction of the pair of side surface portions 171 and the front surface portion 174) is different. Specifically, as shown in FIG. 6, the height dimension in the axial direction of the insulating cover 161 is larger than that of the insulating cover 162. In other words, the width dimension in the axial direction of the pair of side surface portions 171 and the front surface portion 174 of the insulating cover 161 is larger than that of the insulating cover 162. Figure 17 ​As 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.

[0147] Next, the second coil module 150B will be described.

[0148] 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).

[0149] 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.

[0150] The second partial winding 151B has a pair of intermediate conductor portions 152 arranged in parallel with each other in a straight line shape, and a pair of second lap portions 153B connecting the pair of intermediate conductor portions 152 at both axial ends, respectively, and formed in a ring shape by the pair of intermediate conductor portions 152 and the pair of second lap portions 153B. In the second partial winding 151B, the pair of intermediate conductor portions 152 are the same in structure as the intermediate conductor portion 152 of the first partial winding 151A. In contrast, the pair of second lap portions 153B are different in structure from the first lap portion 153A of the first partial winding 151A. The second lap portion 153B of the second partial winding 151B is arranged to extend linearly in the axial direction from the intermediate conductor portion 152, rather than being bent in the radial direction. In Figure 18 The differences between the partial windings 151A, 151B are compared and clarified.

[0151] In the second partial winding 151B, the end portions of the conductor material CR are drawn out from one of the second lap portions 153B (the second lap portion 153B on the upper side of (b)) on both axial sides, and the end portions become the winding end portions 154, 155. Also, as with the first partial winding 151A, in the second partial winding 151B, one of the winding end portions 154, 155 is connected to the current input / output terminal, and the other is connected to the neutral point. Figure 22

[0152] As with the first partial winding 151A, in the second partial winding 151B, the intermediate conductor portions 152 are arranged with the sheet-shaped insulating cover 157 covering the intermediate conductor portions 152. The insulating cover 157 uses a film material FM having an axial dimension of at least the length of the insulating covering range in the axial direction of the intermediate conductor portion 152, and is arranged by winding the film material FM around the intermediate conductor portion 152.

[0153] The structure of the insulating cover 157 is also substantially the same in each of the partial windings 151A, 151B. That is, as shown in Figure 23 the film material FM is arranged to cover around the intermediate conductor portion 152 in a state in which the end portions in the circumferential direction overlap. In the intermediate conductor portion 152, the insulating cover 157 is arranged so as to cover all of the two circumferential side surfaces and the two radial side surfaces. In this case, in the insulating cover 157 surrounding the intermediate conductor portion 152, an overlap portion OL in which the film material FM overlaps is provided at the opposite portion to the intermediate conductor portion 152 in the other phase partial winding 151, that is, at one of the two circumferential side surfaces of the intermediate conductor portion 152. In the present embodiment, the overlap portion OL is provided at the same side in the circumferential direction in each of the pair of intermediate conductor portions 152.

[0154] ​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.

[0155] 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.

[0156] Next, the structure of insulating covers 163 and 164 will be explained.

[0157] 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.

[0158] 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.

[0159] In the insulating cover 163, an opening portion 185a for leading out the winding end portion 154 of the second partial winding 151B is provided in the front surface portion 183, and an opening portion 185b for leading out the winding end portion 155 of the second partial winding 151B is provided in the outer surface portion 182.

[0160] A protruding portion 186 protruding to the radially inner side is provided in the front surface portion 183 of the insulating cover 163. The protruding portion 186 is provided at a position in the center between the circumferential one end and the other end of the insulating cover 163 in a manner of protruding to the radially inner side more than the second lap portion 153B. The protruding portion 186 has a tapered shape in which the front end becomes thinner toward the radially inner side in plan view, and a through-hole 187 extending in the axial direction is provided at the front end portion thereof. Further, the structure of the protruding portion 186 can be arbitrary as long as it protrudes to the radially inner side more than the second lap portion 153B and has the through-hole 187 at a position in the center between the circumferential one end and the other end of the insulating cover 163. However, in view of the overlapping state with the insulating cover 161 on the axial inner side, it is desirable to be formed to be narrow in width in the circumferential direction in order to avoid interference with the winding end portions 154, 155.

[0161] The thickness in the axial direction at the front end portion on the radially inner side of the protruding portion 186 is stepwise thinned, and the through-hole 187 is provided at the low step portion 186a of the thinning. The low step portion 186a corresponds to a portion having a height lower than that of the second lap portion 153B from the axial end surface of the inner cylinder member 81 in a state where the second coil module 150B is assembled to the core assembly CA.

[0162] Further, as shown in Figure 23 a through-hole 188 extending in the axial direction is provided in the protruding portion 186. Therefore, in a state where the insulating covers 161, 163 overlap in the axial direction, an adhesive can be filled between the insulating covers 161, 163 through the through-hole 188.

[0163] Although detailed explanation of illustration is omitted, the insulating cover 164 on the other side in the axial direction has substantially the same structure as the insulating cover 163. As with the insulating cover 163, the insulating cover 164 has a pair of side surface portions 181, an outer surface portion 182 on the axial outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side, and has the through-hole 187 provided at the front end portion of the protruding portion 186. In addition, as a difference from the insulating cover 163, the insulating cover 164 is configured not to have the opening portions for leading out the winding end portions 154, 155 of the second partial winding 151B.

[0164] In the insulating covers 163, 164, the width dimension in the radial direction of the pair of side surface portions 181 is different. Specifically, as shown in Figure 17As shown, the radial width dimension W21 of the side portion 181 in the insulating cover 163 and the radial width dimension W22 of the side portion 181 in the insulating cover 164 satisfy W21 > W22. That is, the insulating cover 163 of the insulating covers 163, 164 is a portion that covers the second lap portion 153B including the winding start end and the winding end end of the conductor material CR, and since the winding start end and the winding end end of the conductor material CR, the winding amount (stacking amount) of the conductor material CR becomes larger than other portions, which can result in a larger winding width. In view of this, the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164. Thus, unlike the case where the width dimensions W21, W22 of the insulating covers 163, 164 are the same dimensions as each other, the adverse situation where the number of turns of the conductor material CR is limited by the insulating covers 163, 164 is suppressed.

[0165] Figure 25 is a view that shows the overlapping positions of the film material FM in a state where the coil modules 150A, 150B are arranged in the circumferential direction. As described above, in each of the coil modules 150A, 150B, the film material FM is covered around the intermediate conductor portion 152 in a manner of overlapping at the circumferential side surface of the intermediate conductor portion 152, that is, the opposite portion to the portion winding 151 in the other phase (see FIG. 10). Figure 20 and Figure 23 ) Moreover, in a state where the coil modules 150A, 150B are arranged in the circumferential direction, the overlapping portions OL of the film material FM are all disposed on the same side (the circumferential right side of the view) of both circumferential sides. Thus, it is configured that the overlapping portions OL of the film material FM do not overlap each other in the circumferential direction in each of the intermediate conductor portions 152 in the portion windings 151A, 151B of different phases adjacent in the circumferential direction. In this case, it is configured that three pieces of the film material FM at the most overlap between each of the intermediate conductor portions 152 arranged in the circumferential direction.

[0166] Next, the structure related to the assembly of each of the coil modules 150A, 150B with respect to the core assembly CA will be described.

[0167] The axial lengths of the coil modules 150A, 150B are different from each other, and the shapes of the lap portions 153A, 153B of the partial windings 151A, 151B are different from each other, so that the first coil module 150A is installed in a state in which the first lap portion 153A is set to the inner side in the axial direction and the second coil module 150B is installed in a state in which the second lap portion 153B is set to the outer side in the axial direction, with respect to the core assembly CA. With respect to the insulating covers 161 to 164, the insulating covers 161, 163 overlap each other in the axial direction at the one end side in the axial direction of each of the coil modules 150A, 150B, and the insulating covers 162, 164 overlap each other in the axial direction at the other end side in the axial direction, and the insulating covers 161 to 164 are fixed with respect to the core assembly CA in this state.

[0168] Figure 26 is a plan view showing a state in which the plurality of insulating covers 161 are arranged in the circumferential direction in a state in which the first coil module 150A is assembled to the core assembly CA, Figure 27 is a plan view showing a state in which the plurality of insulating covers 161, 163 are arranged in the circumferential direction in a state in which the first coil module 150A and the second coil module 150B are assembled to the core assembly CA. Further, Figure 28 (a) of is a longitudinal sectional view showing a state before fixation by the fixing pin 191 in a state in which each of the coil modules 150A, 150B is assembled to the core assembly CA, Figure 28 (b) of is a longitudinal sectional view showing a state after fixation by the fixing pin 191 in a state in which each of the coil modules 150A, 150B is assembled to the core assembly CA.

