Rotary motor

Abstract

A rotary electric motor (10) includes an armature (700) having a multi-phase armature winding (61). The armature winding has a plurality of partial windings (701) formed by winding conductors (CR). The partial windings are arranged at predetermined intervals in the circumferential direction, and the winding ends (702) of the plurality of partial windings are concentrated at predetermined connection points (P11 to P14) and connected in a combined manner to the neutral point or the input / output terminals of a power conversion device.

Description

[0001] Reference to Related Applications

[0002] This application is based on Japanese Patent Application No. 2020-011993 filed on January 28, 2020, the contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present disclosure relates to a rotary electric machine. BACKGROUND

[0004] In the past, a technical solution has been proposed in which a rotary electric machine and a power conversion circuit that controls the rotary electric machine are integrally configured (for example, Patent Literature 1 and the like). Such a power conversion circuit is connected to a stator winding of the rotary electric machine via a bus bar and performs transmission of electric power.

[0005] However, in the stator winding, the phase winding of each phase has a plurality of partial windings that are individually provided as coil modules. Also, in the stator winding, for each phase, the partial windings of each coil module are connected in parallel or in series with the bus bar, thereby configuring the phase winding of each phase.

[0006] Prior Art Documents

[0007] Patent Literature

[0008] Patent Literature 1: Japanese Patent Application Publication No. 2019-106864 SUMMARY

[0009] However, since the stator winding has a plurality of partial windings in each phase, in the case where each partial winding is connected to the bus bar, there is a problem that the more the partial windings, the more the connection sites, and the more the work spent on the connection.

[0010] The present disclosure was made in view of the above-described circumstances, and a main object thereof is to provide a rotary electric machine that can easily perform connection of an armature winding.

[0011] A first way to solve the above-described technical problem is a rotary electric machine including an armature having a multi-phase armature winding, wherein the armature winding has a plurality of partial windings configured by winding a wire, each of the partial windings is arranged in a circumferential direction at a predetermined interval, and winding end portions of the plurality of partial windings are concentrated at a predetermined connection site and collectively connected to a neutral point or an input / output terminal of a power conversion device.

[0012] Thus, it is possible to concentrate the connection sites, and it is possible to reduce the work spent on the connection.

[0013] The second mode is based on the first mode, and the conductor is covered with the insulating film in a state in which the plurality of wires are bundled, the plurality of winding end portions concentrated at one connection point are arranged in one or two rows, and in a direction orthogonal to the arrangement direction and to the extension direction of the conductor, the insulating film on at least either side of each winding end portion is made thinner than the other portion or the insulating film is cut, and the plurality of winding end portions are connected to the neutral point or the input / output terminal via the thinner portion or the cut portion of the insulating film.

[0014] After the plurality of winding end portions are arranged in one or two rows, the insulating film on at least either side in the orthogonal direction is made thinner than the other portion or the insulating film is cut. Then, the plurality of winding end portions are connected to the neutral point or the input / output terminal via the thinner portion or the cut portion of the insulating film. That is, in the orthogonal direction, at least either side of each winding end portion is connected to the neutral point or the input / output terminal.

[0015] Thus, since the connected portions are aligned, the number of connections can be reduced compared to the case in which the winding end portions are connected respectively. Also, at the connection portions, since the insulating film is made thinner than the other portion or the insulating film is cut, the connection can be easily made even if the conductor is covered with the thicker insulating film. Also, in the case in which the insulating film is made thinner or cut, since the thinner portion or the cut portion is aligned, the processing can be easily performed.

[0016] The third mode is based on the second mode, and the wire has a conductor through which a current flows and a fusion layer covering the surface of the conductor, the fusion layer is made thinner than the insulating film, and in a state in which the plurality of wires are bundled, the fusion layers contact and fuse with each other.

[0017] The wires are insulated from each other by the insulating film. On the other hand, although the conductors of the wires are covered with the fusion layer, since no insulating layer is provided, the conductors sometimes contact and conduct with each other. 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 in which the conductors contact each other is very small, and the contact resistance is very large. Thus, even if not completely insulated, the eddy current flowing between the conductors can be suppressed.

[0018] Thus, instead of providing an insulating layer on the surface of the conductor, the fusion layer is provided directly on the conductor and the fusion layers are fused with each other. Thus, the work of providing the insulating layer is not required. Also, by providing the fusion layer, the state in which the plurality of wires are bundled can be easily maintained, so that the wires can be easily covered with the insulating film. By the above, the wire and the rotary electric machine can be easily manufactured. Also, since the insulating layer of the wire is omitted, the space factor of the conductor can be improved.

[0019] In addition, since the fusion layer is formed thinner than the insulating film, at the connection site, by forming the insulating film thinner than other portions or cutting the insulating film, the conductor can be easily connected even without peeling the fusion layer.

[0020] The fourth aspect is the electric rotating machine according to the second or third aspect, further comprising a wire holding member that sandwiches and holds both sides in the orthogonal direction with respect to the plurality of winding end portions arranged.

[0021] Thus, the winding end portions can be stably held and the connection can not be detached.

[0022] The fifth aspect is the electric rotating machine according to any one of the second to fourth aspects, wherein the wire is composed of an angular wire, and when the plurality of winding end portions are arranged, the plurality of winding end portions are arranged in a manner that the flat portion in which the insulating film is formed thinner than other portions or the insulating film is cut is aligned and disposed on at least either side of both sides of each winding end portion in the orthogonal direction, and the plurality of winding end portions are connected to the neutral point or the input / output terminal via the flat portion.

[0023] Thus, compared to a round wire, the contact area can be easily increased, and the winding end portions can be stably held and the connection can not be detached.

[0024] The sixth aspect is the electric rotating machine according to any one of the second to fifth aspects, wherein the winding end portions are connected in a state that the insulating film is cut on at least either side of both sides of each winding end portion in the orthogonal direction and the wire material is exposed.

[0025] At the winding end portions, the wire material can be exposed and connected, and compared to a case where the insulating film remains, the connection can be prevented from being detached. BRIEF DESCRIPTION OF DRAWINGS

[0026] The above and other objects, other 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:

[0027] Figure 1 is a perspective view showing the entire electric rotating machine in the first embodiment.

[0028] Figure 2 is a plan view of the electric rotating machine.

[0029] Figure 3 is a longitudinal sectional view of the electric rotating machine.

[0030] Figure 4 is a transverse sectional view of the electric rotating machine.

[0031] Figure 5is an exploded sectional view of the rotary electric machine.

[0032] Figure 6 is a sectional view of the rotor.

[0033] Figure 7 is a partial cross-sectional view showing the sectional structure of the magnet unit.

[0034] Figure 8 is a graph showing the relationship between the electric angle and the magnetic flux density of the magnet of the embodiment.

[0035] Figure 9 is a graph showing the relationship between the electric angle and the magnetic flux density of the magnet of the comparative example.

[0036] Figure 10 is a perspective view of the stator unit.

[0037] Figure 11 is a longitudinal sectional view of the stator unit.

[0038] Figure 12 is a perspective view of the core assembly viewed from one axial side.

[0039] Figure 13 is a perspective view of the core assembly viewed from the other axial side.

[0040] Figure 14 is a cross-sectional view of the core assembly.

[0041] Figure 15 is an exploded sectional view of the core assembly.

[0042] Figure 16 is a circuit diagram showing the connection state of the partial windings in each phase winding of the three phases.

[0043] Figure 17 is a side view showing the first coil module and the second coil module arranged laterally and contrastively.

[0044] Figure 18 is a side view showing the first partial winding and the second partial winding arranged laterally and contrastively.

[0045] Figure 19 is a graph showing the structure of the first coil module.

[0046] Figure 20 is Figure 19 is a sectional view of the 20-20 line in (a) of

[0047] Figure 21 is a perspective view showing the structure of the insulating cover.

[0048] Figure 22 is a graph showing the structure of the second coil module.

[0049] Figure 23 is Figure 22 a 23-23 line sectional view in (a).

[0050] Figure 24 is a perspective view showing the structure of the insulating cover.

[0051] Figure 25 is a view showing the overlapping position of the thin film material in a state where the coil modules are arranged in the circumferential direction.

[0052] Figure 26 is a plan view showing the assembled state of the first coil module with respect to the core assembly.

[0053] Figure 27 is a plan view showing the assembled state of the first coil module and the second coil module with respect to the core assembly.

[0054] Figure 28 is a longitudinal sectional view showing the fixed state achieved by the fixing pin.

[0055] Figure 29 is a perspective view of the bus bar module.

[0056] Figure 30 is a sectional view showing a part of the longitudinal section of the bus bar module.

[0057] Figure 31 is a perspective view showing the state of assembling the bus bar module to the stator holder.

[0058] Figure 32 is a longitudinal sectional view of the fixing portion that fixes the bus bar module.

[0059] Figure 33 is a longitudinal sectional view showing the state of assembling the relay member to the housing cover.

[0060] Figure 34 is a perspective view of the relay member.

[0061] Figure 35 is a circuit diagram showing the control system of the rotary electric machine.

[0062] Figure 36 is a functional block diagram showing the current feedback control processing of the control device.

[0063] Figure 37 is a functional block diagram showing the torque feedback control processing of the control device.

[0064] Figure 38 is a partial cross-sectional view showing the sectional structure of the magnet unit in the modification.

[0065] Figure 39 is a diagram showing the structure of the stator unit of the inner rotor structure.

[0066] Figure 40 is a plan view showing the assembled state of the coil module with respect to the core assembly.

[0067] Figure 41 is a sectional view of the wire material of Modification 2.

[0068] Figure 42 is a side view of the wire material of Modification 2.

[0069] Figure 43 is a flowchart showing the manufacturing method of the stator winding.

[0070] Figure 44 is a diagram showing the manufacturing process of the stator winding.

[0071] Figure 45 is a diagram showing the connection point of the bobbin and the winding end portion.

[0072] Figure 46 is a diagram showing the connection method of the winding end portion.

[0073] Figure 47 is a diagram showing another example of the bobbin.

[0074] Figure 48 (a) of FIG. 20 is a plan view of a member constituting the bobbin of another example, Figure 48 (b) thereof is a side view thereof.

[0075] Figure 49 (a) of FIG. 20 is a plan view of a member constituting the bobbin of another example, Figure 49 (b) thereof is a side view thereof. DETAILED DESCRIPTION

[0076] Hereinafter, a plurality of embodiments will be described with reference to the drawings. In the plurality of embodiments, the same reference signs are sometimes attached to functionally and / or structurally corresponding portions and / or associated portions, or reference signs differing by more than one digit are attached. For the corresponding portions and / or associated portions, the description of other embodiments can be referred to.

[0077] The rotating electric machine in the present embodiment is used as, for example, a vehicle power source. However, the rotating electric machine is widely used as an industrial, vehicle, home appliance, OA equipment, game machine, or the like. In each of the following embodiments, the same symbol is attached to the same or equivalent portions in the drawings, and the description of the same symbol is referred to for the same symbol portions.

[0078] (First Embodiment)

[0079] The rotating electric machine 10 of the present embodiment is a synchronous multiphase alternating-current motor, and is an outer rotor structure. Figures 1 to 5 An outline of the rotating electric machine 10 is shown. Figure 1 is an overall perspective view of the rotating electric machine 10, Figure 2 is a plan view of the rotating electric machine 10, Figure 3 is a longitudinal sectional view of the rotating electric machine 10 Figure 2 is a 3-3 line sectional view of the rotating electric machine 10, Figure 4 is a transverse sectional view of the rotating electric machine 10 Figure 3 is a 4-4 line sectional view of the rotating electric machine 10, Figure 5 is an exploded sectional view in which constituent elements of the rotating electric machine 10 are shown exploded. In the following description, in the rotating electric machine 10, a direction in which the rotating shaft 11 extends is set as an axial direction, a direction in which the rotating shaft 11 radially extends from the center is set as a radial direction, and a direction in which the rotating shaft 11 extends in a circular manner is set as a circumferential direction.

