Rotary motor

Abstract

A rotating electric motor includes: an armature winding (411) for each phase having a phase winding composed of a plurality of partial windings (451); and a winding support member (CB) disposed radially outside the armature winding and supporting the plurality of partial windings. Each partial winding has a pair of intermediate conductor portions and overlapping portions at one and the other ends in the axial direction, and the plurality of partial windings are arranged circumferentially such that the intermediate conductor portions are arranged circumferentially. In each partial winding, an insulating member (460) is mounted at the overlapping portion to achieve insulation between the partial windings. A support portion (465) is provided on the insulating member in a state of protrusion from the insulating member. The protruding portion of the support portion protruding from the insulating member is mechanically engaged with the winding support member.

Description

[0001] Citation of relevant applications

[0002] This application is based on Japanese Patent Application No. 2020-079443, filed on April 28, 2020, the contents of which are incorporated herein by reference. Technical Field

[0003] The disclosure in this specification relates to a rotary electric motor. Background Technology

[0004] Previously, a rotary electric motor was known, comprising: an excitation element including a magnet portion having multiple magnetic poles; and an armature having a multi-phase armature winding. Additionally, it is known to form the armature integrally into a cylindrical shape by winding the armature winding onto a positioning protrusion provided on a winding frame (see, for example, Patent Document 1).

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Implementation License No. 57-21243 Summary of the Invention

[0008] However, in the armature described in Patent Document 1, since the armature winding is directly wound onto the armature core, it is believed that this will result in undesirable conditions such as the increased size of the manufacturing equipment (flywheel, etc.) used for winding operations. For example, in an armature with a so-called non-pole tooth structure that does not have pole teeth, in other words, in an armature with a structure in which the armature winding is not wound relative to the pole teeth, there is room for improvement in the assembly of the armature winding.

[0009] This disclosure is made in view of the above circumstances, and its purpose is to provide a rotary electric machine in which the armature winding can be easily assembled.

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

[0011] Method 1 is a rotary electric motor, comprising:

[0012] The excitation element has multiple magnetic poles;

[0013] A multiphase armature winding, wherein each phase has a phase winding consisting of multiple partial windings; and

[0014] A winding support member is disposed on the radially inner or radially outer side of the armature winding, opposite to the excitation element, and supports the plurality of partial windings.

[0015] The aforementioned excitation element and the aforementioned armature winding are arranged to be radially opposite to each other.

[0016] The aforementioned partial winding includes: a pair of intermediate conductor portions extending axially and spaced apart circumferentially at predetermined intervals; and an overlapping portion disposed at one end and the other end axially, connecting the pair of intermediate conductor portions in a ring shape.

[0017] Multiple of the aforementioned partial windings are arranged circumferentially such that the aforementioned intermediate conductor portion is arranged circumferentially.

[0018] In the aforementioned partial windings, an insulating member is installed at the aforementioned overlapping portion to achieve insulation between the aforementioned partial windings.

[0019] A support portion is provided on the aforementioned insulating member, protruding from the insulating member.

[0020] The protruding portion of the support portion protruding from the insulating member is mechanically connected to the winding support member.

[0021] In the rotary electric motor with the above-described structure, a portion of the armature winding has a pair of intermediate conductor sections and an overlap section that connects the pair of intermediate conductor sections in a ring shape. Multiple portion windings are arranged circumferentially such that the intermediate conductor sections are arranged circumferentially. In this case, by assembling each portion winding to a winding support member, the armature winding can be assembled regardless of whether the armature has pole teeth. Furthermore, by installing insulating members at the overlap sections of the portion windings, the circumferentially arranged portion windings can be ideally insulated from each other.

[0022] Furthermore, in this structure, a bracket portion protruding from the insulating member is used to mechanically connect the bracket protruding from the insulating member to the winding support member. In this configuration, by using the mechanical connection of the bracket portion to mount a portion of the winding to the winding support member, the mounting of multiple portion windings relative to the winding support member can be performed simply and reliably. When using a winding machine or similar manufacturing apparatus to manufacture the armature, this manufacturing apparatus can be miniaturized. As a result, the assembly of the armature winding can be easily achieved.

[0023] The support portion is preferably an insulator integrally formed within the insulating member by means of embedding or bonding, thereby insulating some windings from each other. Furthermore, the support portion is preferably made of a material with higher strength than the insulating member, such as iron or steel.

[0024] Method 2 is based on Method 1, wherein the bracket portion has a bent portion that bends axially at the end of the insulating member on the side opposite to the protruding side in the radial direction, so that the bent portion is radially opposite to the overlapping portion, and the insulating member is provided therein.

[0025] In the above structure, a bent portion is provided at the end of the support portion on the radially opposite side of the protruding side, and this bent portion is radially opposite to the overlapping portion. In this case, the overlapping portion and the support portion can be radially engaged by the bent portion on the opposite side of the protruding side of the support portion, and in this state, the protruding portion of the support portion is used for mechanical engagement with the winding support member. The bent portion functions as a movement limiting portion that restricts the radial movement of the overlapping portion (partial winding). As a result, radial positional deviation of the partial winding can be suppressed, and the assembly state of each partial winding relative to the winding support member can be maintained in an appropriate state.

[0026] Method 3 is based on Method 2, in which the overlapping portion of the aforementioned partial winding is bent radially while overlapping the winding support member along the axial direction, so that the bent portion is radially opposite to the inner side of the radially protruding bent portion in the overlapping portion in the bent state, and the aforementioned insulating member is provided.