[0169] As shown in Figure 26 , in a state in which a plurality of the first coil modules 150A are assembled to the core assembly CA, the plurality of insulating covers 161 are respectively arranged in a state in which the side surface portions 171 are in abutment with or close to each other. Each of the insulating covers 161 is arranged in a manner in which the boundary line LB at which the side surface portions 171 face each other coincides with the recessed portion 105 of the axial end surface of the inner cylinder member 81. In this case, since the side surface portions 171 of the insulating covers 161 adjacent in the circumferential direction are in abutment with or close to each other, a state in which a through-hole portion extending in the axial direction is formed by each of the recessed portions 177 of the insulating covers 161 and the through-hole portion coincides with the position of the recessed portion 105 is formed.

[0170] In addition, as shown in 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.

[0171] 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.

[0172] 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.

[0173] like Figure 28As shown in (b) of FIG. 17, the fixing pin 191 is assembled to the low-order portion 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end portion of the fixing pin 191 protrudes above the low-order portion 186a, but does not protrude above the upper surface (the outer surface portion 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion of the insulating cover 161 and the protruding portion 186 (the low-order portion 186a) of the insulating cover 163, and has a margin amount that protrudes upward, and thus, it is considered that the work of inserting the fixing pin 191 into the recess 105, 177 and the through-hole 187 (i.e., the fixing work of the fixing pin 191) can be easily performed. In addition, since the upper end portion of the fixing pin 191 does not protrude above the upper surface (the outer surface portion 182) of the insulating cover 163, it is possible to suppress the adverse situation in which the axial length of the stator 60 is increased due to the protrusion of the fixing pin 191.

[0174] After the insulating covers 161, 163 are fixed by the fixing pin 191, the adhesive is filled through the through-hole 188 provided in the insulating cover 163. Thereby, the insulating covers 161, 163 which overlap in the axial direction are firmly bonded to each other. In addition, in the present embodiment, the adhesive is filled through the through-hole 188 provided in the insulating cover 163, but the adhesive can be filled through the through-hole 188 provided in the insulating cover 161. Figure 28 In (a), (b) of FIG. 17, 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 actually, the through-hole 188 is provided in the thin plate portion formed by reducing the wall, etc.

[0175] As shown in (b) of FIG. 17, the fixing pin 191 is assembled to the low-order portion 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end portion of the fixing pin 191 protrudes above the low-order portion 186a, but does not protrude above the upper surface (the outer surface portion 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion of the insulating cover 161 and the protruding portion 186 (the low-order portion 186a) of the insulating cover 163, and has a margin amount that protrudes upward, and thus, it is considered that the work of inserting the fixing pin 191 into the recess 105, 177 and the through-hole 187 (i.e., the fixing work of the fixing pin 191) can be easily performed. In addition, since the upper end portion of the fixing pin 191 does not protrude above the upper surface (the outer surface portion 182) of the insulating cover 163, it is possible to suppress the adverse situation in which the axial length of the stator 60 is increased due to the protrusion of the fixing pin 191. Figure 28

[0176] In the present embodiment, in the coil edge end portion CE, the 18 insulating covers 161, 163 are arranged in the axial direction in and out, and the recesses 105 are provided in the axial end surface of the stator holder 70 at 18 positions which are the same number as the insulating covers 161, 163. Then, the fixing by the fixing pin 191 is performed at the recesses 105 of the 18 positions. ​

[0177] Although not shown, the insulating covers 162, 164 on the axially opposite side are also the same. That is, first, when the first coil module 150A is assembled, since the side surface portions 171 of the insulating covers 162 adjacent in the circumferential direction are in an abutting or close state to each other, a state is created in which through-hole portions extending in the axial direction are formed by the respective recessed portions 177 of the insulating covers 162, and the through-hole portions coincide with the positions of the recessed portions 106 of the axial end surfaces of the outer cylinder member 71. Then, by assembling the second coil module 150B, the positions of the through-holes 187 of the insulating covers 164 coincide with the through-hole portions of the insulating covers 163 and the recessed portions 106 of the outer cylinder member 71, and by inserting the fixing pins 191 into the recessed portions 106, 177, through-holes 187, the insulating covers 162, 164 are fixed integrally with respect to the outer cylinder member 71.

[0178] When the respective coil modules 150A, 150B are assembled to the core assembly CA, it is preferable that the first coil modules 150A are all pre-installed to the outer peripheral side of the core assembly CA, after which the assembly of all the second coil modules 150B and the fixing by the fixing pins 191 are performed. Alternatively, first, two first coil modules 150A and one second coil module 150B are fixed to the core assembly CA with one fixing pin 191, after which the assembly of the first coil modules 150A, the assembly of the second coil modules 150B, and the fixing by the fixing pins 191 are repeated in this order.

[0179] Next, the bus bar module 200 is described.

[0180] The bus bar module 200 is a winding connection member that is electrically connected to the partial windings 151 of the respective coil modules 150 in the stator winding 61, and that connects one end of the partial windings 151 of each phase in parallel for each phase, and connects the other end of the respective partial windings 151 at a neutral point. Figure 29 is a perspective view of the bus bar module 200, Figure 30 is a cross-sectional view showing a part of the longitudinal section of the bus bar module 200.

[0181] The bus bar module 200 has a ring-shaped portion 201 in a circular ring shape, a plurality of connection terminals 202 extending from the ring-shaped portion 201, and three input and output terminals 203 provided for each phase winding. The ring-shaped portion 201 is formed in a circular ring shape, for example, by an insulating member such as resin.

[0182] As Figure 30As shown, the ring-shaped portion 201 has laminated plates 204 that are substantially circular ring-shaped plates and are laminated in the axial direction in multiple layers (five layers in this example), and four bus bars 211 to 214 are provided in a state of being sandwiched between the laminated plates 204. Each of the bus bars 211 to 214 is circular ring-shaped, and includes a bus bar 211 for a U phase, a bus bar 212 for a V phase, a bus bar 213 for a W phase, and a bus bar 214 for a neutral point. The bus bars 211 to 214 are arranged in the axial direction in a state of facing each other in the ring-shaped portion 201. Each of the laminated plates 204 and the bus bars 211 to 214 is joined to each other by an adhesive. As the adhesive, an adhesive sheet is desirable. However, it can also be configured to coat a liquid or semi-liquid adhesive. Furthermore, the connection terminals 202 are connected to the bus bars 211 to 214 in a state of protruding to the radial direction outside from the ring-shaped portion 201, respectively.

[0183] On the upper surface of the ring-shaped portion 201, that is, the upper surface of the laminated plate 204 on the outermost layer side of the laminated plates 204 provided in five layers, a protrusion portion 201a extending in a ring shape is provided.

[0184] In addition, the bus bar module 200 can be configured such that the bus bars 211 to 214 are integrally insert-molded in a state of being embedded in the ring-shaped portion 201. In addition, the arrangement of the bus bars 211 to 214 is not limited to a structure in which all of the bus bars 211 to 214 are arranged in the axial direction with all of the plate surfaces facing in the same direction, and can be a structure in which the bus bars 211 to 214 are arranged in the radial direction, a structure in which the bus bars 211 to 214 are arranged in two rows in the axial direction and in two rows in the radial direction, a structure in which the bus bars 211 to 214 include bus bars having different extension directions of the plate surfaces, or the like.

[0185] In Figure 29 In the connection terminals 202, the connection terminals 202 are arranged in the circumferential direction of the ring-shaped portion 201 and extend in the axial direction at the radial direction outside. The connection terminals 202 include a connection terminal connected to the bus bar 211 for the U phase, a connection terminal connected to the bus bar 212 for the V phase, a connection terminal connected to the bus bar 213 for the W phase, and a connection terminal connected to the bus bar 214 for the neutral point. The connection terminals 202 are provided in the same number as the winding end portions 154, 155 of the partial winding 151 in the coil module 150, and each of the connection terminals 202 is connected to one winding end portion 154, 155 of the partial winding 151. Thus, the bus bar module 200 is connected to the partial winding 151 for the U phase, the partial winding 151 for the V phase, and the partial winding 151 for the W phase, respectively.