[0080] The rotating electric machine 10 generally includes a rotating electric machine main body having a rotor 20, a stator unit 50, and a busbar module 200, and a housing 241 and a housing cover 242 provided in a manner of surrounding the rotating electric machine main body. Each of the above-described members is coaxially arranged with respect to the rotating shaft 11 to which the rotor 20 is integrally provided, and is assembled in a prescribed order in the axial direction, thereby constituting the rotating electric machine 10. The rotating shaft 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. In addition, 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. Rotation of the rotating shaft 11 rotates, for example, an axle of a vehicle. The rotating electric machine 10 can be installed in a vehicle by fixing the housing 241 to a vehicle body frame or the like.

[0081] In the rotating electric machine 10, the stator unit 50 is provided in a manner of surrounding the rotating shaft 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 to 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 therebetween, and the rotor 20 rotates together with the rotating shaft 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".

[0082] Figure 6 is a longitudinal sectional view of the rotor 20. As Figure 6As shown, the rotor 20 has a generally cylindrical rotor frame 21 and an annular magnet unit 22 fixed to the rotor frame 21. The rotor frame 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23. The rotor frame 21 is formed by integrating the cylindrical portion 23 and the end plate 24. The rotor frame 21 functions as a magnet holding member, and the magnet unit 22 is fixed annularly on the radially inner side of the cylindrical portion 23. A through hole 24a is formed in the end plate portion 24. With the through hole 24a inserted, the rotating shaft 11 is fixed to the end plate portion 24 by fasteners 25 such as bolts. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal) to the axial direction. With the flange 11a and the end plate portion 24 in a face-fitting state, the rotor frame 21 is fixed to the rotating shaft 11.

[0083] The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner circumferential surface of the magnet holder 31, and an end plate 33 fixed on one of the two axial sides opposite to the end plate portion 24 of the rotor frame 21. The magnet holder 31 has the same length dimension as the magnets 32 in the axial direction. The magnets 32 are arranged to be surrounded radially outward by the magnet holder 31. The magnet holder 31 and the magnets 32 are fixed at their axial ends in contact with the end plate 33. The magnet unit 22 is equivalent to a "magnet portion".

[0084] Figure 7 This is a partial cross-sectional view showing the cross-sectional structure of magnet unit 22. Figure 7 In the diagram, arrows indicate the direction of the easy magnetization axis of magnet 32.

[0085] In the magnet unit 22, the magnets 32 are arranged in such a way that their polarity changes alternately along the circumference of the rotor 20. Thus, the magnet unit 22 has multiple magnetic poles in the circumferential direction. The magnets 32 are permanent magnets with anisotropic polarity and are constructed using sintered neodymium magnets with an intrinsic coercivity of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more.

[0086] In magnet 32, the radially inner circumferential surface is the flux-acting surface 34 for transmitting magnetic flux. In magnet 32, the directions of the easy magnetization axis are different on the d-axis side (the portion near the d-axis) and the q-axis side (the portion near the q-axis). On the d-axis side, the direction of the easy magnetization axis is parallel to the d-axis, and on the q-axis side, the direction of the easy magnetization axis is orthogonal to the q-axis. In this case, an arc-shaped magnetic circuit is formed along the direction of the easy magnetization axis. In summary, magnet 32 ​​is configured such that, at the center of the magnetic pole, i.e., on the d-axis side, the direction of the easy magnetization axis is parallel to the d-axis compared to the magnetic pole boundary, i.e., on the q-axis side.

[0087] In magnet 32, since the magnetic circuit is formed in an arc shape, the length of the magnetic circuit is longer than the radial thickness of magnet 32. As a result, the magnetic permeability of magnet 32 ​​increases, enabling it to perform the same function as a magnet with a larger quantity of magnets with the same amount of magnets.

[0088] Magnets 32 are arranged in pairs along the circumferential direction to form a magnetic pole. That is, the multiple magnets 32 arranged circumferentially in magnet unit 22 each have a dividing surface along the d-axis and q-axis, and the magnets 32 are arranged in a state of contact or proximity to each other. As described above, the magnets 32 have an arc-shaped magnetic circuit, and at the q-axis, the N and S poles of the circumferentially adjacent magnets 32 face each other. Therefore, it is possible to improve the magnetic permeability near the q-axis. Furthermore, since the magnets 32 on both sides of the q-axis attract each other, the contact state between the magnets 32 can be maintained. Therefore, it still contributes to improving the magnetic permeability.

[0089] In magnet unit 22, since the magnetic flux flows in an arc shape between adjacent N and S poles through each magnet 32, the magnetic path is longer compared to, for example, a radially anisotropic magnet. Therefore, as Figure 8 As shown, the magnetic flux density distribution approximates a sine wave. The result is that, compared to... Figure 9 The radially anisotropic magnets shown as a comparative example have different magnetic flux density distributions, which can concentrate the magnetic flux on the central side of the magnetic poles and improve the torque of the rotary motor 10. Furthermore, in the magnet unit 22 of this embodiment, it can be confirmed that the magnetic flux density distribution differs from that of conventional Hellbeck array magnets. Additionally, in Figure 8 and Figure 9 In the diagram, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. Furthermore, in... Figure 8 and Figure 9 In the diagram, 90° on the horizontal axis represents the d-axis (i.e., the center of the magnetic pole), and 0° and 180° on the horizontal axis represent the q-axis.

[0090] That is, according to the above-described structure, the magnetic flux at the d-axis in the magnetic unit 22 is enhanced, and the flux change near the q-axis is suppressed. Thus, it is possible to ideally realize a magnetic unit 22 with a gentle change in surface magnetic flux from the q-axis to the d-axis in each magnetic pole.

[0091] The sinusoidal matching ratio of the magnetic flux density distribution is preferably, for example, 40% or higher. This reliably increases the magnetic flux in the central portion of the waveform compared to using radially oriented magnets with a sinusoidal matching ratio of around 30% or using parallel-oriented magnets. Furthermore, setting the sinusoidal matching ratio to 60% or higher reliably increases the magnetic flux in the central portion of the waveform compared to flux-concentrated arrays such as the Hellbeck array.

[0092] exist Figure 9In the radially anisotropic magnet shown, the magnetic flux density changes drastically near the q-axis. The more drastic the change in magnetic flux density, the greater the increase in eddy currents in the stator winding 61 of the stator 60 (described later). Furthermore, the change in magnetic flux on the stator winding 61 side also becomes drastic. In contrast, in this embodiment, the magnetic flux density distribution is close to a sinusoidal magnetic flux waveform. Therefore, near the q-axis, the change in magnetic flux density is smaller than that of the radially anisotropic magnet. As a result, the generation of eddy currents can be suppressed.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] In summary, the stator unit 50 has a stator 60 and a stator retainer 70 radially inward therefrom. The stator 60 also has a stator winding 61 and a stator core 62. Furthermore, the stator core 62 and the stator retainer 70 are integrated into a core assembly CA, and multiple partial windings 151 constituting the stator winding 61 are assembled to this core assembly CA. The stator winding 61 corresponds to an "armature winding," the stator core 62 corresponds to an "armature core," and the stator retainer 70 corresponds to an "armature retaining member." The core assembly CA corresponds to a "support member."

[0098] Here, we will first explain the core assembly CA. Figure 12 This is a three-dimensional view of the core assembly CA from one axial side. Figure 13 This is a three-dimensional view of the core assembly CA from the other side of the axial direction. Figure 14 This is a cross-sectional view of the core assembly CA. Figure 15 This is a anatomical view of the core assembly CA.

[0099] As described above, the core assembly CA has a stator core 62 and a stator retainer 70 assembled radially inward thereon. In other words, the stator core 62 is integrally assembled onto the outer peripheral surface of the stator retainer 70.

[0100] The stator core 62 is configured as a stack of iron chips 62a, which are made of electromagnetic steel plates as magnetic materials, stacked axially, and is cylindrical in shape with a predetermined thickness in the radial direction. A stator winding 61 is assembled on the radially outer side of the stator core 62, which is the rotor 20 side. The outer circumferential surface of the stator core 62 is a smooth, curved surface. The stator core 62 functions as a back yoke. The stator core 62 is, for example, constructed by stacking multiple iron chips 62a, which are punched into annular plates, axially. However, a stator core 62 with a helical core structure can also be used. In a helical core structure stator core 62, strip-shaped iron chips are used, which are formed by winding them in a ring shape and stacking them axially, thereby forming a cylindrical stator core 62 as a whole.

[0101] In this embodiment, the stator 60 is a slotless structure without pole teeth for forming slots, but its structure can also use any one of the following (A) to (C).

[0102] (A) In the stator 60, an inter-conductor member is provided between each circumferential conductor portion (the intermediate conductor portion 152 described later), and the inter-conductor member is a magnetic material that satisfies the relationship Wt×Bs≤Wm×Br when the circumferential width dimension of the inter-conductor member of a magnetic pole is set as Wt, the saturation magnetic flux density of the inter-conductor member is set as Bs, the circumferential width dimension of the magnet 32 ​​of a magnetic pole is set as Wm, and the residual magnetic flux density of the magnet 32 ​​is set as Br.

[0103] (B) In the stator 60, an inter-conductor member is provided between each circumferential conductor portion (intermediate conductor portion 152), and a non-magnetic material is used as the inter-conductor member.

[0104] (C) In the stator 60, there is no conductor inter-conductor member between the circumferential conductor portions (intermediate conductor portion 152).

[0105] In addition, such as Figure 15 As shown, the stator retainer 70 has an outer cylinder member 71 and an inner cylinder member 81, which are constructed by setting the outer cylinder member 71 to the radially outer side and the inner cylinder member 81 to the radially inner side, and assembling the above-mentioned members into one piece. The above-mentioned members 71 and 81 are made of metals such as aluminum and cast iron, or carbon fiber reinforced plastic (CFRP).

[0106] The outer cylindrical member 71 is a cylindrical member with both its outer and inner circumferential surfaces being perfectly circular curved surfaces. An annular flange 72 extending radially inward is formed at one axial end. On this flange 72, a plurality of protrusions 73 extending radially inward are formed at predetermined intervals in the circumferential direction (see reference). Figure 13 In addition, opposing surfaces 74 and 75, which are axially opposite to the inner cylinder member 81, are formed on one end side and the other end side of the outer cylinder member 71, respectively, and annular grooves 74a and 75a that extend in a ring shape are formed on the opposing surfaces 74 and 75.

[0107] Furthermore, the inner cylinder member 81 is a cylindrical member with an outer diameter smaller than that of the outer cylinder member 71, and its outer circumferential surface is a perfectly circular curved surface concentric with the outer cylinder member 71. An annular flange 82 extending radially outward is formed at one axial end of the inner cylinder member 81. The inner cylinder member 81 is assembled to the outer cylinder member 71 in a state where its opposing surfaces 74 and 75 are in axial contact. Figure 13 As shown, the outer cylinder component 71 and the inner cylinder component 81 are assembled together by fasteners 84 such as bolts. Specifically, on the inner circumferential side of the inner cylinder component 81, a plurality of protrusions 83 extending radially inward are formed at predetermined intervals in the circumferential direction. When the axial end face of the protrusions 83 overlaps with the protrusions 73 of the outer cylinder component 71, the protrusions 73 and 83 are fastened to each other by fasteners 84.

[0108] likeFigure 14 As shown, when the outer cylinder member 71 and the inner cylinder member 81 are assembled together, an annular gap is formed between the inner circumferential surface of the outer cylinder member 71 and the outer circumferential surface of the inner cylinder member 81. This gap space serves as a refrigerant passage 85 for the flow of refrigerant such as cooling water. The refrigerant passage 85 is arranged annularly in the circumferential direction of the stator retainer 70. More specifically, a passage forming portion 88 is provided in the inner cylinder member 81. The passage forming portion 88 protrudes radially inward from the inner circumferential side of the inner cylinder member 81, and an inlet-side passage 86 and an outlet-side passage 87 are formed therein. Each passage 86 and 87 opens 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 divide the refrigerant passage 85 into an inlet side and an outlet side. Thus, 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.