[0027] In a structure where the overlap portion of a partial winding is bent radially and overlaps with the winding support member axially, an insulating member is arranged at the axial end of the winding support member, overlapping it axially. In this structure, by making the bent portion of the support portion radially opposite the inner side of the bent portion of the overlap portion, the insulating member can be ideally mechanically engaged with the axial end of the winding support member.

[0028] Method 4 is based on Method 2 or Method 3, wherein the insulating member is arranged such that the support portion is sandwiched between two circumferentially separated conductor portions in the overlapping portion.

[0029] The overlap portion of the partial winding has two circumferentially separated conductor portions (i.e., conductor portions extending from each intermediate conductor portion toward the coil edge end side). With the support portion sandwiched between the conductor portions, the circumferential positional displacement of the overlap portion is restricted by the support portion. Therefore, according to the above structure, in addition to suppressing the radial positional displacement of the partial winding, the circumferential positional displacement can also be suppressed.

[0030] Method 5 is based on Methods 2 to 4, wherein the insulating member is an insulating cover that surrounds the overlapping portion from the axial and radial directions. The insulating cover includes a plurality of segmented cover members that are installed from the axial or radial directions relative to the overlapping portion, and the bracket portion is integrally provided in any of the plurality of segmented cover members.

[0031] In the overlapping portion of partial windings, to achieve insulation between the partial windings and insulation between the partial windings and the winding support members, it is desirable to provide an insulating cover that surrounds the overlapping portion axially and radially. In this case, by configuring the insulating cover to include multiple segmented cover members mounted axially or radially relative to the overlapping portion, the installation of the insulating cover relative to the overlapping portion can be easily implemented. Furthermore, by adopting a structure in which a support portion is integrally provided in any one of the multiple segmented cover members, the support portion can be installed simultaneously with the installation of each segmented cover member. Thus, it is possible to ideally provide an insulating cover that surrounds the overlapping portion axially and radially around its entire circumference.

[0032] Method 6 is based on any one of Methods 1 to 5, by arranging the intermediate conductor portion of one of the intermediate conductor portions of the partial winding of another phase between the pair of intermediate conductor portions of the partial winding of the above-mentioned partial winding, so that the intermediate conductor portions of each phase are arranged in a predetermined order along the circumference, and at the coil edge end of the armature winding, the overlapping portions of the partial windings of different phases overlap each other axially, and in the insulating members respectively installed on the overlapping portions along the axial direction, the protruding portions of the support portions provided on the insulating members overlap axially, and the protruding portions of the support portions in this overlapping state are connected to the winding support members by a connecting member.

[0033] In the armature winding with the above structure, each circumferentially arranged partial winding is configured with a portion overlapping circumferentially, and at the coil edge ends, the overlapping portions of the partial windings of different phases overlap each other axially. In this case, in the insulating member installed at each overlapping portion, the protruding portions of each overlapping support portion are joined to the winding support member by a connecting member, thus allowing for simple installation of multiple partial windings relative to the winding support member. Furthermore, since the connecting member forms a heat transfer path between each support portion and the winding support member, the desired structure can also be achieved from the viewpoint of armature winding heat dissipation.

[0034] Method 7 is based on Method 6, in which the overlapping portion overlaps with the overlapping portion of the aforementioned different partial windings at one circumferential end and the other circumferential end along the axial direction in each of the aforementioned partial windings, and the combination of the two aforementioned partial windings connected by the aforementioned connecting member and the aforementioned winding support member is different at one axial end and the other axial end.

[0035] In a configuration where one intermediate conductor from a pair of intermediate conductors in another phase's partial winding is positioned between a pair of intermediate conductors in a partial winding, and the intermediate conductors of each phase are arranged in a predetermined circumferential order, it is conceivable that in each partial winding, the overlap portion overlaps axially with the overlap portions of different partial windings at one and the other circumferential ends. In this case, by making the combination of two partial windings joined by a connecting member and a winding support member different at one and the other axial ends, it is possible to connect adjacent partial windings among all circumferentially arranged partial windings while minimizing the required joint size relative to the winding support member. This reduces the manufacturing burden of the rotating electric machine.

[0036] Method 8 is based on Method 6 or Method 7, wherein the bracket portion has a bushing portion extending axially in the protruding portion protruding from the insulating member, and in the bracket portions that overlap axially, the bushing portions are joined to each other, and the connecting member is inserted into the hollow portion of each bushing portion. In this state, the bracket portions are joined to the winding support member by the connecting member.

[0037] In the above structure, bushings provided on the support sections are used to connect the bushings together axially, and the connecting members are inserted into the hollow portions of each bushing to connect the support sections. In this case, by connecting the bushings, the relative distance between the insulating members in the axial direction can be maintained at a constant level, while the insulating members are connected to the winding support members in an appropriate state.

[0038] Method 9 is based on any one of Methods 6 to 8, wherein the winding support member has a cooling section for cooling the armature winding, and the bracket section is connected to the axial end face of the winding support member through the connecting member.

[0039] In the above structure, the support portion of the insulating member is combined with the winding support member having a cooling portion. In this case, some of the heat generated in the winding is directly transferred to the vicinity of the cooling portion via the support portion, thereby improving the cooling performance of the armature winding.

[0040] Method 10 is based on Method 9, wherein the winding support member includes: an armature core, which is assembled on the radial inner side or radial outer side of the armature winding; and an armature retaining member, which is disposed on the opposite side of the armature winding in the radial inner and outer sides of the armature core, and has the cooling portion, wherein the support portion is connected to the axial end face of the armature retaining member through the connecting member.