[0186] The input / output terminals 203 are, for example, made of bus bar members, and are arranged in a direction extending in the axial 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. The above-described input / output terminals 203 are connected to the respective bus bars 211 to 213 for each phase within the annular portion 201. Through the above-described input / output terminals 203, power is input / output from an inverter, not shown, to the phase windings of each phase of the stator winding 61.

[0187] Further, it is also possible to configure such that a current sensor that detects the phase current of each phase is integrally provided in the bus bar module 200. In this case, it is preferable that a current detection terminal be provided in the bus bar module 200, and that the detection result of the current sensor be output to a control device, not shown, through the current detection terminal.

[0188] Further, as the fixed portion with respect to the stator holder 70, the annular portion 201 has a plurality of protruding portions 205 that protrude toward the inner peripheral side, and a through hole 206 that extends in the axial direction is formed in the protruding portion 205.

[0189] Figure 31 is a perspective view showing a state in which the bus bar module 200 is assembled to the stator holder 70, Figure 32 is a longitudinal sectional view of a fixed portion that fixes the bus bar module 200. Further, the structure of the stator holder 70 before the bus bar module 200 is assembled is described with reference to Figure 12 .

[0190] In Figure 31 , the bus bar module 200 is arranged on the end plate portion 91 in a manner that surrounds the boss portion 92 of the inner cylinder member 81. The bus bar module 200 is fixed to the stator holder 70 (the inner cylinder member 81) by fastening of a fastener 217 in a state in which it is positioned by the pillar portion 95 (refer to Figure 12 ) that is assembled to the inner cylinder member 81.

[0191] More specifically, as shown in Figure 32 , the end plate portion 91 of the inner cylinder member 81 is provided with a pillar portion 95 that extends in the axial direction. Then, the bus bar module 200 is fixed to the pillar portion 95 in a state in which the pillar portion 95 is inserted through the through hole 206 provided in the plurality of protruding portions 205, by the fastener 217. In the present embodiment, a stopper plate 220 made of a metal material such as iron is used to fix the bus bar module 200. The stopper plate 220 includes a fastened portion 222 having a through hole 221 through which the fastener 217 is inserted, a pressing portion 223 that presses the upper surface of the annular portion 201 of the bus bar module 200, and a bent portion 224 that is provided between the fastened portion 222 and the pressing portion 223.

[0192] 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.

[0193] 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.

[0194] 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).

[0195] 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.

[0196] 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.

[0197] Figure 33 This is a longitudinal sectional view showing the state in which the relay component 230 is 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.

[0198] 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 three insertion holes 233 have elongated cross-sectional openings and are arranged such that their long sides all face approximately the same direction.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] The control device 270 includes a microcomputer having a CPU and various memories, and implements energization control by turning on and off the respective switches 261, 262 based on various detection information in the rotary electric machine 10, a request for motoring drive, and power generation. The detection information of the rotary electric machine 10 includes, for example, a rotational angle of the rotor 20 detected by an angle detector such as a resolver (electric angle information), a power supply voltage detected by a voltage sensor (inverter input voltage), and a current of each phase detected by a current sensor. The control device 270 implements the on-off control of the respective switches 261, 262 by, for example, PWM control at a prescribed switching frequency (carrier frequency), rectangular wave control. The control device 270 can also be a built-in control device built in the rotary electric machine 10, or an external control device provided outside the rotary electric machine 10.

[0205] Since the rotary electric machine 10 of the present embodiment has a slotless structure (toothless structure), the inductance of the stator 60 is reduced to make the electric time constant small, and in the case where the electric time constant is small, it is desirable to increase the switching frequency (carrier frequency) and to accelerate the switching speed. In this regard, since the capacitor 264 for supplying electric charge is connected in parallel to the series connection body of the respective switches 261, 262, the wiring inductance is reduced, and even in the structure where the switching speed is accelerated, appropriate surge countermeasures can be taken.

[0206] The high-potential side terminal of the inverter 260 is connected to the positive terminal of the direct current power supply 265, and the low-potential side terminal is connected to the negative terminal (ground) of the direct current power supply 265. The direct current power supply 265 is constituted by, for example, a group battery in which a plurality of single cells are connected in series. In addition, a capacitor 266 for smoothing is connected in parallel to the direct current power supply 265 at the high-potential side terminal and the low-potential side terminal of the inverter 260.

[0207] Figure 36 is a block diagram showing a current feedback control process for controlling the current of each phase of the U phase, the V phase, and the W phase.

[0208] In Figure 36 , the current command value setting section 271 sets the current command value of the d-axis and the current command value of the q-axis using a torque-dq map based on the motoring torque command value or the power generation torque command value for the rotary electric machine 10 and the electric angular velocity ω obtained by time-differentiating the electric angle θ. In addition, for example, when the rotary electric machine 10 is used as a power source for a vehicle, the power generation torque command value is a regenerative torque command value.

[0209] The dq conversion section 272 converts the current detection values (three-phase currents) detected by the current sensors provided for each phase to components in a two-dimensional orthogonal rotating coordinate system with a d-axis in the direction of an axis of a magnetic field (or field direction), i.e., a d-axis current and a q-axis current.

[0210] The d-axis current feedback control section 273 calculates a command voltage for the d-axis as an operation amount for feedback-controlling the d-axis current to a current command value for the d-axis. Further, the q-axis current feedback control section 274 calculates a command voltage for the q-axis as an operation amount for feedback-controlling the q-axis current to a current command value for the q-axis. In each of the above feedback control sections 273, 274, a command voltage is calculated using a PI feedback method based on a deviation of the d-axis current and the q-axis current from the current command values.

[0211] The three-phase conversion section 275 converts the command voltages for the d-axis and the q-axis to command voltages for the U-phase, the V-phase, and the W-phase. In addition, each of the above sections 271 to 275 is a feedback control section that implements feedback control of a fundamental wave current based on a dq conversion theory, and the command voltages for the U-phase, the V-phase, and the W-phase are feedback control values.

[0212] The operation signal generation section 276 generates operation signals for the inverter 260 based on the command voltages for the three phases using a well-known triangular wave carrier comparison method. Specifically, the operation signal generation section 276 generates switching operation signals (duty signals) for the upper and lower arms of each phase by PWM control based on a size comparison of a signal in which the command voltages for the three phases are normalized with a power supply voltage and a carrier signal such as a triangular wave signal. The switching operation signals generated by the operation signal generation section 276 are output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261, 262 for each phase.

[0213] Next, the torque feedback control process will be described. The above process is used mainly for the purpose of increasing the output of the rotating electric machine 10 and reducing losses in a high rotation region and a high output region, and the like in which the output voltage of each inverter 260 becomes large. The control device 270 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotating electric machine 10.

[0214] Figure 37 is a block diagram showing the torque feedback control process corresponding to the U-phase, the V-phase, and the W-phase.

[0215] The voltage amplitude calculation section 281 calculates an instruction value of the magnitude of the voltage vector, that is, a voltage amplitude instruction, on the basis of the power running torque instruction value or the power generation torque instruction value of the rotating electric machine 10, and an electric angular velocity ω obtained by time-differentiating the electric angle θ.

[0216] The dq conversion section 282, like the dq conversion section 272, converts the current detection values detected by the current sensors provided for the respective phases into d-axis current and q-axis current. The torque estimation section 283 calculates torque estimation values corresponding to the U phase, the V phase, and the W phase on the basis of the d-axis current and the q-axis current. In addition, the torque estimation section 283 calculates the voltage amplitude instruction as appropriate on the basis of mapping information that sets the relationship of the d-axis current, the q-axis current, and the voltage amplitude instruction.

[0217] The torque feedback control section 284 calculates an instruction value of the phase of the voltage vector, that is, a voltage phase instruction, as an operation amount for feedback-controlling the torque estimation value to the power running torque instruction value or the power generation torque instruction value. In the torque feedback control section 284, the voltage phase instruction is calculated using a PI feedback method on the basis of the deviation of the torque estimation value with respect to the power running torque instruction value or the power generation torque instruction value.

[0218] The operation signal generation section 285 generates operation signals of the inverter 260 on the basis of the voltage amplitude instruction, the voltage phase instruction, and the electric angle θ. Specifically, the operation signal generation section 285 calculates instruction voltages of the three phases on the basis of the voltage amplitude instruction, the voltage phase instruction, and the electric angle θ, and generates the switching operation signals of the upper and lower arms in the respective phases by PWM control based on the magnitude comparison of a signal in which the calculated instruction voltages of the three phases are normalized with the power source voltage and a carrier signal such as a triangular wave signal. The switching operation signals generated by the operation signal generation section 285 are output to the drivers 263 of the inverter 260, and the switches 261, 262 of the respective phases are turned on and off by the drivers 263.