[0109] 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.

[0110] 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, housed in the annular grooves 74a and 75a of the outer cylinder member 71, and are arranged in a compressed state by the outer cylinder member 71 and the inner cylinder member 81.

[0111] 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 ).

[0112] In addition, such as Figure 12 , Figure 13 As shown, recesses 105 and 106 are formed in the outer cylinder member 71 and the inner cylinder member 81 for fixing the plurality of coil modules 150 described later.

[0113] Specifically, such as Figure 12 As shown, a plurality of recesses 105 are formed at equal intervals along the circumferential direction on the axial end face of the inner cylinder member 81, specifically on the outer axial end face of the end plate portion 91 surrounding the bushing portion 92. Furthermore, as... Figure 13 As shown, a plurality of recesses 106 are formed at equal intervals along the circumferential direction on the axial end face of the outer cylinder member 71, specifically on the axially outer end face of the flange 72. These recesses 105 and 106 are arranged on an imaginary circle concentric with the core assembly CA. The recesses 105 and 106 are respectively located at the same position in the circumferential direction, and their spacing and number are also the same.

[0114] Furthermore, to ensure assembly strength relative to the stator retainer 70, the stator core 62 is assembled in a state that generates radial compressive force relative to the stator retainer 70. Specifically, the stator core 62 is fitted and fixed to the stator retainer 70 with a specified interference fit by thermoforming or pressing. In this case, the stator core 62 and the stator retainer 70 are assembled in a state that generates radial stress from one to the other. Additionally, when increasing the torque of the rotating electric machine 10, for example, by increasing the diameter of the stator 60, the clamping force of the stator core 62 is increased to securely bond it to the stator retainer 70. However, if the compressive stress (in other words, residual stress) of the stator core 62 increases, the stator core 62 may break.

[0115] Therefore, in this embodiment, in the structure where the stator core 62 and the stator retainer 70 are fitted and fixed together with a predetermined interference fit, a limiting portion is provided in the radially opposite portions of the stator core 62 and the stator retainer 70. This limiting portion restricts the circumferential displacement of the stator core 62 through circumferential engagement. That is, as... Figures 12 to 14 As shown, in the radial direction, a plurality of engaging members 111, serving as limiting portions, are provided at predetermined intervals in the circumferential direction between the stator core 62 and the outer cylinder member 71 of the stator retainer 70. These engaging members 111 suppress circumferential positional displacement of the stator core 62 and the stator retainer 70. Furthermore, in this case, it is preferable to configure a recess in at least one of the stator core 62 and the outer cylinder member 71, and to engage the engaging member 111 with this recess. Alternatively, a protrusion may be provided in either the stator core 62 or the outer cylinder member 71, instead of the engaging member 111.

[0116] In the above structure, the stator core 62 and the stator retainer 70 (outer cylinder member 71) are not only fitted and fixed with a predetermined interference fit, but are also constrained by the locking member 111 to limit their circumferential displacement. Therefore, even assuming that the interference fit between the stator core 62 and the stator retainer 70 is relatively small, circumferential displacement of the stator core 62 can be suppressed. Furthermore, even with a relatively small interference fit, the desired displacement suppression effect can be obtained, thus preventing damage to the stator core 62 caused by excessive interference fit. As a result, displacement of the stator core 62 can be appropriately suppressed.

[0117] Alternatively, an annular internal space can be formed on the inner circumference of the inner cylinder member 81, surrounding the rotation axis 11. Electrical components constituting an inverter, acting as a power converter, can be disposed within this internal space. These electrical components are, for example, electrical modules encapsulated with semiconductor switching elements or capacitors. By arranging the electrical modules in contact with the inner circumferential surface of the inner cylinder member 81, the refrigerant flowing through the refrigerant passage 85 can be used to cool the electrical modules. Furthermore, the internal space on the inner circumferential side of the inner cylinder member 81 can be expanded by either not providing multiple protrusions 83 or reducing the protrusion height of the protrusions 83.

[0118] Next, the structure of the stator winding 61 assembled into the core assembly CA will be described in detail. For example... Figure 10 and Figure 11 As shown, the stator winding 61 is assembled to the core assembly CA in the following state: the multiple partial windings 151 constituting the stator winding 61 are assembled in a circumferential arrangement on the radial outer side of the core assembly CA, that is, the radial outer side of the stator core 62.

[0119] The stator winding 61 has multiple phase windings, and the phase windings of each phase are arranged in a predetermined order in the circumferential direction to form a cylindrical (ring-shaped) shape. In this embodiment, the stator winding 61 has a three-phase phase winding by using the phase windings of the U phase, V phase, and W phase.

[0120] like Figure 11 As shown, the stator 60 has, in the axial direction, a portion corresponding to the coil side CS that is radially opposite to the magnet unit 22 of the rotor 20, and a portion corresponding to the axially outer side of the coil side CS, i.e., the coil edge end CE. In this case, the stator core 62 is arranged in the axial direction within the range corresponding to the coil side CS.

[0121] In the stator winding 61, each phase winding has multiple partial windings 151 (see reference). Figure 16Furthermore, this portion of the winding 151 is separately configured as a coil module 150. That is, the coil module 150 is constructed by integrating a portion of the phase winding 151 of each phase, and the stator winding 61 is constructed using a predetermined number of coil modules 150 corresponding to the number of poles. The coil modules 150 (partial windings 151) of each phase are arranged in a predetermined order in the circumferential direction, thereby arranging the conductor portions of each phase in a predetermined order at the coil side CS of the stator winding 61. Figure 10 The diagram shows the arrangement of the U-phase, V-phase, and W-phase conductors on the coil side CS. In this embodiment, the number of magnetic poles is set to 24, but this number can be arbitrary.

[0122] In the stator winding 61, portions of the windings 151 of each coil module 150 for each phase are connected in parallel or in series to form the phase windings of each phase. Figure 16 This is a circuit diagram showing the connection status of some windings 151 in each phase of a three-phase circuit. Figure 16 The diagram shows the state in which some windings 151 in each phase winding are connected in parallel.

[0123] like Figure 11 As shown, the coil module 150 is assembled radially outward of the stator core 62. In this case, the coil module 150 is assembled with its axially extending ends protruding further outward than the stator core 62 (i.e., the coil edge end CE side). That is, the stator winding 61 has a portion corresponding to the coil edge end CE protruding further outward than the stator core 62, and a portion corresponding to the coil side CS further inward than the coil edge end CE.

[0124] The coil module 150 has two shapes: one where a portion of the winding 151 bends radially inward at the coil end CE, i.e., towards the stator core 62; and another where a portion of the winding 151 extends linearly axially without bending radially inward at the coil end CE. In the following description, for convenience, the portion of the winding 151 with the bent shape at both axial ends will be referred to as "first portion winding 151A," and the coil module 150 having this first portion winding 151A will be referred to as "first coil module 150A." Conversely, the portion of the winding 151 without the bent shape at both axial ends will be referred to as "second portion winding 151B," and the coil module 150 having this second portion winding 151B will be referred to as "second coil module 150B."

[0125] Figure 17 This is a side view showing the first coil module 150A and the second coil module 150B arranged horizontally and compared. Figure 18This is a side view showing the first winding 151A and the second winding 151B arranged laterally and compared. As shown in the figures above, the axial lengths of each coil module 150A, 150B and each winding 151A, 151B are different from each other, and the end shapes on both sides of the axial direction are different from each other. The first winding 151A is roughly C-shaped when viewed from the side, and the second winding 151B is roughly I-shaped when viewed from the side. In the first winding 151A, insulating covers 161 and 162, which serve as "first insulating covers," are installed on both sides of the axial direction. In the second winding 151B, insulating covers 163 and 164, which serve as "second insulating covers," are installed on both sides of the axial direction.

[0126] Next, the structure of coil modules 150A and 150B will be explained in detail.

[0127] 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).

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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".

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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).

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] Next, the structure of insulating covers 161 and 162 will be described.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] Furthermore, in the insulating cover 161, in each of the pair of side portions 171, a semi-circular recess 177 extending axially is provided at both ends of the front surface portion 174, that is, at the intersection of each side portion 171 and the front surface portion 174. In addition, in the outer surface portion 172, a pair of protrusions 178 extending axially are provided at symmetrical positions along both sides of the circumference with reference to the center line of the insulating cover 161 in the circumferential direction.

[0145] Supplementary description of the recess 177 of the insulating cover 161. For example... Figure 20 As shown, the first overlapping portion 153A of the first winding 151A is curved, protruding radially inward, i.e., towards the CA side of the core assembly. In this structure, a gap is formed between adjacent first overlapping portions 153A in the circumferential direction, with the gap widening as it approaches the front end of the first overlapping portion 153A. Therefore, in this embodiment, a recess 177 is provided in the side portion 171 of the insulating cover 161 at a position outside the curved portion of the first overlapping portion 153A, utilizing the gap between the circumferentially arranged first overlapping portions 153A.

[0146] Alternatively, a temperature sensing unit (thermometer) can be provided in the first winding 151A. In this configuration, it is preferable to provide an opening in the insulating cover 161 for leading out a signal line extending from the temperature sensing unit. In this case, the temperature sensing unit can be ideally housed within the insulating cover 161.

[0147] Although detailed descriptions of the illustrations are omitted, the insulating cover 162 on the other axial side has a structure substantially the same as that of the insulating cover 161. Similar to the insulating cover 161, the insulating cover 162 has a pair of side portions 171, an axially outer outer surface portion 172, an axially inner inner surface portion 173, and a radially inner front surface portion 174. Furthermore, in the insulating cover 162, semi-circular recesses 177 are provided at the circumferential ends of the front surface portion 174 in the pair of side portions 171, and a pair of protrusions 178 are provided in the outer surface portion 172. As a difference from the insulating cover 161, the insulating cover 162 is configured not to have openings for leading out the winding ends 154, 155 of the first partial winding 151A.

[0148] In the insulating covers 161 and 162, the axial height dimension (i.e., the axial width dimension of the pair of side portions 171 and the front surface portion 174) is different. Specifically, as Figure 17As shown, the axial height dimension W11 of insulating cover 161 and the axial height dimension W12 of insulating cover 162 are both greater than W11. That is, when the conductor material CR is wound in multiple layers, it is necessary to switch the winding layers of conductor material CR (track change) in a direction orthogonal to the winding direction (circumferential direction). Due to this switching, the winding width may increase. As a supplement, insulating cover 161 of insulating covers 161 and 162 is the portion that covers the first overlap portion 153A on the side including the winding start end and winding end end of conductor material CR. Since it includes the winding start end and winding end end of conductor material CR, the amount of winding (layer overlap) of conductor material CR is greater than other portions, resulting in a larger winding width. Taking this into consideration, the axial height dimension W11 of insulating cover 161 is greater than the axial height dimension W12 of insulating cover 162. Thus, unlike the case where the height dimensions W11 and W12 of the insulating covers 161 and 162 are the same, the undesirable situation where the number of turns of the conductor material CR is limited by the insulating covers 161 and 162 is suppressed.

[0149] Next, the second coil module 150B will be described.

[0150] 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).

[0151] 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.