[0041] As a winding support member, it is configured to include an armature core and an armature retaining member radially inner or outer of the armature core, and the support portion of the insulating member is joined to the armature retaining member located beyond the armature core by a connecting member. In this case, since it is not necessary to connect the connecting member relative to the armature core, it is not necessary to provide recesses or the like on the armature core for connecting the connecting member, and adverse conditions such as cogging torque can be suppressed.

[0042] Method 11 is based on Method 9 or Method 10, wherein the winding support member has a cylindrical portion and a base portion extending radially from the axial end of the cylindrical portion, the bracket portion is mechanically connected to the base portion of the winding support member, and the winding support member has an annular refrigerant passage in the cylindrical portion as the cooling portion, the refrigerant passage being provided within the range including the cylindrical portion and the base portion.

[0043] In the above structure, a refrigerant passage is provided in the winding support member within the area including the cylindrical portion and the base portion. Therefore, in the structure where the support portion and the base portion of the winding support member are mechanically combined, heat transfer from the support portion to the refrigerant passage of the winding support member can be ideally implemented.

[0044] Method 12 is based on any one of methods 1 to 10, wherein the winding support member has a cylindrical portion and a base portion extending radially from the axial end of the cylindrical portion, and the bracket portion is mechanically connected to the base portion of the winding support member.

[0045] In the above structure, since the radially extending base portion of the winding support member is configured as a connection point for mechanically engaging the support portion, this connection point is made easy, and the engagement of the support portion can be ideally achieved. Furthermore, in a structure formed by radially bending the overlap portion of a portion of the winding, it is preferable that the base portion and the overlap portion of the winding support member extend in the same radial direction and overlap axially. Attached Figure Description

[0046] The above-mentioned objects, other objects, features, and advantages of this disclosure will become clearer with reference to the accompanying drawings and the following detailed description. The accompanying drawings are described below.

[0047] Figure 1 This is a perspective view showing the overall rotary motor in the first embodiment.

[0048] Figure 2 This is a top view of a rotary electric motor.

[0049] Figure 3 This is a longitudinal sectional view of a rotating electric motor.

[0050] Figure 4 This is a cross-sectional view of a rotary electric machine.

[0051] Figure 5 This is an exploded view of a rotary electric motor.

[0052] Figure 6 This is a cross-sectional view of the rotor.

[0053] Figure 7 This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit.

[0054] Figure 8 This is a graph showing the relationship between the electrical angle of the magnet and the magnetic flux density in the embodiment.

[0055] Figure 9 This is a graph showing the relationship between the electric angle and magnetic flux density of the magnet in the comparative example.

[0056] Figure 10 This is a 3D view of the stator unit.

[0057] Figure 11 This is a longitudinal sectional view of the stator unit.

[0058] Figure 12 This is a three-dimensional view of the core assembly viewed from one axial side.

[0059] Figure 13 This is a three-dimensional view of the core assembly viewed from the other side of the axial direction.

[0060] Figure 14 This is a cross-sectional view of the iron core assembly.

[0061] Figure 15 This is an anatomical view of the iron core assembly.

[0062] Figure 16 It is a circuit diagram that shows the connection status of some windings in each phase of a three-phase circuit.

[0063] Figure 17 It is a side view showing the first coil module and the second coil module arranged horizontally and compared.

[0064] Figure 18 It is a side view showing the first and second windings arranged laterally and compared.

[0065] Figure 19 This is a diagram showing the structure of the first coil module.

[0066] Figure 20 yes Figure 19 Sectional view of line 20-20 in (a).

[0067] Figure 21 It is a three-dimensional diagram showing the structure of the insulating cover.

[0068] Figure 22 This is a diagram showing the structure of the second coil module.

[0069] Figure 23 yes Figure 22 Sectional view along line 23-23 in (a).

[0070] Figure 24 It is a three-dimensional diagram showing the structure of the insulating cover.

[0071] Figure 25 This is a diagram showing the overlapping positions of the thin film material when the coil modules are arranged circumferentially.

[0072] Figure 26 This is a top view showing the assembled state of the first coil module relative to the core assembly.

[0073] Figure 27 This is a top view showing the assembly state of the first and second coil modules relative to the core assembly.

[0074] Figure 28 It is a longitudinal sectional view showing the fixed state achieved by the fixing pin.

[0075] Figure 29 This is a 3D view of the busbar module.

[0076] Figure 30 It is a sectional view showing a portion of the longitudinal section of the busbar module.

[0077] Figure 31 It is a three-dimensional view showing the state of the busbar module assembled on the stator retainer.

[0078] Figure 32 This is a longitudinal sectional view of the fixed part that secures the busbar module.

[0079] Figure 33 This is a longitudinal sectional view showing the relay components assembled in the outer casing.

[0080] Figure 34 This is a 3D diagram of the relay components.

[0081] Figure 35 This is a circuit diagram representing the control system of a rotating electric machine.

[0082] Figure 36 This is a functional block diagram representing the current feedback control processing of the control device.

[0083] Figure 37 This is a functional block diagram representing the torque feedback control processing of the control device.

[0084] Figure 38This is a partial cross-sectional view showing the cross-sectional structure of the magnet unit in the modified example.

[0085] Figure 39 This is a diagram showing the structure of the stator unit with an internal rotor structure.