[0219] The operation signal generation section 285 can also generate the switching operation signals on the basis of mapping information, that is, pulse pattern information, that sets the relationship of the voltage amplitude instruction, the voltage phase instruction, the electric angle θ, and the switching operation signals, and the voltage amplitude instruction, the voltage phase instruction, and the electric angle θ.

[0220] (Modified Examples)

[0221] Hereinafter, modified examples related to the above-described embodiments will be described.

[0222] • The structure of the magnets in the magnet unit 22 can also be changed as described below. In the embodiment described above, the magnet unit 22 is formed by arranging the magnets 22a in the circumferential direction of the rotor 20. However, the magnet unit 22 can also be formed by arranging the magnets 22a in the radial direction of the rotor 20. Figure 38In the illustrated magnet unit 22, the direction of the easy magnetization axis in the magnet 32 is inclined with respect to the radial direction, and a linear magnet magnetic path is formed in the direction of the easy magnetization axis. In this structure, the magnet magnetic path length of the magnet 32 can also be made longer than the radial thickness dimension, and an increase in permeance can be achieved.

[0223] • A Halbach array magnet can also be used in the magnet unit 22.

[0224] • In each partial winding 151, the direction in which the lap portion 153 is bent can be either of the radial directions, and as a relationship with the core assembly CA, the first lap portion 153A can be bent toward the core assembly CA side, or the first lap portion 153A can also be bent toward the opposite side of the core assembly CA. Also, the second lap portion 153B can be bent in either of the radial directions, as long as it is in a state of spanning a portion of the first lap portion 153A in the circumferential direction at the axially outer side of the first lap portion 153A.

[0225] • As the partial winding 151, one type of partial winding 151 can also be provided instead of two types of partial windings 151 (first partial winding 151A, second partial winding 151B). Specifically, it is preferable to form the partial winding 151 in a substantially L shape or a substantially Z shape when viewed from the side. In the case where the partial winding 151 is formed in a substantially L shape when viewed from the side, it is configured so that the lap portion 153 is bent in either of the radial directions at the axially one end side, and the lap portion 153 is provided so as not to be bent radially at the axially other end side. Also, in the case where the partial winding 151 is formed in a substantially Z shape when viewed from the side, it is configured so that the lap portion 153 is bent in opposite directions with respect to each other in the radial direction at the axially one end side and the axially other end side. In either case, as described above, it is preferable to be configured so that the coil module 150 is fixed to the core assembly CA by the insulating cover covering the lap portion 153.

[0226] • In the above-described structure, a structure in which all of the partial windings 151 for each phase winding in the stator winding 61 are connected in parallel has been described, but this can also be changed. For example, it can also be configured so that all of the partial windings 151 for each phase winding are divided into a plurality of parallel connection groups, and the plurality of parallel connection groups are connected in series. That is, it can also be configured so that all of the 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, or the like, and they are connected in series. Alternatively, it can also be configured so that all of a plurality of partial windings 151 for each phase winding in the stator winding 61 are connected in series.

[0227] • It is also possible to configure the stator winding 61 in the rotary electric machine 10 to have two-phase phase windings (U-phase winding and V-phase winding). In this case, it is sufficient to configure, for example, in the partial winding 151, a pair of intermediate conductor portions 152 to be provided with one coil pitch apart, and to arrange an intermediate conductor portion 152 in the partial winding 151 of the other phase between the pair of intermediate conductor portions 152.

[0228] • Instead of the surface magnet type rotary electric machine of the outer rotor type, it is also possible to embody the rotary electric machine 10 as a surface magnet type rotary electric machine of the inner rotor type. Figure 39 (a) and (b) of FIG. 12 are diagrams showing the structure of the stator unit 300 in the case of being configured as an inner rotor structure. In (a) of FIG. 12, Figure 39 (a) of FIG. 12 is a perspective view showing the state of assembling the coil modules 310A, 310B to the core assembly CA, Figure 39 (b) of FIG. 12 is a perspective view showing the partial windings 311A, 311B included in each of the coil modules 310A, 310B. In this example, the stator holder 70 is assembled to the radially outer side of the stator core 62, thereby constituting the core assembly CA. In addition, a plurality of coil modules 310A, 310B are configured to be assembled to the radially inner side of the stator core 62.

[0229] The partial winding 311A has substantially the same structure as the above-described first partial winding 151A, and has a pair of intermediate conductor portions 312, and a lap portion 313A formed by bending to the core assembly CA side (radially outer side) on both axial sides. In addition, the partial winding 311B has substantially the same structure as the above-described second partial winding 151B, and has a pair of intermediate conductor portions 312, and a lap portion 313B provided on both axial sides in a manner of spanning the lap portion 313A on the axial outer side in the circumferential direction. An insulating cover 315 is attached to the lap portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the lap portion 313B of the partial winding 311B.

[0230] In the insulating cover 315, a semicircular recess 317 extending in the axial direction is provided in the side surface portion on both circumferential sides. In addition, in the insulating cover 316, a protruding portion 318 protruding further to the radially outer side than the lap portion 313B is provided, and a through hole 319 extending in the axial direction is provided in the tip portion of the protruding portion 318.

[0231] Figure 40 is a plan view showing the state of assembling the coil modules 310A, 310B to the core assembly CA. In addition, in Figure 40 In the stator holder 70 of FIG. 13, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end surface of the stator holder 70. In addition, the stator holder 70 has a cooling structure realized by a liquid refrigerant or air, and as an air cooling structure, for example, a plurality of heat dissipation fins are formed on the outer peripheral surface.

[0232] In Figure 40 which, the insulating covers 315, 316 are arranged in an axially overlapping state. In addition, the recess 317 provided to the side surface portion of the insulating cover 315 and the through hole 319 provided to the protruding portion 318 of the insulating cover 316 at a central position between one end and the other end in the circumferential direction of the insulating cover 316 communicate in the axial direction, and fixation by the fixing pin 321 is achieved at each of the above portions.

[0233] In addition, in Figure 40 which, the fixation positions of the insulating covers 315, 316 achieved by the fixing pin 321 are at the axial end faces of the stator holder 70 that are more radially outward than the stator core 62, and fixation with respect to the stator holder 70 is achieved by the fixing pin 321. In this case, since a cooling structure is provided in the stator holder 70, the heat generated in the partial windings 311A, 311B is easily transferred to the stator holder 70. Thereby, the cooling performance of the stator winding 61 can be improved.

[0234] • The stator 60 used in the rotary electric machine 10 can also have a protruding portion (e.g., a pole tooth) extending from the back yoke. In this case, assembly of the back yoke with respect to the stator core, the coil module 150, or the like is sufficient.

[0235] • As the rotary electric machine, it is not limited to a star-connected rotary electric machine, but can also be a delta-connected rotary electric machine.

[0236] • As the rotary electric machine 10, in addition to a rotary field type rotary electric machine in which an excitation element is the rotor and an armature is the stator, a rotary armature type rotary electric machine in which an armature is the rotor and an excitation element is the stator can also be adopted.

[0237] (Modified Example 2)

[0238] In the above-described embodiments or the above-described modified examples, the structure of the conductor material CR as the conductor can also be changed as described below. Hereinafter, the structure of the conductor material CR in this modified example is described in detail. In this modified example, mainly the different portions of the structures described in the above-described embodiments and the above-described modified examples, and the like are described. Furthermore, in this modified example, as the basic structure of the rotary electric machine 10, the structure of the first embodiment is described as an example.

[0239] In the above-described embodiments, the stator 60 has a slotless structure (see Figure 4 , and the magnet unit 22 has a magnet 32 having a polarity anisotropy that increases the magnetic flux density at the d-axis (see Figure 7 ). Therefore, the magnetic flux of the magnet that links each conductor material CR increases, and as a result, the eddy current loss is expected to increase. Therefore, in Modified Example 2, it is configured as described below.

[0240] Figure 41 (a) is a sectional view of the intermediate conductor portion 152 of the first coil module 150A in Modification 2, Figure 41 (b) is a sectional view of a portion of the intermediate conductor portion 152 in (a) enlarged. Also, Figure 41 (a) is a sectional view of the intermediate conductor portion 152 of the first coil module 150A in Modification 2, Figure 42 An enlarged sectional view of the conductor material CR is shown. Also, in this Modification 2, the first coil module 150A is exemplified to explain the conductor material CR, but the conductor material CR of the second coil module 150B is the same.