[0152] The second winding 151B has a pair of intermediate conductor portions 152 arranged parallel to each other in a straight line; and a pair of second overlapping portions 153B connecting the pair of intermediate conductor portions 152 at their respective axial ends, forming a ring shape through the pair of intermediate conductor portions 152 and the pair of second overlapping portions 153B. In the second winding 151B, the pair of intermediate conductor portions 152 has the same structure as the intermediate conductor portions 152 of the first winding 151A. In contrast, the structure of the pair of second overlapping portions 153B is different from the structure of the first overlapping portion 153A of the first winding 151A. The second overlapping portions 153B of the second winding 151B are arranged to extend straight along the axial direction from the intermediate conductor portions 152 instead of bending radially. Figure 18 The differences between some windings 151A and 151B are compared and clearly stated.

[0153] In the second winding 151B, the end of the conductor material CR is connected from one of the second overlaps 153B on both axial sides. Figure 22 The second overlapping portion 153B on the upper side of (b) is led out, and its ends become winding ends 154 and 155. Moreover, similar to the first part of the winding 151A, in the second part of the winding 151B, one of the winding ends 154 and 155 is connected to the current input / output terminal, and the other is connected to the neutral point.

[0154] Similar to the first winding 151A, the second winding 151B is configured such that each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157. The insulating cover 157 is made of a thin film material FM with an axial dimension having 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.

[0155] The structure of the insulating sheath 157 is roughly the same in the various windings 151A and 151B. That is, as... Figure 23 As shown, the thin film material FM covers the periphery of the intermediate conductor portion 152 in a state where the circumferential ends overlap. In the intermediate conductor portion 152, the insulating cover 157 is provided in such a way that it covers all of the two circumferential sides and two radial sides. In this case, on the insulating cover 157 surrounding the intermediate conductor portion 152, an overlapping portion OL of the thin film material FM is provided on one of the two circumferential sides of the intermediate conductor portion 152, opposite to the intermediate conductor portion 152 in the partial windings 151 of other phases. In this embodiment, in a pair of intermediate conductor portions 152, overlapping portions OL are provided on the same circumferential side.

[0156] 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.

[0157] 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.

[0158] Next, the structure of insulating covers 163 and 164 will be explained.

[0159] 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.

[0160] 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.

[0161] In the insulating cover 163, an opening 185a is provided on the front surface portion 183 for leading out the winding end 154 of the second partial winding 151B, and an opening 185b is provided on the outer surface portion 182 for leading out the winding end 155 of the second partial winding 151B.

[0162] A protrusion 186 protruding radially inward is provided on the front surface portion 183 of the insulating cover 163. The protrusion 186 is positioned at the center of the insulating cover 163 from one circumferential end to the other, protruding further radially inward than the second overlapping portion 153B. When viewed from above, the protrusion 186 has a tapered shape that tapers towards the radially inward front end, and a through hole 187 extending axially is provided at its front end. Furthermore, the structure of the protrusion 186 can be arbitrary, as long as it protrudes further radially inward than the second overlapping portion 153B and has a through hole 187 at the center of the insulating cover 163 from one circumferential end to the other. However, considering the overlap with the axially inward insulating cover 161, it is desirable to form a narrower circumferential width to avoid interference with the winding ends 154 and 155.

[0163] The axial thickness of the protrusion 186 at its radially inner front end is stepped, and a through hole 187 is provided in the lower step 186a where the thickness is reduced. This lower step 186a corresponds to the portion where the height from the axial end face of the inner cylinder member 81 is lower than the height of the second overlap 153B when the second coil module 150B is assembled to the core assembly CA.

[0164] In addition, such as Figure 23 As shown, a through hole 188 extending axially is provided in the protrusion 186. Therefore, when the insulating covers 161 and 163 overlap axially, adhesive can be filled between the insulating covers 161 and 163 through the through hole 188.

[0165] Although detailed descriptions of the illustrations are omitted, the insulating cover 164 on the other axial side has a structure substantially the same as that of the insulating cover 163. Similar to the insulating cover 163, the insulating cover 164 has a pair of side portions 181, an axially outer outer surface portion 182, a radially inner front surface portion 183, and a radially outer rear surface portion 184, and has a through hole 187 provided at the front end of the protrusion 186. Furthermore, unlike the insulating cover 163, the insulating cover 164 is configured not to have openings for leading out the winding ends 154, 155 of the second partial winding 151B.

[0166] In insulating covers 163 and 164, the radial width dimensions of a pair of side portions 181 are different. Specifically, as... Figure 17As shown, the radial width dimension W21 of the side portion 181 in insulating cover 163 and the radial width dimension W22 of the side portion 181 in insulating cover 164 are both greater than W21. That is, insulating cover 163 in insulating covers 163 and 164 is the portion that covers the second overlap portion 153B, which includes the winding start end and winding end end of the conductor material CR. Since it includes the winding start end and winding end end of the conductor material CR, the amount of winding (layering) of the conductor material CR is greater than that of other portions, which may result in a larger winding width. Considering this, the radial width dimension W21 of insulating cover 163 is greater than the radial width dimension W22 of insulating cover 164. Thus, unlike the case where the width dimensions W21 and W22 of insulating covers 163 and 164 are the same, the undesirable situation of limiting the number of turns of the conductor material CR due to insulating covers 163 and 164 is suppressed.

[0167] Figure 25 This diagram shows the overlapping positions of the thin film material FM when the coil modules 150A and 150B are arranged circumferentially. As described above, in each coil module 150A and 150B, the thin film material FM is covered around the intermediate conductor portion 152 in such a way that it overlaps with the circumferential side of the intermediate conductor portion 152 in the opposite portions of the partial windings 151 of other phases. Figure 20 and Figure 23 Furthermore, with the coil modules 150A and 150B arranged circumferentially, the overlapping portions OL of the thin film material FM are all positioned on the same side on both circumferentially (the right side of the circumferential direction in the figure). This configuration ensures that in the intermediate conductor portions 152 of adjacent circumferentially adjacent phase windings 151A and 151B, the overlapping portions OL of the thin film material FM do not overlap circumferentially. In this configuration, a maximum of three thin film materials FM overlap between each of the circumferentially arranged intermediate conductor portions 152.

[0168] Next, the structure related to the assembly of each coil module 150A, 150B relative to the core assembly CA will be described.

[0169] The axial lengths of each coil module 150A and 150B are different from each other, and the shapes of the overlapping portions 153A and 153B of some windings 151A and 151B are different from each other. They are installed on the core assembly CA with the first overlapping portion 153A of the first coil module 150A positioned axially inside and the second overlapping portion 153B of the second coil module 150B positioned axially outside. Regarding the insulating covers 161 to 164, the insulating covers 161 and 163 overlap axially at one axial end of each coil module 150A and 150B, and the insulating covers 162 and 164 overlap axially at the other axial end. The insulating covers 161 to 164 are fixed relative to the core assembly CA.

[0170] Figure 26 This is a top view showing the multiple insulating covers 161 arranged circumferentially with the first coil module 150A assembled into the core assembly CA. Figure 27 This is a top view showing the multiple insulating covers 161, 163 arranged circumferentially with the first coil module 150A and the second coil module 150B assembled into the core assembly CA. Furthermore, Figure 28 (a) is a longitudinal sectional view showing the state before the coil modules 150A and 150B are fixed by the fixing pin 191 after being assembled into the core assembly CA. Figure 28 (b) is a longitudinal sectional view showing the state after the coil modules 150A and 150B are assembled into the core assembly CA and fixed by the fixing pin 191.

[0171] like Figure 26 As shown, with multiple first coil modules 150A assembled into the core assembly CA, multiple insulating covers 161 are respectively configured such that their side faces 171 are in contact or close to each other. Each insulating cover 161 is configured such that the boundary line LB of the side faces 171 aligns with the recess 105 on the axial end face of the inner cylinder member 81. In this case, since the side faces 171 of the circumferentially adjacent insulating covers 161 are in contact or close to each other, the following state is achieved: through the recesses 177 of the insulating covers 161, axially extending through holes are formed, and the positions of these through holes and recesses 105 are aligned.

[0172] In addition, such as Figure 27As shown, a second coil module 150B is also assembled relative to the integral core assembly CA and the first coil module 150A. Along with this assembly, multiple insulating covers 163 are respectively configured such that the side portions 181 are in contact or close to each other. In this state, the overlapping portions 153A, 153B are configured to intersect each other on a circle on which the intermediate conductor portions 153 are arranged circumferentially. Each insulating cover 163 is configured such that the protrusion 186 overlaps the insulating cover 161 axially, and the through hole 187 of the protrusion 186 communicates axially with the through hole portion formed by each recess 177 of the insulating cover 161.

[0173] 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.

[0174] Moreover, such as Figure 28 As shown in (a) and (b), in the overlapping portion where the protrusions 186 of the insulating cover 161 and the 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.

[0175] like Figure 28As shown in (b), the retaining pin 191 is assembled to the lower step 186a in the protrusion 186 of the insulating cover 163. In this state, the upper end of the retaining pin 191 protrudes upwards from the lower step 186a, but does not protrude upwards from the upper surface (outer surface 182) of the insulating cover 163. In this case, the retaining pin 191 is longer in axial height than the overlapping portion of the insulating cover 161 and the protrusion 186 (lower step 186a) of the insulating cover 163, and has a margin for upward protrusion. Therefore, it is believed that the retaining pin 191 can be easily inserted into the recesses 105, 177 and the through hole 187 (i.e., during the fixing operation of the retaining pin 191). In addition, since the upper end of the retaining pin 191 does not protrude upwards from the upper surface (outer surface 182) of the insulating cover 163, the undesirable situation of the stator 60 becoming longer due to the protrusion of the retaining pin 191 can be suppressed.

[0176] After securing the insulating covers 161 and 163 with the retaining pins 191, adhesive is filled through the through holes 188 provided in the insulating cover 163. Thus, the axially overlapping insulating covers 161 and 163 are firmly bonded together. Furthermore, in Figure 28 In (a) and (b), for convenience, the through hole 188 is shown in the range from the upper surface to the lower surface of the insulating cover 163, but in reality, the through hole 188 is provided in the thin plate portion formed by reducing the wall or the like.

[0177] like Figure 28 As shown in (b), the insulating covers 161, 163, fixed by the fixing pin 191, are positioned radially inward (on the left side of the figure) on the axial end face of the stator retainer 70, and are fixed relative to the stator retainer 70 by the fixing pin 191. That is, the first overlap portion 153A is fixed relative to the axial end face of the stator retainer 70. In this case, since a refrigerant passage 85 is provided in the stator retainer 70, the heat generated in the first part of the winding 151A is directly transferred from the first overlap portion 153A to the vicinity of the refrigerant passage 85 in the stator retainer 70. Furthermore, the fixing pin 191 is inserted into the recess 105 of the stator retainer 70, thereby promoting the transfer of heat to the stator retainer 70 side. With this structure, the cooling performance of the stator winding 61 can be improved.

[0178] In this embodiment, 18 insulating covers 161 and 163 are arranged overlappingly in the axial direction at the coil end CE. On the axial end face of the stator retainer 70, recesses 105 are provided at 18 locations, the same number as the insulating covers 161 and 163. Then, the 18 locations are fixed by retaining pins 191 at the recesses 105.

[0179] Although not shown, the insulating covers 162 and 164 on opposite axial sides are also the same. That is, firstly, when assembling the first coil module 150A, since the side portions 171 of the circumferentially adjacent insulating covers 162 are in abutting or close to each other, the following state is achieved: through-hole portions extending axially are formed by the recesses 177 of the insulating covers 162, and the position of these through-hole portions coincides with the position of the recess 106 on the axial end face of the outer cylinder member 71. Then, when assembling the second coil module 150B, the position of the through-hole 187 on the insulating cover 164 side coincides with the through-hole portion on the insulating cover 163 side and the recess 106 of the outer cylinder member 71, and the insulating covers 162 and 164 are integrally fixed relative to the outer cylinder member 71 by inserting the fixing pin 191 into the recesses 106, 177 and the through-hole 187.