[0086] Figure 40 This is a top view showing the assembled state of the coil module relative to the core assembly.

[0087] Figure 41 This is a perspective view showing the overall stator unit in the second embodiment.

[0088] Figure 42 (a) is a top view of the stator unit, and (b) is a cross-sectional view of the stator unit.

[0089] Figure 43 This is a longitudinal sectional view of the stator unit.

[0090] Figure 44 It is an exploded 3D diagram that represents the core assembly and stator windings separately.

[0091] Figure 45 This is a longitudinal sectional view of the iron core assembly.

[0092] Figure 46 It is a three-dimensional diagram showing the structure of the coil module.

[0093] Figure 47 It is a three-dimensional diagram that represents the components of the coil module in an unconstructed manner.

[0094] Figure 48 (a) is Figure 46 (a) is a sectional view along line 48-48, and (b) is a sectional view.

[0095] Figure 49 (a) is Figure 46 (a) is a sectional view along line 49-49, and (b) is a dissected sectional view.

[0096] Figure 50 This is a 3D view of the support structure.

[0097] Figure 51 It is a three-dimensional diagram showing the positional relationship between a portion of the winding and the support section.

[0098] Figure 52 This is a top view showing the configuration of the three winding sections.

[0099] Figure 53 It is a diagram showing the specific structure of the combined components.

[0100] Figure 54 This is a top view showing the coil modules on the lower side arranged circumferentially.

[0101] Figure 55 This is a top view of the stator unit in the third embodiment.

[0102] Figure 56 This is a longitudinal sectional view of the stator unit.

[0103] Figure 57 It is an exploded 3D diagram that represents the core assembly and stator windings separately.

[0104] Figure 58 This is a 3D view of the coil module.

[0105] Figure 59 It is a three-dimensional diagram showing the positional relationship between a portion of the winding and the support section.

[0106] Figure 60 This is a top view showing the coil modules on the lower side arranged circumferentially.

[0107] Figure 61 This is a sectional view of the stator representing a modified example.

[0108] Figure 62 This is a sectional view of the stator representing a modified example.

[0109] Figure 63 This is a sectional view of the stator representing a modified example. Detailed Implementation

[0110] Hereinafter, several embodiments will be described with reference to the accompanying drawings. In several embodiments, sometimes functionally and / or structurally corresponding and / or related parts are labeled with the same reference numeral, or reference numerals differing by more than one hundred positions. For corresponding and / or related parts, please refer to the description of other embodiments.

[0111] The rotary motor in this embodiment is used as, for example, a vehicle power source. However, rotary motors can be widely used in industrial applications, vehicles, home appliances, office automation (OA) equipment, game consoles, and so on. Furthermore, in the following embodiments, the same or equivalent parts are labeled with the same symbols in the drawings, and descriptions of the parts with the same symbols are provided.

[0112] (First Implementation)

[0113] The rotary motor 10 in this embodiment is a synchronous multiphase AC motor with an external rotor structure (external rotation structure). Figures 1 to 5 An outline of the rotary motor 10 is shown. Figure 1 This is a three-dimensional view showing the entire rotary motor 10. Figure 2 This is a top view of the rotary motor 10. Figure 3 This is a longitudinal sectional view of the rotary motor 10. Figure 2 (3-3 line section view), Figure 4 This is a cross-sectional view of the rotary motor 10. Figure 3 (4-4 line sectional view) Figure 5 This is an exploded view showing the components of the rotary electric machine 10. In the following description, in the rotary electric machine 10, the direction in which the rotation shaft 11 extends is defined as the axial direction, the direction in which it extends radially from the center of the rotation shaft 11 is defined as the radial direction, and the direction in which it extends circumferentially around the rotation shaft 11 is defined as the circumferential direction.

[0114] The rotary motor 10 generally includes: a main body having a rotor 20, a stator unit 50, and a busbar module 200; and a housing 241 and a housing cover 242 provided to surround the main body. All of the above components are coaxially arranged with respect to a rotating shaft 11 integrally provided on the rotor 20, and are assembled axially in a predetermined order to constitute the rotary motor 10. The rotating shaft 11 is supported by a pair of bearings 12 and 13 respectively provided on the stator unit 50 and the housing 241, and is rotatable in this state. Furthermore, the bearings 12 and 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls disposed between the inner and outer rings. The rotation of the rotating shaft 11 causes, for example, the axle of a vehicle to rotate. The rotary motor 10 can be mounted in a vehicle by fixing the housing 241 to a vehicle body frame or the like.

[0115] In the rotary electric motor 10, a stator unit 50 is arranged to surround a rotating shaft 11, and a rotor 20 is disposed radially outside the stator unit 50. The stator unit 50 includes a stator 60 and a stator retainer 70 assembled radially inside it. The rotor 20 and the stator 60 are arranged radially opposite each other with an air gap between them, and the rotor 20 rotates integrally with the rotating shaft 11, thereby rotating radially outside the stator 60. The rotor 20 is equivalent to an "excitation element", and the stator 60 is equivalent to an "armature".

[0116] Figure 6 This is a longitudinal sectional view of rotor 20. (As shown) Figure 6As shown, the rotor 20 has a generally cylindrical rotor frame 21 and an annular magnet unit 22 fixed to the rotor frame 21. The rotor frame 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23. The rotor frame 21 is formed by integrating the cylindrical portion 23 and the end plate portion 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 facet engagement state, the rotor frame 21 is fixed to the rotating shaft 11.

[0117] 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".

[0118] 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.

[0119] 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.