[0241] As shown in (a) and (b) of FIG. 17, Figure 41 , Figure 42 In Modification 2, the cross section of the conductor material CR is substantially quadrangular. Also, the conductor material CR is configured by winding the intermediate conductor portion 152 of the first coil module 150A in a manner of being layered in the circumferential direction and the radial direction.

[0242] Each of the conductor materials CR is configured by covering a plurality of wire materials 601 with an insulating film 602 in a state of being bundled. Thereby, the insulating properties are ensured between the conductor materials CR overlapping each other in the circumferential direction or the radial direction, and between the conductor material CR and the stator core 62, respectively.

[0243] In addition, the stator winding 61 configured by the conductor material CR is maintained in the insulating property by the insulating film 602 except for exposed portions for connection. As the exposed portions, for example, are the winding end portions 154, 155.

[0244] The wire material 601 includes a conductor 603 through which a current flows and a fusion layer 604 covering the surface of the conductor 603. As the conductor 603, for example, is an electrically conductive metal such as copper. The conductor 603 is an angular wire in which the cross section is quadrangular. In this Modification 2, the cross section of the conductor 603 is a flat rectangular shape in which the thickness dimension in the radial direction is longer than the thickness dimension in the circumferential direction. In addition, as the fusion layer 604, for example, is an epoxy adhesive resin. The heat resistance is about 150°C.

[0245] The fusion layer 604 is configured to be thinner than the insulating film 602, for example, to have a thickness of 10 μm or less. In the wire material 601, only the fusion layer 604 is formed on the surface of the conductor 603, and no insulating layer is separately provided. In addition, the fusion layer 604 can be configured by an insulating member. That is, this is an idea of giving consideration to both the resin of the self-fusing wire and the insulation. Although the insulating layer and the fusion layer are generally separated, the epoxy adhesive resin corresponding to the fusion layer 604 also functions as the insulating layer, and the structure generally called the insulating layer is omitted.

[0246] Further, the fusion layer 604 melts at a lower temperature than the insulating film 602. Alternatively, it has a feature of having a higher dielectric constant. Due to the feature of melting at a low temperature, it has an effect of easily making conduction at the end portions between the wire members 601. Further, it is easy to perform fusion, etc. Further, as a reason why the dielectric constant can be higher, a premise that the potential difference between the wire members 601 is smaller than the potential difference between the conductor materials CR can be cited. By thus setting, even if the fusion layer 604 melts, it is possible to effectively reduce the eddy current loss only by the contact resistance.

[0247] Further, since the fusion layer 604 covers the surface of the conductor 603 in a manner that the thickness dimension is substantially uniform, the cross section of the wire member 601 has a flat rectangular shape in which the thickness dimension in the radial direction is longer than the thickness dimension in the circumferential direction, in correspondence with the cross sectional shape of the conductor 603.

[0248] Further, when the plurality of wire members 601 are bundled, as shown in (b) and (c) of FIG. 6, the wire members 601 are stacked in the circumferential direction. On the other hand, the wire members 601 are arranged in one layer in the radial direction. That is, the conductor material CR is constituted by the plurality of (four in this modification example) wire members 601a to 601d arranged in one layer in the radial direction. In this modification example, in the conductor material CR, the wire members 601a to 601d are arranged in the circumferential direction. Figure 41 Figure 42 Further, as shown in (b) and (c) of FIG. 6, the wire members 601 are stacked in the circumferential direction. On the other hand, the wire members 601 are arranged in one layer in the radial direction. That is, the conductor material CR is constituted by the plurality of (four in this modification example) wire members 601a to 601d arranged in one layer in the radial direction. In this modification example, in the conductor material CR, the wire members 601a to 601d are arranged in the circumferential direction. Figure 42

[0249] Then, in a state where the plurality of wire members 601 are bundled, the fusion layers 604 contact and fuse with each other. Thereby, the adjacent wire members 601 are fixed to each other, thereby suppressing vibration and sound generated by the wire members 601 rubbing against each other. Further, by bundling and collecting the plurality of wire members 601 including the fusion layers 604 and causing the fusion layers 604 to fuse with each other, the shape is maintained. Further, the stacked state of the wire members 601 is maintained.

[0250] The insulating film 602 is made of resin, for example, a modified PI enamel resin having a heat resistance of 220°C to 240°C. By being a modified PI, oil resistance is obtained. It is not subjected to hydrolysis, sulfur erosion, etc. with respect to ATF, etc. Further, in this case, the linear expansion coefficient of the epoxy adhesive resin is larger than that of the modified PI enamel resin.

[0251] The insulating film 602 is formed in a wide belt shape and is spirally wound with respect to the outer periphery of the plurality of wire members 601 that are bundled. As shown in (a) of FIG. 7, the insulating film 602 is spirally wound with respect to the outer periphery of the plurality of wire members 601 that are bundled. Figure 43 Figure 43 ​​​The insulating film 602 is wound in a slightly staggered spiral (in the left-right direction). Specifically, it is wound so that approximately half the width of the insulating film 602 is overlapped. Thus, the insulating film 602 is configured as a double layer at any point except at the ends. However, it does not necessarily have to be a double layer; it can also be three or more layers. Alternatively, it can be a single layer as long as no gaps are created.

[0252] Furthermore, the insulating film 602 is configured to have higher insulation performance than the fusion layer 604 of the wire 601, and can provide insulation between phases. For example, if the thickness of the fusion layer 604 of the wire 601 is set to approximately 1 μm, it is desirable to set the total thickness of the insulating film 602 to approximately 9 μm to 50 μm, thereby ideally achieving phase insulation. Specifically, if the insulating film 602 is configured as two layers, the thickness of each layer can be set to approximately 5 μm.

[0253] Here, Figure 44 The electrical connection of the multiple wires 601a to 601d constituting the conductor material CR is shown. The stator winding 61 is constructed by winding the conductor material CR, and is connected to other stator windings 61 or the neutral point at the winding ends 154 and 155 of the conductor material CR. Therefore, the multiple wires 601a to 601d constituting the conductor material CR are interconnected with each other.

[0254] Next, based on Figure 45 The manufacturing method of the stator winding 61 of the rotary electric machine 10 will be described in more detail. Figure 45 It is a flowchart illustrating the manufacturing process. Figure 46 This is a schematic diagram of the manufacturing line.

[0255] The conductor 603 is drawn out from a plurality of cylindrical spools 701 (reels) on which the wire conductor 603 is wound, and a fusion layer 604 is applied to the surface (step S101). Alternatively, the wire 601 with the fusion layer 604 already coated on the conductor 603 can be pre-wound onto the spool 701 and stored therein, and the wire 601 can be drawn out from the spool 701.

[0256] Then, the wires 601 are bundled and assembled (step S102). At this time, the fusion layers are brought into contact with each other and fused together. In addition, in step S102, tension is applied to each wire 601 to make it straight. Alternatively, it can be made straight before assembly (before step S102). This step S102 is the assembly process.

[0257] On the other hand, the wide strip of insulating film 602 is rolled to further thin it (step S103). Furthermore, the rolling process hardens the insulating film 602, increasing its tensile strength compared to before processing. Step S103 is the rolling process.

[0258] After that (after step S102 and step S103), the insulating film 602 after the rolling process is spirally wound with respect to the outer periphery of the plurality of wires 601 in the bundled state, and the outer periphery is covered (step S104). Step S104 is a covering process. Then, in a state where the plurality of wires 601 is covered with the insulating film 602, a crushing process is performed in such a manner that the cross section becomes a prescribed shape (for example, a rectangular shape) (step S105). Thus, the conductor material CR is formed. In addition, the crushing process can be performed after the collecting process of bundling the wires 601.

[0259] Then, as explained in the first embodiment, the stator winding 61 is formed by winding the conductor material CR (step S106). For example, the stator winding 61 is formed by winding the conductor material CR along the stator winding bobbin 702. Step S106 is a winding process. Further, it is configured to maintain the straightness of the wire 601 before the wire 601 becomes linear to the winding for forming the stator winding 61 (step S102 to step S106). That is, the manufacturing wire is formed in such a manner that the wire is not wound on the cylindrical bobbin again after the conductor material CR is formed.

[0260] With the structure in the above-described modification example 2, the following effects can be obtained.

[0261] The magnet unit 22 is configured to be oriented such 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, that is, the magnetic pole boundary. Thus, the closer to the d-axis, the easier the magnetic flux density is to be parallel to the radial direction. That is, the closer to the d-axis, the easier the radial component of the magnetic flux density is to be large, and on the other hand, the easier the circumferential component is to be small. Thus, by thinning the thickness dimension of the wire 601 in the circumferential direction, the eddy current loss can be more effectively suppressed.