[0180] When assembling the coil modules 150A and 150B into the core assembly CA, it is best to pre-install all the first coil modules 150A onto the outer periphery of the core assembly CA, and then assemble all the second coil modules 150B and secure them with the fixing pins 191. Alternatively, first, secure the two first coil modules 150A and one second coil module 150B to the core assembly CA with a fixing pin 191, and then repeat the assembly of the first coil modules 150A, the assembly of the second coil modules 150B, and the securing with the fixing pins 191 in this order.

[0181] Next, the bus module 200 will be described.

[0182] The bus module 200 is a winding connection component that is electrically connected to a portion of the winding 151 of each coil module 150 in the stator winding 61. For each phase, one end of the portion of the winding 151 of each phase is connected in parallel, and the other end of each portion of the winding 151 is connected at the neutral point. Figure 29 This is a 3D view of busbar module 200. Figure 30 It is a sectional view showing a portion of the longitudinal section of busbar module 200.

[0183] The bus module 200 has: an annular portion 201 in the shape of a ring; a plurality of connection terminals 202 extending from the annular portion 201; and three input / output terminals 203 provided for each phase winding. The annular portion 201 is formed into an annular shape, for example, by means of an insulating member such as resin.

[0184] like Figure 30As shown, the annular portion 201 has a multi-layered plate 204 that is generally circular and stacked axially in multiple layers (five layers in this example), and four busbars 211 to 214 are arranged between the multi-layered plates 204. Each busbar 211 to 214 is annular and includes a busbar 211 for the U phase, a busbar 212 for the V phase, a busbar 213 for the W phase, and a busbar 214 for the neutral point. The busbars 211 to 214 are arranged axially with their surfaces facing each other within the annular portion 201. The multi-layered plates 204 and the busbars 211 to 214 are joined together by an adhesive. An adhesive sheet is preferred as the adhesive. However, a liquid or semi-liquid adhesive may also be used. Furthermore, the connecting terminals 202 are connected to each busbar 211 to 214 in a manner that protrudes radially outward from the annular portion 201.

[0185] On the upper surface of the annular portion 201, that is, on the upper surface of the outermost layer of the five-layer laminate 204, a protrusion 201a extending in an annular shape is provided.

[0186] Furthermore, the busbar module 200 can be configured such that each busbar 211 to 214 is embedded within the annular portion 201, or the busbars 211 to 214 can be integrally embedded with each busbar at a predetermined interval. Additionally, the arrangement of the busbars 211 to 214 is not limited to a structure in which all are arranged axially and all plate surfaces face the same direction; it can also be a structure arranged radially, a structure arranged in two rows axially and two rows radially, or a structure including busbars with different extension directions of the plate surfaces, etc.

[0187] exist Figure 29 In this configuration, each connection terminal 202 is arranged circumferentially along the annular portion 201 and extends axially at its radially outer side. The connection terminals 202 include terminals connected to the busbar 211 for the U phase, the busbar 212 for the V phase, the busbar 213 for the W phase, and the busbar 214 for the neutral point. The connection terminals 202 are provided in the same number as the winding ends 154 and 155 of each partial winding 151 in the coil module 150, and each connection terminal 202 is connected to one winding end 154 or 155 of each partial winding 151. Thus, the busbar module 200 is connected to the partial windings 151 of the U phase, the V phase, and the W phase, respectively.

[0188] The input / output terminals 203 are, for example, constructed from busbar components and arranged in an axially extending direction. The input / output terminals 203 include an input / output terminal 203U for the U-phase, an input / output terminal 203V for the V-phase, and an input / output terminal 203W for the W-phase. These input / output terminals 203 are connected to each busbar 211-213 for each phase within the annular portion 201. Through these input / output terminals 203, power is input and output to each phase winding of the stator winding 61 via an inverter (not shown).

[0189] Alternatively, the bus module 200 may be configured to integrate current sensors for detecting the phase current of each phase. In this case, it is preferable to provide current detection terminals in the bus module 200 and output the detection results of the current sensors to a control device (not shown) via the current detection terminals.

[0190] In addition, as the fixed part relative to the stator retainer 70, the annular part 201 has a plurality of protrusions 205 protruding inward to the circumferential side, and through holes 206 extending in the axial direction are formed in the protrusions 205.

[0191] Figure 31 This is a perspective view showing the busbar module 200 assembled on the stator retainer 70. Figure 32 This is a longitudinal sectional view of the fixed portion of the fixed busbar module 200. Additionally, the structure of the stator retainer 70 before assembling the busbar module 200 is shown in reference. Figure 12 .

[0192] exist Figure 31 In this configuration, the busbar module 200 is mounted on the end plate portion 91 in such a way that it surrounds the bushing portion 92 of the inner cylinder member 81. The busbar module 200 is further mounted on the support portion 95 (see reference 81) of the inner cylinder member 81. Figure 12 In the positioned state, it is fixed to the stator retainer 70 (inner cylinder component 81) by fastening with fasteners such as bolts 217.

[0193] More in detail, such as Figure 32 As shown, an axially extending support portion 95 is provided on the end plate portion 91 of the inner cylinder component 81. Then, the busbar module 200 is fixed to the support portion 95 by fasteners 217 with the support portion 95 inserted into the through holes 206 provided in the plurality of protrusions 205. In this embodiment, a stop plate 220 made of a metal material such as iron is used to fix the busbar module 200. The stop plate 220 includes: a fastening portion 222 having an insertion hole 221 through which the fastener 217 is inserted; a pressing portion 223 pressing against the upper surface of the annular portion 201 of the busbar module 200; and a bending portion 224 disposed between the fastening portion 222 and the pressing portion 223.

[0194] 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 under the elastic force of the bending portion 224.

[0195] 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.

[0196] 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).

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] 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.

[0203] 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.

[0204] 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.

[0205] 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.

[0206] The control device 270 includes a microcomputer with a CPU and various memories. Based on various detection information from the rotating electric motor 10, requests for power operation and power generation, it implements power control by switching on and off various switches 261 and 262. The detection information of the rotating electric motor 10 includes, for example, the rotation angle of the rotor 20 (electrical angle information) detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the current flowing through each phase detected by a current sensor. The control device 270 implements the switching on and off control of each switch 261 and 262 through, for example, PWM control or rectangular wave control at a predetermined switching frequency (carrier frequency). The control device 270 can be a built-in control device integrated into the rotating electric motor 10, or an external control device located outside the rotating electric motor 10.

[0207] Since the rotary motor 10 of this embodiment has a slotless structure (poleless tooth structure), the inductance of the stator 60 is reduced, resulting in a smaller electrical time constant. With this smaller electrical time constant, it is desirable to increase the switching frequency (carrier frequency) and accelerate the switching speed. In this regard, since a capacitor 264 for charge supply is connected in parallel with the series connection of the switches 261 and 262 of each phase, the wiring inductance is reduced, and even in a structure with accelerated switching speed, appropriate surge countermeasures can be taken.

[0208] The high-potential side terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265, and the low-potential side terminal is connected to the negative terminal (ground) of the DC power supply 265. The DC power supply 265 is composed of, for example, a battery pack of multiple individual cells connected in series. In addition, a smoothing capacitor 266 is connected in parallel with the DC power supply 265 at both the high-potential side terminal and the low-potential side terminal of the inverter 260.

[0209] Figure 36 This is a block diagram representing the current feedback control process that controls the current of each phase (U, V, and W).

[0210] exist Figure 36 In this configuration, the current command value setting unit 271 uses torque-dq mapping to set the current command values ​​for the d-axis and q-axis based on the power operating torque command value or generator torque command value for the rotary motor 10 and the electrical angular velocity ω obtained by time differentiation of the electrical angle θ. Furthermore, for example, when the rotary motor 10 is used as a power source for a vehicle, the generator torque command value is the regenerative torque command value.

[0211] The dq conversion unit 272 converts the current detection values ​​(three-phase currents) detected by the current sensors set for each phase into components of an orthogonal two-dimensional rotating coordinate system with the excitation direction (direction of an axis of a magnetic field, or field direction) as the d-axis, namely the d-axis current and the q-axis current.

[0212] The d-axis current feedback control unit 273 calculates the command voltage for the d-axis as an operational quantity for controlling the d-axis current feedback to the current command value for the d-axis. Similarly, the q-axis current feedback control unit 274 calculates the command voltage for the q-axis as an operational quantity for controlling the q-axis current feedback to the current command value for the q-axis. In each of the feedback control units 273 and 274, the command voltage is calculated using a PI feedback method based on the deviations of the d-axis and q-axis currents from the current command values.

[0213] The three-phase conversion unit 275 converts the command voltages of the d-axis and q-axis into command voltages for the U-phase, V-phase, and W-phase. Furthermore, each of the aforementioned units 271 to 275 is a feedback control unit that implements feedback control of the fundamental current based on the dq conversion theory, and the command voltages of the U-phase, V-phase, and W-phase are feedback control values.

[0214] The operation signal generation unit 276 uses a well-known triangular wave carrier comparison method to generate operation signals for the inverter 260 based on the three-phase command voltages. Specifically, the operation signal generation unit 276 generates switching operation signals (duty cycle signals) for the upper and lower arms of each phase by comparing the magnitudes of a signal that normalizes the three-phase command voltages using the power supply voltage with a carrier signal such as a triangular wave signal using PWM control. The switching operation signals generated by the operation signal generation unit 276 are output to the driver 263 of the inverter 260, and the driver 263 turns the switches 261 and 262 of each phase on and off.

[0215] Next, the torque feedback control process will be explained. Under operating conditions where the output voltage of each inverter 260 increases, such as in high-rotation and high-output regions, the above-mentioned process is primarily used to maximize the output of the rotating motor 10 and reduce losses. Based on the operating conditions of the rotating motor 10, the control device 270 selects and executes either the torque feedback control process or the current feedback control process.

[0216] Figure 37 This is a block diagram representing the torque feedback control processing corresponding to phases U, V, and W.

[0217] The voltage amplitude calculation unit 281 calculates the voltage vector magnitude command value, i.e., the voltage amplitude command, based on the power operating torque command value or generator torque command value of the rotating motor 10 and the electric angular velocity ω obtained by time differentiation of the electric angle θ.

[0218] Similar to the dq conversion unit 272, the dq conversion unit 282 converts the current detection values ​​detected by the current sensors provided for each phase into d-axis current and q-axis current. The torque estimation unit 283 calculates the torque estimation values ​​corresponding to phases U, V, and W based on the d-axis current and q-axis current. Furthermore, the torque estimation unit 283 calculates the voltage amplitude command based on mapping information that sets the relationship between the d-axis current, q-axis current, and voltage amplitude command.

[0219] The torque feedback control unit 284 calculates the command value of the voltage vector phase, i.e., the voltage phase command, as an operating quantity for feeding back the torque estimate value to the power operating torque command value or the generator torque command value. In the torque feedback control unit 284, the voltage phase command is calculated using a PI feedback method based on the deviation of the torque estimate value from the power operating torque command value or the generator torque command value.

[0220] The operation signal generation unit 285 generates operation signals for the inverter 260 based on voltage amplitude commands, voltage phase commands, and electrical angle θ. Specifically, the operation signal generation unit 285 calculates the command voltages for the three phases based on the voltage amplitude commands, voltage phase commands, and electrical angle θ. It then generates switching operation signals for the upper and lower arms of each phase through PWM control that compares the magnitudes of a signal that normalizes the calculated three-phase command voltages using the power supply voltage with a carrier signal such as a triangular wave signal. The switching operation signals generated by the operation signal generation unit 285 are output to the driver 263 of the inverter 260, and the driver 263 turns the switches 261 and 262 of each phase on and off.

[0221] Alternatively, the operation signal generation unit 285 can also generate a switching operation signal based on the mapping information of the relationship between the set voltage amplitude command, voltage phase command, electrical angle θ and the switching operation signal, namely pulse mode information, voltage amplitude command, voltage phase command and electrical angle θ.

[0222] (Modified Example)

[0223] Hereinafter, variations related to the above embodiments will be described.