[0120] In magnet 32, the radially inner (stator 60 side) circumferential surface is the flux-acting surface 34 for transmitting magnetic flux. Magnet unit 22 is configured to generate concentrated magnetic flux in the region near the d-axis, which serves as the center of the magnetic pole, at the flux-acting surface 34 of magnet 32. Specifically, 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, while 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 to be oriented 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] exist Figure 9 In 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.

[0127] 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 weak.

[0128] 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.

[0129] like Figure 3As 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.

[0130] 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.

[0131] 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."

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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).

[0136] (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.

[0137] (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.

[0138] (C) In the stator 60, there is no conductor inter-conductor member between the circumferential conductor portions (intermediate conductor portion 152).

[0139] 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).

[0140] 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 13In 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.

[0141] 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.

[0142] like Figure 14 As shown, when the outer cylinder member 71 and the inner cylinder member 81 are assembled together, an annular gap is formed between the inner circumferential surface of the outer cylinder member 71 and the outer circumferential surface of the inner cylinder member 81. This gap space serves as a refrigerant passage 85 for the flow of refrigerant such as cooling water. The refrigerant passage 85 is arranged annularly in the circumferential direction of the stator retainer 70. More specifically, a passage forming portion 88 is provided in the inner cylinder member 81. The passage forming portion 88 protrudes radially inward from the inner circumferential side of the inner cylinder member 81, and an inlet-side passage 86 and an outlet-side passage 87 are formed therein. Each passage 86 and 87 opens onto the outer circumferential surface of the inner cylinder member 81. In addition, a partition portion 89 is provided on the outer circumferential surface of the inner cylinder member 81 to separate the refrigerant passage 85 into an inlet side and an outlet side. 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.

[0143] 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.

[0144] 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.

[0145] 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 ).

[0146] 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.

[0147] 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.

[0148] 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.

[0149] Therefore, in this embodiment, in the structure where the stator core 62 and the stator retainer 70 are fitted and fixed together with a predetermined interference fit, a limiting portion is provided in the radially opposite portions of the stator core 62 and the stator retainer 70. This limiting portion restricts the circumferential displacement of the stator core 62 through circumferential engagement. That is, as... Figures 12-14 As shown, in the radial direction, a plurality of engaging members 111, serving as limiting portions, are provided at predetermined intervals 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.

[0150] 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.

[0151] 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.

[0152] 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.

[0153] 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.

[0154] 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.

[0155] In the stator winding 61, each phase winding has multiple partial windings 151 (see reference). Figure 16 Furthermore, 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.

[0156] 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.

[0157] 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.

[0158] 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."

[0159] Figure 17 This is a side view showing the first coil module 150A and the second coil module 150B arranged horizontally and compared. Figure 18 This 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.

[0160] Next, the structure of coil modules 150A and 150B will be explained in detail.

[0161] 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).

[0162] 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.

[0163] 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.

[0164] 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 11 The 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.

[0165] 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".

[0166] 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.

[0167] 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.

[0168] 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.

[0169] 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).

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] Next, the structure of insulating covers 161 and 162 will be described.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] Supplementary description of the recess 177 of the insulating cover 161. For example... Figure 20As 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.

[0180] 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.

[0181] 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.

[0182] 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.

[0183] Next, the second coil module 150B will be described.

[0184] 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).

[0185] 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.

[0186] 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.

[0187] 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.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] Next, the structure of insulating covers 163 and 164 will be explained.

[0193] 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.

[0194] 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.

[0195] 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.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] 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.

[0202] Next, the structure related to the assembly of each coil module 150A, 150B relative to the core assembly CA will be described.

[0203] 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.

[0204] Figure 26 This is a top view showing the state in which multiple insulating covers 161 are 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.

[0205] 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.

[0206] 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.

[0207] 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.

[0208] 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.

[0209] 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.

[0210] 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.

[0211] 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.

[0212] 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.

[0213] 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.

[0214] 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.

[0215] Next, the bus module 200 will be described.

[0216] 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.

[0217] 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.

[0218] 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.

[0219] 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.

[0220] 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.

[0221] 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.

[0222] 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).

[0223] 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.

[0224] 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.

[0225] 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 .

[0226] 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.

[0227] 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.

[0228] 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.

[0229] 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.

[0230] 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).

[0231] Next, the relay member 230 that electrically connects the input / output terminals 203 of the bus module 200 to an external device outside the rotary motor 10 will be described.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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.

[0237] 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.

[0238] 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.

[0239] 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.

[0240] 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.

[0241] 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.

[0242] 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.

[0243] Figure 36 This is a block diagram representing the current feedback control process that controls the current of each phase (U, V, and W).

[0244] 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.

[0245] 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.

[0246] 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.

[0247] 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.

[0248] 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.

[0249] 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.

[0250] Figure 37 This is a block diagram representing the torque feedback control processing corresponding to phases U, V, and W.

[0251] 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.

[0252] 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.

[0253] 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.

[0254] The operation signal generation unit 285 generates operation signals for the inverter 260 based on voltage amplitude commands, voltage phase commands, and electrical angle θ. Specifically, the operation signal generation unit 285 calculates the command voltages for the three phases based on the voltage amplitude commands, voltage phase commands, and electrical angle θ. It then generates switching operation signals for the upper and lower arms of each phase through PWM control based on a signal that normalizes the calculated three-phase command voltages using the power supply voltage and a carrier signal such as a triangular wave signal. The switching operation signals generated by the operation signal generation unit 285 are output to the driver 263 of the inverter 260, and the driver 263 turns the switches 261 and 262 of each phase on and off.