[0262] Further, since the cross sections of the wires 601a to 601d are flat shapes that are long in the radial direction, the reduction effect of the circulating current is improved. That is, the magnet flux varies depending on the circumferential position of the magnet unit 22. Therefore, the magnet flux that links with each of the wires 601a to 601d of each conductor material CR varies with the rotation of the rotor 20, and a difference occurs between the electromotive forces generated in each of the wires 601a to 601d at a certain time. Here, in the above modification example 2, the cross sections of the wires 601a to 601d are flat shapes that are long in the radial direction. Therefore, in each conductor material CR, it is possible to reduce the width dimension in the circumferential direction of the plurality of wires 601a to 601d arranged in a row. As a result, in each conductor material CR, it is possible to reduce the difference between the electromotive forces generated in each of the wires 601a to 601d at a certain time. Thus, it is possible to reduce the difference between the electromotive forces generated in the above wires 601a to 601d that constitute the conductor material CR, and thus it is possible to reduce the circulating current.

[0263] Further, by being flat and long in the radial direction, it is possible to reduce the gap in the radial direction within the conductor material CR, that is, the gap between the conductors 603 or between the insulating film 602 and the conductors 603, and thus it is possible to improve the space factor of the conductors 603.

[0264] The conductor materials CR are insulated by the insulating film 602. On the other hand, although the conductors 603 of the wires 601a to 601d are covered with the fusion layer 604, since no insulating layer is provided, the conductors 603 sometimes come into contact with each other and conduct. However, the potential difference between the conductors 603 is small, and when the plurality of wires 601a to 601d are bundled or the insulating film 602 is covered, even if the fusion layer 604 is broken, the area where the conductors 603 come into contact with each other is very small, and the contact resistance is very large. Therefore, even if not completely insulated, it is possible to suppress the flow of eddy current between the conductors 603.

[0265] Therefore, instead of providing an insulating layer on the surface of the conductors 603, the fusion layer 604 is provided directly on the conductors 603 and the fusion layers 604 are fused to each other. Thus, there is no need for the work of providing an insulating layer. Further, by providing the fusion layer 604, it is possible to easily maintain the state in which the plurality of wires 601a to 601d are bundled, and thus it is easy to cover with the insulating film 602. By the above, it is easy to manufacture the conductor material CR and the rotary electric machine 10, and since the insulating layer of the wires 601a to 601d is omitted, it is possible to improve the space factor of the conductors 603.

[0266] In each conductor material CR, the wire 601a to 601d is arranged in one layer in the radial direction. Therefore, unlike a structure in which the wires 601a to 601d of each conductor material CR are stacked in multiple layers in the radial direction, a difference in electromotive force caused by a difference in the arrangement position of the wires 601a to 601d in the radial direction does not occur. Thus, a difference in electromotive force generated in the wires 601a to 601d that constitute the conductor material CR can be reduced, and thus the circulating current flowing through the conductor material CR can be reduced.

[0267] In addition, by being provided in one layer, a gap between the conductors 603 in the radial direction within the insulating film 602 can be eliminated compared to a case in which the insulating film 602 is provided in multiple layers. That is, the area occupancy factor of the conductors 603 can be improved. In addition, the wires 601 of the conductor material CR are arranged in one layer in the radial direction. Therefore, unlike a structure in which the wires 601 of the conductor material CR are stacked in multiple layers in the radial direction, a difference in electromotive force caused by a difference in the arrangement position of the wires 601 in the radial direction does not occur. That is, generally, the magnetic flux differs depending on the position in the radial direction, but in the above structure, a difference in electromotive force caused by a difference in the arrangement position of the wires 601 in the radial direction does not occur. Thus, a difference in electromotive force generated in each wire 601a to 601d can be reduced, and thus the circulating current can be reduced.

[0268] The insulating film 602 is formed in a band shape and is spirally wound with respect to the outer periphery of the plurality of wires 601 that are bundled. Since the insulating film 602 in a band shape is wound with respect to the plurality of wires 601 to form the conductor material CR, the insulating film 602 can be made thin compared to a case in which the plurality of wires 601 are resin-molded or the like. In addition, since fusion is performed by the fusion layer 604, the wires 601 can maintain the shape in the bundled state, and thus the band-shaped insulating film 602 can be easily wound.

[0269] Unlike a conventional process in which a film is formed by extrusion processing, since the insulating film 602 is subjected to rolling processing, the insulating film 602 can be work-hardened while being made thin. Therefore, in a case in which the conductor material CR is wound to form the stator winding 61, the insulating film 602 does not break. That is, the insulating film 602 as a reinforcing band can withstand a force unique to the division line at which the divided wires 601 irregularly move when bent and the insulating film 602 is broken. In addition, in a case in which a film is formed by extrusion processing, cracking can occur. In addition, since the insulating film 602 can be made thin, the area occupancy factor of the conductors 603 with respect to the accommodation space of the stator winding 61 can be improved.

[0270] In the covering process of step S104, the insulating films 602 are spirally wound in a manner so as to overlap each other while being wound with respect to the outer periphery of the plurality of wire materials 601 that are bundled. Thus, it is possible to prevent foreign matter such as dust or water from reaching the wire materials 601 from the outside through the gaps between the insulating films 602. In addition, since the insulating films 602 overlap each other, even if the conductor material CR is wound to form the stator winding 61, it is difficult for a gap to occur. In addition, with respect to the gaps between the wire materials 601, it is difficult to perform electrodeposition or enamel coating, etc. well, and bubbles can occur, but by using the belt-shaped insulating films 602, it is possible to solve this problem.

[0271] After the conductor material CR is formed (after the covering process), in the case where the conductor material CR is wound on a bobbin, the conductor material CR that is drawn out of the bobbin can be bent, and a slight straightness deviation can occur, thereby hindering an increase in the space factor. That is, in the case where the conductor material CR is wound on a bobbin, there is a technical problem unique to the split line where the wire on the inner side of the bobbin and the wire on the outer side are stretched differently. Specifically, only the wire on the outer side of the bobbin is in a stretched state. Moreover, in the case where the conductor material CR that is stretched only on the outer side is drawn out of the bobbin in order to form the stator winding 61, since a part thereof is in a contracted state, the conductor material CR becomes wavy. When winding is performed in order to form the stator winding 61, gaps can occur between the conductor materials CR, thereby hindering an increase in the space factor, and increasing copper loss.

[0272] Therefore, in the gathering process of step S101, the plurality of wire materials 601 are pressed to be straight in a bundled state, and before the conductor material CR is wound to form the stator winding 61 in the winding process of step S106 after the gathering process, each wire material 601 is maintained to be straight. Thus, compared to the case where the conductor material CR is wound on a cylindrical bobbin again, it is possible to improve the straightness of the conductor material CR. That is, it is difficult for the straightness of the conductor material CR to deviate based on the difference in curvature between the outer peripheral side and the inner peripheral side when winding the conductor material CR on a bobbin, thereby making it difficult for wavy deformation to occur. Thus, when the conductor material CR is wound to form the stator winding 61, it is difficult for gaps to occur between the conductor materials CR, thereby making it possible to improve the space factor.

[0273] The first coil module 150A has a shape in which the partial winding 151 at the coil edge end portion CE is bent to the stator core 62 side, that is, the radial inner side. However, as described above, since the insulating film 602 is subjected to press working, the tensile strength is improved, and thus it is difficult for the insulating film 602 to break, and it is possible to appropriately insulate. In addition, by bending the coil edge end portion CE in the radial direction, it is possible to suppress the axial length of the stator winding 61.

[0274] The insulating film 602 is configured to be thicker than the fused layer 604. This ensures the required intra-phase and inter-phase breakdown voltages and prevents eddy current losses without increasing copper losses. Copper losses are caused by the reduction in copper area due to the increased thickness of the film.

[0275] When the magnet unit 22 is configured as described above, the magnetic flux easily passes through in a straight radial direction due to the orientation of the magnet 32, thus reducing the lateral magnetic flux. That is, since the circumferential magnetic flux is easily reduced, it is not necessary to excessively thin the wire 601 in the circumferential direction. The thinner fusion layer 604 covering the wire 601 increases the duty cycle of the conductor 603.

[0276] (Another example of variation 2)

[0277] The structure in Modification 2 described above can also be modified as explained below. Furthermore, in this other example, the parts that differ from the structures described in the above embodiments and modifications will be explained. In this modification, the structure of Modification 2 will be used as an example to illustrate the basic structure.