[0224] The structure of the magnet in magnet unit 22 can also be changed as described below. Figure 38In the magnet unit 22 shown, the direction of the easy magnetization axis in the magnet 32 ​​is inclined relative to the radial direction, and a straight magnetic circuit is formed along the direction of the easy magnetization axis. In this structure, the length of the magnetic circuit of the magnet 32 ​​can be longer than the radial thickness dimension, and the magnetic permeability can be improved.

[0225] • A Hellbeck array magnet can also be used in magnet unit 22.

[0226] In each winding 151, the bending direction of the overlapping portion 153 can be either radially inward or outward. In relation to the core assembly CA, the first overlapping portion 153A can be bent towards the core assembly CA, or it can be bent towards the opposite side of the core assembly CA. Furthermore, the second overlapping portion 153B only needs to be in a state where it circumferentially crosses a portion of the first overlapping portion 153A on its axially outer side; the second overlapping portion 153B can be bent in either radially inward or outward.

[0227] • As a partial winding 151, it is also possible to have only one partial winding 151 instead of two partial windings 151 (first partial winding 151A and second partial winding 151B). Specifically, it is preferable to form the partial winding 151 in a generally L-shaped or generally Z-shaped manner when viewed from the side. When the partial winding 151 is formed in a generally L-shaped manner when viewed from the side, the overlapping portion 153 is configured to bend in either a radially inward or outward direction at one axial end, and the overlapping portion 153 is configured not to bend radially at the other axial end. Alternatively, when the partial winding 151 is formed in a generally Z-shaped manner when viewed from the side, the overlapping portion 153 is configured to bend radially in opposite directions at one axial end and the other axial end. In either case, as described above, it is preferable to fix the coil module 150 to the core assembly CA by an insulating cover covering the overlapping portion 153.

[0228] The above structure describes the parallel connection of all partial windings 151 for each phase winding in the stator winding 61, but this can be modified. For example, it can be configured such that all partial windings 151 for each phase winding are divided into multiple parallel connection groups, and these multiple parallel connection groups are connected in series. That is, it can also be configured such that all n partial windings 151 in each phase winding are divided into two parallel connection groups of n / 2 each, three parallel connection groups of n / 3 each, etc., and connected in series. Alternatively, it can be configured such that all partial windings 151 in the stator winding 61 are connected in series for each phase winding.

[0229] • Alternatively, the stator winding 61 in the rotary motor 10 can be configured to have two phase windings (U-phase winding and V-phase winding). In this case, it is sufficient to configure, for example, in a partial winding 151, a pair of intermediate conductor portions 152 are separated by a coil spacing, and an intermediate conductor portion 152 of another phase partial winding 151 is arranged between the pair of intermediate conductor portions 152.

[0230] • Instead of an external rotor type surface magnet type rotary motor, the rotary motor 10 can also be embodied as an internal rotor type surface magnet type rotary motor. Figure 39 Figures (a) and (b) are diagrams illustrating the structure of the stator unit 300 when it is configured as an internal rotor structure. Figure 39 (a) is a perspective view showing the state in which coil modules 310A and 310B are assembled into the core assembly CA. Figure 39 (b) is a perspective view showing the partial windings 311A ​​and 311B included in each coil module 310A and 310B. In this example, the stator retainer 70 is assembled to the radially outer side of the stator core 62, thereby forming the core assembly CA. Alternatively, multiple coil modules 310A and 310B are configured to be assembled to the radially inner side of the stator core 62.

[0231] Partial winding 311A ​​has a structure substantially the same as the first partial winding 151A described above, having a pair of intermediate conductor portions 312 and overlapping portions 313A formed by bending on both axial sides toward the core assembly CA side (radially outward). Partial winding 311B has a structure substantially the same as the second partial winding 151B described above, having a pair of intermediate conductor portions 312 and overlapping portions 313B arranged on both axial sides such that they circumferentially span the overlapping portions 313A on the axial outward. An insulating cover 315 is installed on the overlapping portion 313A of partial winding 311A, and an insulating cover 316 is installed on the overlapping portion 313B of partial winding 311B.

[0232] In the insulating cover 315, semi-circular recesses 317 extending axially are provided on the side portions on both circumferential sides. In addition, the insulating cover 316 is provided with a protrusion 318 that protrudes radially outward more than the overlapping portion 313B, and a through hole 319 extending axially is provided at the front end of the protrusion 318.

[0233] Figure 40 This is a top view showing the coil modules 310A and 310B assembled in the core assembly CA. Additionally, in Figure 40 In this structure, a plurality of recesses 105 are formed at equal intervals along the circumferential direction on the axial end face of the stator retainer 70. Furthermore, the stator retainer 70 has a cooling structure achieved by liquid refrigerant or air, and as an air-cooled structure, for example, a plurality of heat dissipation fins are formed on the outer peripheral surface.

[0234] exist Figure 40 In this configuration, insulating covers 315 and 316 are arranged in an axially overlapping state. Furthermore, the recess 317 provided on the side of the insulating cover 315 and the through hole 319 provided in the protrusion 318 of the insulating cover 316, which is located at the center between one end of the insulating cover 316 and the other end, are axially connected, and are fixed by fixing pins 321 in each of the above-mentioned parts.

[0235] In addition, Figure 40 In this configuration, the insulating covers 315 and 316, secured by the fixing pins 321, are located on the axial end face of the stator retainer 70, which is radially outer than the stator core 62, and are fixed relative to the stator retainer 70 using the fixing pins 321. In this case, since a cooling structure is provided in the stator retainer 70, some of the heat generated in the windings 311A ​​and 311B is easily transferred to the stator retainer 70. This improves the cooling performance of the stator windings 61.

[0236] The stator 60 used in the rotary motor 10 may also have protrusions (e.g., pole teeth) extending from the back yoke. In this case, it is sufficient to assemble the back yoke with coil modules 150 and the like relative to the stator core.

[0237] • As a rotary motor, it is not limited to a rotary motor with a star connection, but can also be a rotary motor with a delta connection.

[0238] • As a rotating electric motor 10, in addition to a rotating excitation type rotating electric motor with an excitation element as the rotor and an armature as the stator, a rotating armature type rotating electric motor with an armature as the rotor and an excitation element as the stator can also be used.

[0239] (Variation Example 2)

[0240] In the above-described embodiments or modifications, the structure may be changed as described below. Hereinafter, in this modification, the parts that differ from the structures described in the above embodiments and modifications will be explained. Furthermore, in this modification, the structure of the first embodiment will be used as an example to describe the basic structure of the rotary motor 10.

[0241] Figure 41 An enlarged cross-sectional view of the conductor material CR is shown. In Modified Example 2, the cross-section of the conductor material CR is quadrilateral. However, the cross-section of the conductor material CR is not limited to a quadrilateral; it can be any shape, such as a polygon or a circle other than a quadrilateral. Furthermore, the conductor material CR is constructed by covering it with an insulating film 502 while multiple wires 501 are bundled together. Thus, insulation is ensured between the conductor materials CR overlapping each other circumferentially or radially, and between the conductor material CR and the stator core 62.

[0242] In addition, apart from the exposed portion used for connection, the stator winding 61, made of conductor material CR, is kept insulated by an insulating film 502. An example of an exposed portion is the winding end.

[0243] The wire 501 includes a conductor 503 through which current flows and a fusion layer 504 covering the surface of the conductor 503. The conductor 503 is, for example, a conductive metal such as copper. The conductor 503 has a quadrilateral cross-section, but it can also be other shapes (e.g., polygons, ellipses, etc.) such as circles. The fusion layer 504 is, for example, an epoxy adhesive resin. The heat resistance is approximately 150°C.

[0244] The fusion layer 504 is configured to be thinner than the insulating film 502, for example, less than 10 μm thick. In the wire 501, only the fusion layer 504 is formed on the surface of the conductor 503, and no separate insulating layer is provided. Alternatively, the fusion layer 504 can also be composed of insulating components. That is, this takes into account both the resin of the self-fusing wire and the insulation. Although the insulating layer and the fusion layer are usually separated, the epoxy adhesive resin, which corresponds to the fusion layer 504, also serves as an insulating layer, omitting the structure usually referred to as an insulating layer.

[0245] Furthermore, the fusion layer 504 melts at a lower temperature than the insulating film 502, or it has a high dielectric constant. Due to its low-temperature melting characteristic, it facilitates conductivity at the ends between the wires 501. Additionally, it facilitates welding. Furthermore, as a reason for the potentially high dielectric constant, the potential difference between the wires 501 can be smaller than the potential difference between the conductor materials CR. With this configuration, even if the fusion layer 504 melts, eddy current losses can be effectively reduced solely by contact resistance.

[0246] Then, with the multiple wires 501 bundled together, the fusion layer 504 comes into contact with and fuses with each other. This fixes adjacent wires 501 together, thereby suppressing vibrations and noise caused by friction between the wires 501. Furthermore, by bundling and assembling the multiple wires 501, including the fusion layer 504, and fusing the fusion layer 504 with each other, the shape is maintained.

[0247] The insulating film 502 is a modified PI enamel resin with a heat resistance of 220℃~240℃. By using modified PI, oil resistance is achieved. It is not susceptible to hydrolysis or sulfur corrosion by ATF and similar materials. Furthermore, in this case, the linear expansion coefficient of the epoxy adhesive resin is greater than that of the modified PI enamel resin.

[0248] The insulating film 502 is formed as a wide strip, spirally wound relative to the outer periphery of the bundled wires 501. For example... Figure 42As shown, the insulating film 502 overlaps with each other along the extension direction of the wire 501. Figure 42 The insulating film 502 is wound in a slightly staggered spiral shape (in the left-right direction). Specifically, it is wound so that approximately half the width of the insulating film 502 is overlapped. Thus, the insulating film 502 is configured as a double layer at any location except the ends. Furthermore, it does not necessarily have to be a double layer; it can also be three or more layers. Additionally, it can be a single layer as long as no gaps are created.

[0249] Furthermore, the insulating film 502 is configured to have higher insulation performance than the fusion layer 504 of the wire 501, and can provide insulation between phases. For example, if the thickness of the fusion layer 504 of the wire 501 is set to approximately 1 μm, it is desirable to set the total thickness of the insulating film 502 to approximately 9 μm to 50 μm, thereby ideally achieving phase insulation. Specifically, if the insulating film 502 is configured as two layers, the thickness of each layer can be set to approximately 5 μm.

[0250] Next, based on Figure 43 and Figure 44 The manufacturing method of the stator winding 61 of the rotary electric machine 10 will be described in more detail. Figure 43 It is a flowchart representing the manufacturing process. Figure 44 This is a schematic diagram of the manufacturing line.

[0251] The conductor 503 is drawn out from a plurality of cylindrical spools 601 (reels) on which the wire conductor 503 is wound, and a fusion layer 504 is applied to the surface (step S101). Alternatively, the wire 501 with the fusion layer 504 already coated on the conductor 503 can be pre-wound onto the spool 601 and stored therein, and the wire 501 can be drawn out from the spool 601.

[0252] Then, the wires 501 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 501 to make it straight. Alternatively, it can be made straight before assembly (before step S102). This step S102 is the assembly process.

[0253] On the other hand, the wide strip of insulating film 502 is rolled to further thin it (step S103). Furthermore, the rolling process hardens the insulating film 502, increasing its tensile strength compared to before processing. Step S103 is the rolling process.

[0254] Afterwards (following steps S102 and S103), a rolled strip of insulating film 502 is spirally wound around the outer periphery of the bundled wires 501 and covered (step S104). Step S104 is the covering process. Then, with the bundled wires 501 covered by the insulating film 502, a crushing process is performed to shape the cross-section into a predetermined shape (e.g., a quadrilateral) (step S105). This forms the conductor material CR. Alternatively, the crushing process can be performed after the bundling process of the wires 501.