[0255] 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.

[0256] (Modified Example)

[0257] Hereinafter, variations related to the first embodiment described above will be described.

[0258] The structure of the magnet 32 ​​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 linear magnetic circuit is formed along the direction of this easy magnetization axis. That is, the magnet 32 ​​is configured such that, between the magnetic flux action surface 34a on the stator 60 side (radially inner side) and the magnetic flux action surface 34b on the opposite side of the stator (radially outer side), the direction of the easy magnetization axis is inclined relative to the d-axis, and is linearly oriented such that it is close to the d-axis on the stator 60 side in the circumferential direction and far away from the d-axis on the opposite side of the stator. In this structure, the length of the magnetic circuit of the magnet 32 ​​can be longer than the radial thickness dimension, and an increase in magnetic permeability can be achieved.

[0259] • A Hellbeck array magnet can also be used in magnet unit 22.

[0260] 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.

[0261] • 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.

[0262] 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.

[0263] • 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.

[0264] • 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.

[0265] 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.

[0266] 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.

[0267] 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.

[0268] 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.

[0269] 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.

[0270] 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.

[0271] • 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.

[0272] (Second Implementation)

[0273] Next, the rotary motor in the second embodiment will be described. The rotary motor in this embodiment is an internal rotor type surface magnet rotary motor, which includes: a rotor (excitation element) having multiple magnetic poles with alternating polarity along the circumferential direction; and a stator (armature) having multi-phase stator windings, wherein the rotor is rotatably supported on the radially inner side of the stator.

[0274] The structure of the stator unit 400 constituting the stator 410 of this embodiment will be described in detail below.

[0275] Figure 41 This is a three-dimensional view showing the entire stator unit 400. Figure 42 (a) is a top view of stator unit 400. Figure 42 (b) is a cross-sectional view of stator unit 400. Figure 43 This is a longitudinal sectional view of stator unit 400. Figure 44 This is an exploded perspective view showing the core assembly CB and stator winding 411 separated within stator unit 400. Additionally, Figure 43 Is it through Figure 42 A sectional view at line 43-43 of the stator center point C in (a).

[0276] In summary, the stator unit 400 has a stator 410 and a stator retainer 420 extending radially outward therefrom. The stator 410 also has a stator winding 411 and a stator core 412. Furthermore, the stator core 412 and the stator retainer 420 are integrated into a core assembly CB, and multiple partial windings 451 constituting the stator winding 411 are assembled to this core assembly CB. The stator winding 411 corresponds to an "armature winding," the stator core 412 corresponds to an "armature core," and the stator retainer 420 corresponds to an "armature retaining member." Additionally, the core assembly CB corresponds to a "winding support member."

[0277] exist Figure 43 In the diagram, the rotor 430, located radially inside the stator 410, is represented by an imaginary line. The rotary electric motor MG is configured to include the stator 410 and the rotor 430. The rotor 430 is capable of rotating integrally with the rotation shaft 431. The rotor 430 has the same structure as the rotor 20 described in the first embodiment, and therefore will be described simply here.

[0278] The rotor 430 has a rotor frame fixed to the rotation shaft 431 as a magnet holding member and an annular magnet unit fixed to the rotor frame as a magnet part. However, in this embodiment, since it has an inner rotor structure, the magnet unit is fixed to the radially outer side of the rotor frame. In the magnet unit, the magnet has multiple magnetic poles along the circumferential direction, and more specifically, multiple magnets are arranged in a manner in which the polarity alternates along the circumferential direction of the rotor. The magnet unit is configured to generate magnetic flux in a concentrated manner in the region near the d-axis, which is the center of the magnetic pole, at the magnetic flux action surface of the magnet. Specifically, in the magnet, the directions of the easy magnetization axis on the d-axis side and the q-axis side are different. 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 (see reference). Figure 7In the rotating electric machine MG, the stator winding 411 and the magnetic units of the rotor 430 are radially opposite each other, and an air gap is formed between them.

[0279] The core assembly CB is described. Figure 45 This is a longitudinal sectional view of the core assembly CB. Additionally, with... Figure 43 Similarly, Figure 45 yes Figure 42 A sectional view at line 43-43 of (a).

[0280] like Figure 44 and Figure 45 As shown, the core assembly CB has a bottomed cylindrical stator retainer 420 and a cylindrical stator core 412 assembled on the inner circumferential side of the stator retainer 420. The stator core 412 is configured as a core body laminate formed by stacking iron chips made of electromagnetic steel plates as magnetic bodies in the axial direction. A stator winding 411 is assembled on the radially inner side of the stator core 412, which is the rotor side. The stator core 412 does not have pole teeth (the concavity and convexity of the inner circumferential surface) and functions as a back yoke. The stator core 412 of this embodiment can have the same structure as the stator core 62 of the first embodiment, and the same applies to the slotless structure.

[0281] like Figure 45 As shown, the stator retainer 420 has: a cylindrical portion 421; a bottom 422 disposed on one axial end of the cylindrical portion 421; and an annular flange 423 disposed on the other axial end of the cylindrical portion 421 and extending radially outward. A through hole 424 is provided in the bottom 422 for insertion of a rotating shaft 431 integrally disposed on the rotor 430. The stator retainer 420 is preferably made of, for example, a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP). Furthermore, the bottom 422 and the flange 423 respectively correspond to the "base portion".