[0278] In the magnet 32 ​​of the above-described modified example 2, such as Figure 47 As shown, multiple arc-shaped easy magnetization axes can be formed, centered on an orientation center point C10 set on the q-axis, and a magnetic circuit can be formed along these easy magnetization axes. Among these multiple arc-shaped easy magnetization axes is an easy magnetization axis on arc OA, which is centered on the orientation center point C10 set on the q-axis and passes through the first intersection point P1 of the d-axis side end and the stator side circumferential surface (magnetic flux action surface 34). Furthermore, the shape of the magnetic circuit can be an arc-shaped portion of a circle or an arc-shaped 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. Additionally, in Figure 47 In this configuration, the orientation center point C10 is set between the magnet 32 ​​and the stator winding 61, but it can also be set at a position closer to the opposite side of the stator (the magnet holding member 31 side) than the stator side circumferential surface (magnetic flux action surface 34).

[0279] Furthermore, it can also be set that the tangent Tn1 at the first intersection point P1 is parallel to the d-axis, but if... Figure 47 As shown, the tangent at the first intersection point P1 on the arc OA can also be set to have a predetermined orientation tilt angle θ10 relative to the d-axis. To explain in detail, in the magnet 32, the easy magnetization axes can also be arranged such that, at least at the first intersection point P1 on the d-axis side end and the stator side circumferential surface, they have a tilt angle relative to the d-axis within a predetermined angular range (e.g., 15° to 45° [deg]).

[0280] Furthermore, it is believed that compared to making the easy magnetization axis parallel to the d-axis, by tilting multiple easy magnetization axes to a certain extent, the vector of magnetic flux flowing out from the stator side peripheral surface (magnetic flux action surface 34) can be concentrated on the d-axis, thereby increasing the magnetic flux density on the d-axis.

[0281] However, when the easy magnetization axis is tilted to a certain degree or more, the radial vector component of the magnetic flux flowing out from the stator side circumferential surface (magnetic flux action surface 34) is too small, thereby reducing the magnetic flux density along the d-axis. Therefore, considering the shape of the magnet 32, the size of the air gap, etc., a specified angle range for the orientation tilt angle is set in a way that makes the magnetic flux density at the d-axis at least greater than that when it is parallel to the d-axis.

[0282] In the above-described variation 2, to increase the linear force of the magnetic flux density of the magnet 32, a dual-rotor rotary motor configured by clamping the stator winding 61 with the magnet 32 ​​can also be used. Specifically, as shown in... Figure 48 As shown, in the dual-rotor rotary motor 10, the magnet unit 22 has a first magnet section 501 and a second magnet section 502. The first magnet section is arranged radially inward of the intermediate conductor section 152 and faces the intermediate conductor section 152, while the second magnet section is arranged radially outward of the intermediate conductor section 152 and faces the intermediate conductor section 152. Both the first magnet section 501 and the second magnet section 502 are annular, and the diameter of the first magnet section 501 is smaller than that of the second magnet section 502. Furthermore, both the first magnet section 501 and the second magnet section 502 have multiple magnetic poles with alternating polarities along the circumferential direction. Moreover, they are arranged to radially sandwich the intermediate conductor section 152 through the first magnet section 501 and the second magnet section 502. At this time, a predetermined air gap is formed between the first magnet section 501 and the intermediate conductor section 152, and between the second magnet section 502 and the intermediate conductor section 152.

[0283] Furthermore, the magnetic poles of the first magnet section 501 on the d-axis and the magnetic poles of the second magnet section 502, which are radially opposite to the magnetic poles of the first magnet section 501, are set to be different. That is, the N pole of the first magnet section 501 and the S pole of the second magnet section 502 are arranged to be radially opposite, and the S pole of the first magnet section 501 and the N pole of the second magnet section 502 are arranged to be radially opposite.

[0284] By configuring it as described above, the magnetic flux density at the d-axis tends to be parallel to the radial direction. That is, the radial component of the magnetic flux density tends to increase, while the circumferential component tends to decrease. Therefore, as... Figure 48 As shown in (b), by thinning the circumferential thickness of conductor 603, eddy current losses can be suppressed more effectively.

[0285] • In the above-described modification example 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 604 can also be different from that of the insulating film 602. That is, as described above, the potential difference between the conductors 603 is small, and when the plurality of wires 601 are bundled or the insulating film 602 is covered, even if the fusion layer 604 is broken, the area of contact between the conductors 603 is very small, and the contact resistance is very large. Therefore, even if not completely insulated, it is possible to suppress the flow of eddy current between the conductors 603. In addition, even if the fusion layer 604 is broken after manufacture so that the conductors 603 come into contact with each other, it can be said that there is no problem. Therefore, it is possible to select an arbitrary material having a linear expansion coefficient different from that of the insulating film 602 as the fusion layer 604, and the design becomes easy. For example, it is also possible to make the linear expansion coefficient of the fusion layer 604 larger than that of the insulating film 602.

[0286] In addition, of course, it is also possible to make the linear expansion coefficient of the fusion layer 604 smaller than that of the insulating film 602. In the case where the linear expansion coefficient of the fusion layer 604 is made smaller than that of the insulating film 602, the fusion layer 604 is not easily broken, and the site of contact between the conductors 603 does not increase, so it is possible to suppress the increase in eddy current loss.

[0287] • In the above-described modification example 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 604 can also be the same as that of the insulating film 602. Thereby, it is possible to suppress the simultaneous cracking of the fusion layer 604 and the insulating film 602.

[0288] • In the modification example 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 604 can also be different from that of the conductor 603. Furthermore, in the case where the linear expansion coefficient (linear expansion rate) of the fusion layer 604 is between the linear expansion coefficient of the conductor 603 and the linear expansion coefficient of the insulating film 602, the fusion layer 604 becomes a buffer, so it is possible to suppress the cracking of the insulating film 602.

[0289] • As the insulating film 602 of the above-described modification example 2, PA, PI, PAI, PEEK, or the like can also be used. In addition, as the fusion layer 604, fluorine, polycarbonate, silicon, epoxy resin, polyethylene naphthalate, LCP can also be used.

[0290] • In the above-described modification example 2, the cross-sectional shape of the conductor 603 need not be a rectangular shape as long as it is a flat shape that is long in the radial direction, and for example, it can also be an elliptical shape or a polygonal shape. In addition, the cross-sectional shape of the wire material CR can also be any one of a hexagonal shape, a pentagonal shape, a quadrangular shape, a triangular shape, and a circular shape.

[0291] • In the above-described modification example 2, the crushing process is provided, but the crushing process can be omitted as long as the conductor 603 is a flat rectangular shape and can be bundled without a gap. Further, in the case where the conductor 603 is a wire in a circular shape, it is desirable to provide the crushing process. The crushing process can be performed after the wire material 601 is bundled, but the crushing process can be provided before the wire material 601 is bundled in such a manner that the cross-sectional shape of each wire material 601 becomes a prescribed shape.

[0292] • In the above-described modification example 2, a gap can be provided between the insulating film 602 and the wire material 601 or between the wire materials. In addition, the shapes of the conductor 603 and the fusion layer 604 need not all be the same, and the shapes of a part or all of the conductor 603 or the fusion layer 604 can be made different by the crushing process or the like. In addition, of course, the shapes of a part or all of the conductor 603 or the fusion layer 604 can be slightly deformed by the crushing process.

[0293] • In the above-described modification example 2, the conductor 603 of the wire material 601 can be configured as a composite body in which a relatively thin fiber-shaped conductive member is bundled. For example, as the conductor, a composite body of a CNT (carbon nanotube) fiber can be used. As the CNT fiber, a fiber including a boron-containing fine fiber in which at least a part of carbon is replaced with boron can be used. As the carbon fine fiber, in addition to the CNT fiber, a vapor-phase growth carbon fiber (VGCF) or the like can be used, but the CNT fiber is preferably used.

[0294] • In the above-described embodiment and modification example 2, the stator winding 61 is covered and sealed by the sealing members such as the insulating covers 161 to 164 and the insulating covering member 157, but can be sealed by resin molding in such a manner as to cover the periphery of each conductor material CR that is wound. In this case, it is desirable to provide a sealing member formed by resin molding in a range including the coil end portion CE of the stator winding 61. That is, it is desirable that substantially the entire stator winding 61 except for the winding end portions 154, 155, that is, the connection portions, be sealed by resin.