[0255] Then, as described 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 using a bobbin 602. Step S106 is the winding process. Furthermore, the straightness of the wire 501 is maintained from the time the wire 501 is straightened until it is wound to form the stator winding 61 (steps S102 to S106). That is, the manufacturing line is formed in such a way that it is not wound onto a cylindrical bobbin again after the conductor material CR is formed.

[0256] In the first embodiment, a partial winding 151 is formed by winding the conductor material CR as described above. Furthermore, as explained in the first embodiment, the stator winding 61 is composed of multiple partial windings 151. In the stator winding 61 of the first embodiment, the partial windings 151 of each coil module 150 for each phase are connected in parallel via the bus module 200, thereby forming the phase windings for each phase.

[0257] Furthermore, in the first embodiment, the connection terminals 202 of the bus module 200 are provided in the same number as the winding ends 154, 155 of each partial winding 151 in the coil module 150, and each of the connection terminals 202 is connected to one winding end 154, 155 of each partial winding 151. Therefore, there is a problem that the connection process requires considerable effort. Therefore, in this modified example 2, the bus module 200 is omitted and configured as follows. Furthermore, in modified example 2, as... Figure 45 As shown, the stator unit 700 with an internal rotor structure will be used as an example for explanation.

[0258] In variation example 2, such as Figure 45 As shown, the partial windings 701A and 701B are arranged at predetermined intervals in the circumferential direction. Partial winding 701A has a structure that is substantially the same as that of partial windings 151A and 311A ​​mentioned above. In addition, partial winding 701B has a structure that is substantially the same as that of partial windings 151B and 311B mentioned above. Hereinafter, they are collectively referred to as partial windings 701.

[0259] Furthermore, the winding ends 702 of the multiple partial windings 701 are collectively connected to the neutral point or the input / output terminals of the power conversion device. To explain in more detail, the winding ends 702 of the multiple partial windings 701 connected in parallel with each phase are concentrated at a connection point defined for each phase, and are collectively connected to the input / output terminals of an inverter (not shown).

[0260] Specifically, the winding end 702a of the U-phase portion of winding 701 is led out from the portion of winding 701, converged and collected at the designated connection point P11, and connected to the input / output terminals of the inverter. The winding end 702b of the V-phase portion of winding 701 is led out from the portion of winding 701, converged and collected at the designated connection point P12, and connected to the input / output terminals of the inverter. The winding end 702c of the W-phase portion of winding 701 is led out from the portion of winding 701, converged and collected at the designated connection point P13, and connected to the input / output terminals of the inverter. Similarly, the winding end 702d of the portion of winding 701 connected to the neutral point is converged and collected at the designated connection point P14, and connected to the neutral point.

[0261] Connection points P11 to P14 are arranged at predetermined intervals in the circumferential direction. In addition, connection points P11 to P14 are located at different positions in the axial direction.

[0262] Furthermore, in order to bring together the ends 702a to 702d of each winding at connection points P11 to P14, the lap joint 703 connecting each part of the winding 701 to the ends 702a to 702d is held by an annular bobbin 704. The bobbin 704 is axially positioned near the end of the coil with the rotation axis 11 as its center.

[0263] The bobbin 704 has: a first bobbin 704a that holds the lap line 703 of the U phase; a second bobbin 704b that holds the lap line 703 of the V phase; a third bobbin 704c that holds the lap line 703 of the W phase; and a fourth bobbin 704d that holds the lap line 703 connected to the neutral point.

[0264] The first spool 704a to the fourth spool 704d are made of annular resin plates and are stacked at predetermined intervals in the axial direction. In addition, the first spool 704a to the fourth spool 704d are made of approximately the same size and are arranged around the rotation axis 11.

[0265] Multiple grooves are formed on the surfaces of the first to fourth spindles 704a and 704d, and an overlap line 703 is disposed and held in each groove. In addition, it is desirable that the longer the overlap line 703 is, the more radially inward it is disposed in the groove.

[0266] The connection method of the winding ends 702a to 702d, which are concentrated at connection points P11 to P14, will be described below. Hereinafter, the winding end 702a of the U phase, which is concentrated and summarized at connection point P11, will be used as an example for description, but the winding ends 702b to 702d, which are concentrated and summarized at connection points P12 to P14, are the same.

[0267] like Figure 46 As shown in (c), the winding ends 702a of the U phase, concentrated and connected at connection point P11, are arranged in a row. When multiple winding ends 702a are arranged in a row, they are arranged such that the planar portions are aligned on at least one side of each winding end 702a in an orthogonal direction orthogonal to the extension direction of the conductor material CR and the arrangement direction. The extension direction of the conductor material CR is in... Figure 46 In (c), the direction is perpendicular to the paper.

[0268] In this embodiment, the cross-sectional shape of the conductor material CR is square. Therefore, in this modified example 2, when the multiple winding ends 702a are arranged in a row, the upper surface 722 and lower surface 723 of the winding ends 702a are aligned by arranging the side surfaces 721 of the winding ends 702a to overlap each other. Through the aligned upper surface 722 and lower surface 723, a planar portion along the arrangement direction is formed on both sides of each winding end 702a in the orthogonal direction.

[0269] Furthermore, a four-corner annular conductor retaining member 710 is installed to cover the multiple winding ends 702a arranged in this manner. That is, the conductor retaining member 710 is installed in a way that clamps and holds the multiple winding ends 702a arranged in a row on both sides in the orthogonal direction. In this modified example 2, the conductor retaining member 710 is made of a conductive metal. Alternatively, the conductor retaining member 710 may also be a conductive strip. Alternatively, welding additives may be welded to the winding ends 702a to form the conductor retaining member 710. Alternatively, the conductor retaining member 710 may be formed as a clip that clamps in from the orthogonal direction.

[0270] In this consolidated state, multiple winding ends 702a are connected to the input / output terminals of phase U via wire holding members 710. Furthermore, winding ends 702d connected to the neutral point are connected to the neutral point via wire holding members 710.

[0271] Furthermore, the winding end 702a, i.e., the conductor material CR, is covered by a relatively thick insulating film 502. Therefore, it is necessary to remove the insulating film 502 to connect it to the conductor holding member 710. However, removing all the insulating film 502 covering the circumferential surface of the winding end 702a is time-consuming. Therefore, when the winding ends 702a are arranged in a row, the insulating film 502 on at least one side of each winding end 702a is removed in an orthogonal direction orthogonal to the arrangement direction. In this modified example 2, the insulating film 502 on the upper surface 722 of each winding end 702a is removed.

[0272] The connection method of each winding end 702a is described in detail below. First, as... Figure 46 As shown in (a), when the winding ends 702a, which are corners, are arranged in a row, the upper surface 722 and the lower surface 723 are aligned along the arrangement direction by overlapping the side surfaces 721 without gaps.

[0273] In this state, the insulating film 502 on the upper surface 722 of the winding ends 702a arranged in a row is completely removed, exposing the wire 501 (see reference). Figure 46 (b)). At this time, by cutting along the arrangement direction, it is possible to maintain the plane while removing the insulating film 502 of all winding ends 702a.

[0274] Then, as Figure 46 As shown in (c), the wire holding member 710 is installed in such a way that it covers the ends 702a of the multiple windings arranged in a row. That is, the wire holding member 710 clamps and fixes the ends 702a of the multiple windings arranged in a row from both sides of their orthogonal direction.

[0275] Furthermore, the wire 501 is covered by a fusion layer 504, but it is thin enough compared to the insulating film 502 and melts at a lower temperature than the insulating film 502. Alternatively, it may have a higher dielectric constant. Therefore, when or after mounting the wire holding member 710 to the ends 702a of the plurality of windings, heat is applied to melt the fusion layer 504 and connect it to the wire holding member 710.

[0276] According to this modified example 2, the following effects are achieved.

[0277] The winding ends 702a to 702d of multiple partial windings 701 are concentrated at predetermined connection points P11 to P14 and connected collectively to the neutral point or the input / output terminals of the power conversion device. This allows for the aggregation of the connection points of the winding ends 702a to 702d, reducing the effort required for connection compared to the case where each winding end 702a to 702d is connected to the bus module 200 individually, as in the first embodiment.

[0278] Multiple winding ends 702a to 702d, concentrated at connection points P11 to P14, are arranged in a row. Then, in an orthogonal direction, the insulating film 502 on one side of the upper surface 722 of one of the two sides of the winding ends 702a to 702d is removed. Furthermore, a conductive wire holding member 710 is connected to the side of the upper surface 722 where the insulating film 502 has been removed. Then, the combined winding ends 702a to 702d are connected to the neutral point or input / output terminals.

[0279] In this way, since the upper surfaces 722 of the connected winding ends 702a to 702d are aligned, the number of connections can be reduced compared to connecting the winding ends 702a to 702d separately. Furthermore, since the insulating film 502, which serves as the connection point, is removed, connections can be easily made even if the conductor material CR is covered by a thicker insulating film 502. Additionally, when the insulating film 502 is removed, the alignment of the upper surfaces 722 facilitates processing.

[0280] The conductor materials CR are insulated from each other by an insulating film 502. On the other hand, although the conductors 503 of the wire 501 are covered by a fusion layer 504, since there is no insulating layer, the conductors 503 may sometimes come into contact and conduct electricity. However, the potential difference between the conductors 503 is small, and even if the fusion layer 504 breaks when multiple wires 501 are bundled or covered with the insulating film 502, the contact area between the conductors 503 is very small, resulting in a very high contact resistance. Therefore, even without complete insulation, the flow of eddy currents between the conductors 503 can be suppressed.

[0281] Therefore, instead of providing an insulating layer on the surface of the conductor 503, a fusion layer 504 is directly provided on the conductor 503 and fused together with each other. This eliminates the need for an insulating layer. Furthermore, by providing the fusion layer 504, it is easy to maintain the bundled state of multiple wires 501, making it easy to cover them with the insulating film 502. This facilitates the manufacture of the wire material CR and the rotary motor 10. Additionally, since the insulating layer of the wires 501 is omitted, the duty cycle of the conductor 503 can be increased.

[0282] In addition, since the fusion layer 504 is formed thinner than the insulating film 502 and melts at a lower temperature, the conductor 503 can be easily connected even if the fusion layer 504 is not peeled off and only the insulating film 502 is removed.

[0283] It includes a conductor holding member 710 that clamps and holds the ends 702a to 702d of multiple windings arranged in a row on both sides in an orthogonal direction. As a result, the winding ends 702a to 702d can be stably held and the connection can be prevented from falling off.

[0284] The conductor material CR is composed of angled wires with aligned upper surfaces 722, and the connection is made via these upper surfaces 722. This increases the contact area compared to round wires, allowing for stable holding of the winding ends 702a to 702d and preventing the connection from coming loose.

[0285] The insulating film 502 on one side of the upper surface 722 of the winding ends 702a to 702d is removed, and the wire 501 is exposed while connected to the conductor retaining member 710. As a result, the connection is more difficult to detach than when the insulating film 502 remains.

[0286] The insulating film 502 is formed in a strip shape and is spirally wound around the outer periphery of the bundled wires 501. Since the insulating film 502 is wound around the multiple wires 501 to form the conductor material CR, the insulating film 502 can be made thinner compared to cases where the multiple wires 501 are resin-molded. Furthermore, since the wires are fused together via the fusion layer 504, the wires 501 can maintain their shape in a bundled state, making it easy to wind the strip-shaped insulating film 502.

[0287] Unlike conventional processes that form films through extrusion, the insulating film 502 is rolled, allowing it to be thinned and work-hardened simultaneously. Therefore, when the stator winding 61 is formed by winding the conductor material CR, the insulating film 502 will not crack. That is, the insulating film 502, acting as a reinforcing strip, can withstand the forces inherent in the dividing lines that cause the segmented wires 501 to move irregularly when bent, potentially damaging the insulating film 502. In contrast, films formed through extrusion are prone to cracking. Furthermore, because the insulating film 502 can be thinned, the occupancy factor of the conductor 503 relative to the stator winding 61 can be increased.