[0282] Furthermore, a refrigerant passage 425 for circulating refrigerant such as cooling water is formed in the cylindrical portion 421 of the stator retainer 420 as a cooling section. The refrigerant passage 425 is arranged annularly in the circumferential direction of the stator retainer 420; details are not shown, but it is configured such that refrigerant flows in from the inlet, flows circumferentially through the refrigerant passage 425, and then flows out from the outlet. Figure 45 In the illustrated structure, a refrigerant passage 425 is provided within the area including the cylindrical portion 421 of the stator retainer 420 and the bottom portion 422. However, the refrigerant passage 425 may also be further provided within the area including the flange 423. The refrigerant passage 425 is preferably provided at least in the cylindrical portion 421, and more specifically, at a position that forms the radial outer side of the stator core 412.

[0283] like Figure 45As shown, recesses 427 and 428 for fixing the plurality of coil modules 450 described later are formed in the stator retainer 420. Specifically, a plurality of recesses 427 are formed at equal intervals along the circumferential direction in the flange 423 of the stator retainer 420. In addition, a plurality of recesses 428 are formed at equal intervals along the circumferential direction in the bottom 422 of the stator retainer 420. The recesses 427 and 428 are arranged on an imaginary circle concentric with the core assembly CB. In this embodiment, the number of recesses 427 and 428 is set to half the number of coil modules 450, but it may also be the same as the number of coil modules 450.

[0284] Next, the structure of the stator winding 411 assembled into the core assembly CB will be described in detail. For example... Figures 41-43 As shown, the stator winding 411 is assembled to the core assembly CB in the following state: multiple partial windings 451 constituting the stator winding 411 are assembled in a circumferential arrangement on the radial inner side of the core assembly CB, that is, on the radial inner side of the stator core 412.

[0285] The stator winding 411 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 411 has three phase windings by using phase windings of phase U, phase V and phase W.

[0286] In the stator winding 411, each phase winding has multiple partial windings 451, and each partial winding 451 is individually configured as a coil module 450. That is, the coil module 450 is constructed by integrating the partial windings 451 of each phase winding, and the stator winding 411 is constructed using a predetermined number of coil modules 450 corresponding to the number of poles. The coil modules 450 (partial windings 451) of each phase are arranged in a predetermined order along the circumferential direction, thereby arranging the conductor portions of each phase in a predetermined order at the coil side CS of the stator winding 411. Figure 44 A structure in which multiple coil modules 450 are arranged circumferentially is shown. In this embodiment, the number of magnetic poles is set to 24, but this number can be arbitrary. In the stator winding 411, portions of the windings 451 of each coil module 450 for each phase are connected in parallel or in series to form the phase windings of each phase.

[0287] like Figure 43As shown, the stator 410 has an axial portion corresponding to the coil side CS, which is radially opposite to the stator core 412, and a portion corresponding to the axially outer side of the coil side CS, i.e., the coil edge end CE. The coil side CS is also the portion radially opposite to the magnet unit of the rotor 430. The coil module 450 is assembled radially inside the stator core 412. In this case, the coil module 450 is assembled with its axially end portions protruding further axially outward than the stator core 412 (i.e., the coil edge end CE side).

[0288] All coil modules 450 for the stator winding 411 are constructed in the same manner and arranged circumferentially in a state of being staggered by two layers in the axial direction. In this embodiment, as a partial winding 451, a winding with radial bending directions at the coil edge ends CE on both sides of the axial direction is used. At one end of the axial direction, the coil edge end portion (overlap portion) of the partial winding 451 is bent radially inward, and at the other end of the axial direction, the coil edge end portion (overlap portion) of the partial winding 451 is bent radially outward. That is, the partial winding 451 has a generally Z-shaped appearance when viewed from the side.

[0289] In the stator winding 411, each of the N coil modules 450 used in the stator winding 411 has N / 2 coil modules arranged in two layers in the axial direction. In this embodiment, the 12 coil modules 450 are divided into two groups of six, and the coil modules 450 in each group are assembled in two layers in the axial direction.

[0290] Figure 46 This is a 3D view showing the structure of coil module 450. Figure 47 It is a three-dimensional view showing the components of the coil module 450 disassembled.

[0291] like Figure 46 and Figure 47 As shown, the coil module 450 has: a partial winding 451 formed by winding multiple layers of conductor material CR; and insulating covers 460 and 470 installed on one axial end and the other axial end of the partial winding 451.

[0292] Partial winding 451 includes: a pair of intermediate conductor portions 452 arranged parallel to each other in a straight line; and a pair of overlapping portions 453, 454 connecting the pair of intermediate conductor portions 452 at their respective axial ends, forming a ring shape through the pair of intermediate conductor portions 452 and the pair of overlapping portions 453, 454. The pair of intermediate conductor portions 452 are arranged apart by a predetermined coil spacing, and intermediate conductor portions 452 of other phase partial windings 451 can be arranged circumferentially between the pair of intermediate conductor portions 452. In this embodiment, the pair of intermediate conductor portions 452 are arranged apart by two coil spacings, and an intermediate conductor portion 452 of another two phase partial windings 451 is arranged between each pair of intermediate conductor portions 452.