[0295] Further, when the rotary electric machine 10 is used as a vehicle power source, the above-described sealing member is preferably composed of a high-heat-resistant fluororesin, an epoxy resin, a PPS resin, a PEEK resin, an LCP resin, a silicone resin, a PAI resin, a PI resin, or the like. Further, when the linear expansion coefficient is considered from the viewpoint of suppressing cracking caused by a difference in expansion, it is desirable that the sealing member and the insulating film 602 have the same material. That is, it is desirable to exclude a silicone resin whose linear expansion coefficient is generally more than twice that of other resins. In addition, in an electrical product such as an electric vehicle that does not have a device that utilizes combustion, a PPO resin, a phenol resin, and an FRP resin having heat resistance of about 180°C also become candidates. In a field in which the ambient temperature of the rotary electric machine is considered to be lower than 100°C, the above-described limitation does not apply.

[0296] Furthermore, when a sealing member is provided, the linear expansion coefficient of the sealing member can be different from that of the insulating film 602. For example, the linear expansion coefficient of the insulating film 602 can be smaller than that of the sealing member, and also smaller than that of the fusion layer 604. This prevents simultaneous cracking. That is, expansion caused by external temperature changes can be temporarily prevented by the insulating film 602, which has a smaller linear expansion coefficient. The reverse is also true.

[0297] Alternatively, the linear expansion coefficient of the insulating film 602 can be a value between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604. For example, the linear expansion coefficient of the sealing member can be greater than that of the insulating film 602, and the linear expansion coefficient of the insulating film 602 can be greater than that of the fusion layer 604. That is, the linear expansion coefficient is higher closer to the outside. Alternatively, the linear expansion coefficient of the sealing member can be less than that of the insulating film 602, and the linear expansion coefficient of the insulating film 602 can be less than that of the fusion layer 604. That is, the linear expansion coefficient is higher closer to the inside. Thus, even if there is a difference between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604, the insulating film 602 can act as a buffer by sandwiching an insulating film 602 with an intermediate linear expansion coefficient. Therefore, it is possible to suppress the simultaneous cracking of the sealing member and the fusion layer 604 due to external temperature changes of the stator winding 61 or the heating of the conductor 603.

[0298] In the modified example 2 described above, the bond strength between conductor 603 and fusion layer 604, the bond strength between fusion layer 604 and insulating film 602, and the bond strength between sealing member and insulating film 602 can also be different. For example, the bond strength can be configured such that the bond strength is weaker closer to the outer side. In addition, the bond strength can be controlled by, for example, the tensile strength required when peeling the two films. By setting the bond strength as described above, even if a temperature difference occurs between the inner and outer layers due to heating or cooling, cracking (simultaneous cracking) on ​​both the inner and outer layers can be suppressed.

[0299] • In the above-described variation 2, after the conductor material CR is formed, it can also be temporarily wound onto a cylindrical spool and stored therein. That is, as... Figure 49 As shown, after step S105, after forming the conductor material CR, the wire can also be temporarily wound onto a cylindrical spool and stored therein (step S105a). Then, the conductor material CR can be drawn out from the spool (step S105b), and as described in the first embodiment, the stator winding 61 can be formed by winding the conductor material CR (step S106).

[0300] In this case, when the wire material CR is wound on the bobbin, the straightness of the wire material CR is deviated based on the difference in the curvature of the outer periphery side and the inner periphery side, and a wavy deformation is generated. Therefore, when the wire material CR is wound to form the stator winding 61, a gap is easily formed between the wire materials CR. Therefore, a filling material such as varnish is filled in the minute gap between the wires (step S107). Thus, the vibration can be reduced. In addition, since the wire material CR is temporarily wound on the cylindrical bobbin after being formed, it is not necessary to maintain the straightness of the wire material 601 before the wire material 601 is made linear and is wound for forming the stator winding 61 (steps S102 to S106). That is, it is not necessary to implement the above-described processes in one manufacturing line, and the degree of freedom of the manufacturing line can be improved.

[0301] • Even in the case where the rotating electric machine includes a pole tooth or a structure equivalent to the pole tooth, it is possible to reduce the circulating current by applying the structure of Modification 2.

[0302] The disclosure of the present specification is not limited to the illustrated embodiments. The disclosure includes the illustrated embodiments and modifications made by those skilled in the art based thereon. For example, the disclosure is not limited to the combination of the components and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have an additional portion that can be added to the embodiments. The disclosure includes embodiments in which components and / or elements of the embodiments are omitted. The disclosure includes substitution or combination of components and / or elements between one embodiment and another embodiment. The technical scope of the disclosure is not limited to the description of the embodiments. Several technical scopes of the disclosure should be understood as indicated by the description of the claims, and also include all modifications within the meaning and scope equivalent to the description of the claims.

[0303] Although the disclosure is described based on the embodiments, it should be understood that the disclosure is not limited to the above-described embodiments, structures. The disclosure also includes various modifications, modifications within the equivalent scope. In addition to this, various combinations, modes, further including only one element, more than one or less than one other combination, mode also belong to the scope, idea range of the disclosure.

Claims

1. A rotary electric machine comprising a rotating shaft, an excitation element including a magnet portion having a plurality of magnetic poles whose polarities alternate in a circumferential direction of the rotating shaft, and an armature having a plurality of phases of armature windings, either of the excitation element and the armature being provided as a rotor that is provided integrally with the rotating shaft, the armature winding of each phase is constituted by winding a wire, and has a wire portion that is arranged at a prescribed interval along the circumferential direction of the rotating shaft at a position opposite the magnet portion, each of the wire portions is formed by arranging the wire in one or more rows along the circumferential direction of the rotating shaft and in one or more rows along a radial direction of the rotating shaft, each of the wires is constituted by bundling a plurality of wire members, and is constituted by being covered with an insulating film in a state in which the plurality of wire members are stacked along the circumferential direction of the rotating shaft, each of the wires is constituted by connecting the wire members that constitute the wire in parallel, a cross section of each of the wire members is in a flat shape that is longer in the radial direction of the rotating shaft.

2. The rotary electric machine according to claim 1, wherein the wire member has a cross section in a flat shape that is longer in the radial direction of the rotating shaft, and includes a conductor through which a current flows and a fusion layer that covers a surface of the conductor, the fusion layer is constituted to be thinner than the insulating film, and causes fusion layers to contact and fuse with each other in a state in which a plurality of wire members are stacked along the circumferential direction of the rotating shaft.

3. The rotary electric machine according to claim 2, wherein a linear expansion coefficient of the fusion layer is smaller than a linear expansion coefficient of the insulating film.

4. The rotary electric machine according to claim 2, wherein a linear expansion coefficient of the fusion layer is between a linear expansion coefficient of the conductor and a linear expansion coefficient of the insulating film.

5. The rotary electric machine according to claim 2, wherein an adhesive strength between the fusion layer and the insulating film is weaker than an adhesive strength between the conductor and the fusion layer.

6. The rotary electric machine according to any one of claims 1 to 5, wherein in each of the wires, the wire members are arranged in only one layer in the radial direction of the rotating shaft.

7. The rotary electric machine according to any one of claims 1 to 5, wherein the magnet portions are respectively oriented such that a direction of an easy axis is more parallel to a d-axis on a d-axis side that is a center of a magnetic pole than on a q-axis side that is a boundary of the magnetic pole, and a magnet magnetic circuit is formed along the easy axis.

8. The rotary electric machine according to claim 6, wherein the magnet portions are respectively oriented such that a direction of an easy axis is more parallel to a d-axis on a d-axis side that is a center of a magnetic pole than on a q-axis side that is a boundary of the magnetic pole, and a magnet magnetic circuit is formed along the easy axis.

9. The rotary electric machine according to any one of claims 1 to 5, wherein the magnet portion has a first magnet portion that is arranged opposite the wire portion on an inside in the radial direction of the rotating shaft of the wire portion, and a second magnet portion that is arranged opposite the wire portion on an outside in the radial direction of the rotating shaft of the wire portion, The poles of the first magnet portion at the d-axis as the center of the poles are different from the poles of the second magnet portion opposite to the poles of the first magnet portion in the radial direction of the rotation axis.

10. The rotary electric machine according to claim 6, wherein the magnet portion has a first magnet portion configured to be opposite to the conductor portion on the inside in the radial direction of the rotation axis of the conductor portion, and a second magnet portion configured to be opposite to the conductor portion on the outside in the radial direction of the rotation axis of the conductor portion, the poles of the first magnet portion at the d-axis as the center of the poles are different from the poles of the second magnet portion opposite to the poles of the first magnet portion in the radial direction of the rotation axis.

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