[0288] In the covering process of step S104, when the insulating film 502 is wound relative to the outer periphery of the bundled wires 501, it is wound in a spiral shape such that the insulating films 502 overlap. This prevents foreign matter such as dust and water from reaching the wires 501 from the outside through the gaps between the insulating films 502. Furthermore, because the insulating films 502 overlap, gaps are less likely to occur even when winding the conductor material CR to form the stator winding 61. Additionally, gaps between the wires 501 cannot be properly electrodeposited or enamel coated, and bubbles may form; however, this problem is solved by using the strip-shaped insulating film 502.

[0289] After the conductor material CR is formed (after the covering process), when the conductor material CR is wound on the spool 601, the conductor material CR drawn from the spool 601 will bend, resulting in a slight straightness deviation, which hinders the improvement of the duty cycle. That is, when the conductor material CR is wound on the spool, there is a technical problem specific to the dividing line, such as the different stretching of the inner and outer wires of the spool 601. Specifically, only the outer wire of the spool 601 is stretched. Moreover, when the conductor material CR stretched only on the outer side is drawn from the spool 601 to form the stator winding 61, since a portion becomes contracted, the conductor material CR becomes wavy. When it is wound to form the stator winding 61, gaps will be generated between the conductor materials CR, which hinders the improvement of the duty cycle and increases copper losses.

[0290] Therefore, in the assembly process of step S101, pressure is applied to the multiple wires 501 in a bundled state to straighten them. After the assembly process, before the conductor material CR is wound to form the stator winding 61 in the winding process of step S106, each wire 501 is maintained in a straight shape. Therefore, compared with the case where the conductor material CR is wound again on the cylindrical spool 601, the straightness of the conductor material CR can be improved. That is, it is less likely that the straightness of the conductor material CR will deviate due to the difference in curvature between the outer and inner circumferences when winding the conductor material CR onto the spool 601, thereby reducing the likelihood of wavy deformation. Therefore, when the conductor material CR is wound to form the stator winding 61, gaps are less likely to form between the conductor materials CR, thereby improving the duty cycle.

[0291] The insulating film 502 is configured to be thicker than the fused layer 504. 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.

[0292] (Another example of variation 2)

[0293] The structure of the conductor material CR and the stator winding 61 in Modification 2 can also be modified as described 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.

[0294] In the above embodiment, the winding end 702a, which is the U-phase, is concentrated at one connection point P11, but it can also be concentrated at multiple locations. Similarly, the winding ends 702b and 702c, which are the V-phase and W-phase, can also be concentrated at multiple locations and then connected to the input / output terminals. Likewise, the winding end 702d, which is connected to the neutral point, can also be concentrated at multiple locations and then connected to the neutral point.

[0295] In the above embodiment, the insulating film 502 on the upper surface 722 is completely removed, but it may not be completely removed, but rather removed in a way that makes it thinner than other parts. Alternatively, the insulating film 502 at the connection portion (upper surface 722 in modified example 2) may be formed thinner beforehand. Alternatively, it may be thinned by melting.

[0296] In the above embodiment, the insulating film 502 on both sides of the orthogonal direction of the winding ends 702a to 702d, namely the upper surface 722 and the lower surface 723, can be made thinner or removed. This allows for a reliable connection.

[0297] • In the above embodiment, the winding ends 702a to 702d may also be arranged in two rows. In this case, it is necessary to make the insulating film 502 of the upper surface 722 of the winding ends 702a to 702d of the first row located on both sides of the orthogonal direction thinner or remove it for connection.

[0298] In the above embodiment, when cutting the insulating film 502, a portion of the wire 501 can also be cut at the same time. This allows for more reliable removal of the insulating film 502.

[0299] In the above embodiments, the bonding line 703 may not be held by the spool 704. For example, it may be resin molded. Furthermore, the shape and structure of the spool 704 can be arbitrarily changed. For example, as... Figures 47 to 49 As shown, it can also be composed of multiple components. Figures 47 to 49 In this process, components 800A and 800B, which are provided for each coil module, are combined to form a bobbin 801. Additionally, a bonding wire 703 is wired into... Figure 48 In the slot 802 of component 800A shown in (b). Then, using Figure 49 The cover 803 of component 800B shown in (b) covers the lap joint 703 of the wiring in the slot 802 from the radial outside.

[0300] In the modified example 2 described above, the linear expansion coefficient (linear expansion rate) of the fusion layer 504 can also be different from that of the insulating film 502. That is, as described above, the potential difference between the conductors 503 is small, and even if the fusion layer 504 breaks, the contact area between the conductors 503 is very small and the contact resistance is very large when multiple wires 501 are bundled or when the insulating film 502 is covered. Therefore, even without complete insulation, the flow of eddy currents between the conductors 503 can be suppressed. In addition, even if the fusion layer 504 breaks after manufacturing and the conductors 503 come into contact with each other, there is no problem. Therefore, any material with a linear expansion coefficient different from that of the insulating film 502 can be selected as the fusion layer 504, and the design becomes easier. For example, the linear expansion coefficient of the fusion layer 504 can also be made greater than that of the insulating film 502.

[0301] Alternatively, the linear expansion coefficient of the fusion layer 504 can be made smaller than that of the insulating film 502. When the linear expansion coefficient of the fusion layer 504 is smaller than that of the insulating film 502, the fusion layer 504 is less prone to cracking, and the contact area between the conductors 503 does not increase, thereby suppressing the increase of eddy current loss.

[0302] In the modified example 2 described above, the linear expansion coefficient (linear expansion rate) of the fusion layer 504 can also be the same as that of the insulating film 502. This allows for the suppression of simultaneous cracking of the fusion layer 504 and the insulating film 502.

[0303] In Modification 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 504 can also be different from that of the conductor 503. Furthermore, when the linear expansion coefficient (linear expansion rate) of the fusion layer 504 is between that of the conductor 503 and the insulating film 502, the fusion layer 504 acts as a buffer, thereby suppressing cracking of the insulating film 502.

[0304] • As the insulating film 502 in the above-described modified example 2, PA, PI, PAI, PEEK, etc. can also be used. In addition, as the fusion layer 504, fluorine, polycarbonate, silicon, epoxy resin, polyethylene naphthalate, LCP, etc. can also be used.

[0305] • In the above-described variation 2, a crushing process is provided. However, as long as the conductor 503 is a square wire and can be bundled without gaps, the crushing process can be omitted. Furthermore, when the conductor 503 is a round wire, it is desirable to provide a crushing process. The crushing process can be performed after bundling the wires 501, but it can also be performed before bundling the wires 501, with each wire 501 having a square cross-sectional shape.

[0306] In the above-described variation 2, the cross-sectional shape of the conductor 503 can be any one of hexagonal, pentagonal, quadrilateral, triangular, and circular, and the cross-sectional shape of the wire material CR can also be any one of hexagonal, pentagonal, quadrilateral, triangular, and circular. Furthermore, the shapes of the conductor 503 and the fusion layer 504 do not need to be completely identical; a crushing process or similar procedure can be used to make part or all of the shapes of the conductor 503 or the fusion layer 504 different. Additionally, a crushing process can also be used to deform the shape of part or all of the conductor 503 or the fusion layer 504.

[0307] In the above-described variation 2, the conductor 503 of the wire 501 can also be configured as a composite consisting of bundled finer fibrous conductive components. For example, the conductor can be a composite of CNT (carbon nanotube) fibers. As CNT fibers, fibers including boron-containing microfibers in which at least a portion of the carbon is replaced by boron can also be used. Besides CNT fibers, vapor-grown carbon fibers (VGCF) can also be used as carbon microfibers, but CNT fibers are preferred.

[0308] In the modified example 2 described above, the conductor material CR can also be formed by twisting together multiple wires 501. In this case, the generation of eddy currents in each wire 501 can be further suppressed. Furthermore, by twisting together the wires 501, portions with opposite directions of magnetic field application are generated in a single wire 501, thereby canceling out the back electromotive force. Therefore, eddy currents can still be reduced. In particular, by using fibrous conductive components to form the wires 501, the wires can be made thinner and the number of twists can be greatly increased, thereby further ideally reducing eddy currents.

[0309] In the modified example 2 described above, the bond strengths of the conductor 503 and the fusion layer 504, the bond strengths of the fusion layer 504 and the insulating film 502, and the bond strengths of the sealing member and the insulating film 502 can also be different. For example, the bond strength can be configured such that the bond strength is weaker closer to the outer side. Furthermore, 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.

[0310] The disclosure of this specification is not limited to the illustrated embodiments. This disclosure includes illustrated embodiments and modifications made by those skilled in the art based thereon. For example, this disclosure is not limited to combinations of components and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. This disclosure may have additional portions that can be added to the embodiments. This disclosure includes embodiments in which components and / or elements of the embodiments are omitted. This disclosure includes substitutions or combinations of components and / or elements between one embodiment and another. The scope of the disclosed technology is not limited to the description of the embodiments. Several technical scopes of the disclosure should be understood to be expressed by the description of the claims, and also include all modifications within the meaning and scope of equivalence to the description of the claims.

[0311] Although this disclosure has been described based on embodiments, it should be understood that this disclosure is not limited to the above embodiments and structures. This disclosure also includes various modifications and equivalent variations. In addition, various combinations and methods, and further including only one element, one or more other combinations and methods, also fall within the scope and spirit of this disclosure.

Claims

1. A rotary electric machine including an armature having an armature winding of a plurality of phases, the armature winding having a plurality of partial windings formed by winding a wire, each of the partial windings being arranged in a circumferential direction at a prescribed interval, the winding end portions of the plurality of partial windings being concentrated at a predetermined connection site and collectively connected to a neutral point or input / output terminals of a power conversion device, the wire being configured to be covered by an insulating film in a state in which a plurality of wire members are bundled, the plurality of winding end portions concentrated at one of the connection sites being arranged in one or two rows, in an orthogonal direction orthogonal to the arrangement direction and orthogonal to the extending direction of the wire, the insulating film of at least either side of each of the winding end portions being formed thinner than other portions or being cut away, the plurality of winding end portions being connected to the neutral point or the input / output terminals via the portion where the insulating film is formed thinner or the portion where the insulating film is cut away, the wire member including a conductor through which a current flows and a fusion layer covering a surface of the conductor, the fusion layer being configured to be thinner than the insulating film, and in a state in which a plurality of wire members are bundled, the fusion layers contact and fuse with each other, the fusion layer melting at a lower temperature than the insulating film, and the fusion layer having a higher dielectric constant than the insulating film, and the fusion layer melting due to heat when the winding end portions are connected to the neutral point or the input / output terminals, a portion between the conductors of the fusion layer having a thickness smaller than a thickness of the insulating film.

2. The rotary electric machine according to claim 1, wherein the rotary electric machine includes a wire holding member that clamps and holds both sides in the orthogonal direction with respect to the plurality of winding end portions arranged in a row.

3. The rotary electric machine according to claim 1 or 2, wherein the wire is configured by an angular wire, in arranging the plurality of winding end portions, the arrangement is performed in a manner in which a flat portion is alignedly arranged in at least either side of each of the winding end portions in the orthogonal direction, the insulating film of the flat portion is formed thinner than other portions or is cut away, the plurality of winding end portions are connected to the neutral point or the input / output terminals via the flat portion.

4. The rotary electric machine according to claim 1 or 2, wherein the winding end portions are connected in a state in which the insulating film of at least either side of each of the winding end portions is cut away and the wire member is exposed in the orthogonal direction.

5. The rotary electric machine according to claim 4, wherein the winding end portions are connected in a state in which the insulating film of at least either side of each of the winding end portions is cut away and the wire member is exposed in the orthogonal direction.

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