[0293] The overlapping portions 453 and 454 on both sides of the axial direction are configured to correspond to the coil edge end CE (refer to...). Figure 43 The portions 453 and 454 are formed by bending in opposite directions radially. Each overlapping portion 453 and 454 is configured to bend in a direction orthogonal to the intermediate guide portion 152, i.e., orthogonal to the axial direction. The top view (shape viewed from the axial direction) of the overlapping portion 453 on one end of the axial direction and the overlapping portion 454 on the other end of the axial direction are different; one overlapping portion 453 is circumferentially wider at the bending front end, and the other overlapping portion 454 is circumferentially narrower at the bending front end. In this case, the radially extending portions of each overlapping portion 453 and 454 are arranged in a radially extending direction from the center point of the stator.

[0294] In each winding 451, the intermediate conductor portion 452 is configured as coil side conductor portions arranged one by one in the circumferential direction at the coil side CS. In addition, each overlap portion 453, 454 is configured as coil side end conductor portions that connect the intermediate conductor portions 452 of the same phase at two different positions in the circumferential direction at the coil side end CE.

[0295] Similar to the partial winding 151 in the first embodiment described above, the partial winding 451 is formed by winding the conductor material CR in multiple layers such that the cross-section of the conductor assembly portion is quadrilateral. Regarding the intermediate conductor portion 452, the conductor material CR is arranged in multiple rows circumferentially and in multiple rows radially, thereby forming a roughly rectangular cross-section (see reference). Figure 20 ).

[0296] In partial winding 451, each intermediate conductor portion 452 is provided covered with a sheet-like insulating cover 455. The structure of the insulating cover 455 is the same as that of the insulating cover 157 in partial winding 151. That is, the insulating cover 455 uses a thin film material with an axial dimension having at least the length of the axial insulating coverage area of ​​the intermediate conductor portion 452, and is provided by winding the thin film material around the intermediate conductor portion 452. Furthermore, the insulating cover 455 is provided around the intermediate conductor portion 452 such that the circumferential ends of the thin film material overlap.

[0297] Next, the structure of the insulating covers 460 and 470 will be described. The insulating covers 460 and 470 are insulating members provided in each overlapping portion 453 and 454 to achieve insulation between the partial windings 451, and they surround the entire circumference of the overlapping portions 453 and 454.

[0298] An insulating cover 460 is installed on the overlapping portion 453 on one axial side of a portion of the winding 451, and an insulating cover 470 is installed on the overlapping portion 454 on the other axial side of the portion of the winding 451. The insulating covers 460 and 470 are formed of insulating materials such as synthetic resin, and the insulating covers 460 and 470 provide insulation between the windings at the overlapping portions 453 and 454 of the portion of the winding 451. Figure 48 (a) is used Figure 46 A cross-sectional view of the 48-48 wire after the overlap portion 453 side of the coil module 450 has been cut off. Figure 48 (b) is to Figure 48 The structural breakdown shown in (a) is an anatomical view. Additionally, Figure 49 (a) is used Figure 46 A cross-sectional view of line 49-49 after the overlap portion 454 of coil module 450 is cut off. Figure 49 (b) is to Figure 49 The structural decomposition of (a) is represented by the anatomical view.

[0299] like Figure 48 As shown in (a) and (b), the insulating cover 460 is configured to be axially separable, having an outer cover 461 that covers the overlapping portion 453 from the outer side of the axial direction and an inner cover 462 that covers the overlapping portion 453 from the inner side of the axial direction. The outer cover 461 has an end plate portion 463 facing the outer end face of the overlapping portion 453 and a peripheral wall portion 464 extending axially from the end plate portion 463. A support portion 465 made of a metal plate is integrally provided in the end plate portion 463. For example, the support portion 465 is provided embedded in the end plate portion 463 (outer cover 461), which is a resin molded body.

[0300] Furthermore, the outer cover 461 and the inner cover 462 are “segmented covers” that can be installed radially in addition to axially (the same applies to the outer cover 471 and the inner cover 472 described later).

[0301] The support portion 465 is a support member that supports the coil edge portion when the coil module 450 is assembled into the core assembly CB, and its structure is as follows: Figure 50 As shown in (a). Additionally, in Figure 50 In (a), the end plate portion 463 of the outer cover 461 is represented by an imaginary line.

[0302] A portion of the support portion 465 protrudes radially from the end plate portion 463 of the outer cover 461, and through holes 465a and 465b are provided in this protruding portion. More specifically, the support portion 465 is configured to protrude at two different circumferential positions on the outer side of the end plate portion 463. One protruding portion, when viewed from above, protrudes radially outward at the circumferential center of the end plate portion 463, and through hole 465a is provided in this protruding portion. The other protruding portion protrudes circumferentially outward from the end plate portion 463, and through hole 465b is provided in this protruding portion.

[0303] Furthermore, the support portion 465 has a flexed portion 465c that bends axially. The flexed portion 465c bends at the end of the insulating cover 460 on the radially opposite side of the protruding side of the support. In the assembled state of the insulating cover 460, the flexed portion 465c is radially opposite to the overlapping portion 453. In this embodiment, the overlapping portion 453 of a portion of the winding 451 is bent radially outward, and the flexed portion 465c is radially opposite to the inner side of the radially protruding bent portion in the bent overlapping portion 453. Thus, the flexed portion 465c or the peripheral wall portion 464 integrated with the flexed portion 465c can engage with the overlapping portion 453 on the opposite side of the through hole 465a.

[0304] The bent portion 465c has bent portions 465d and 465e formed by bending at both ends in the circumferential direction in a radially inward manner. These bent portions 465d and 465e are engaging portions that can engage with the overlapping portion 453 from the inside of the bending direction when the insulating cover 460 is assembled to the overlapping portion 453 of a portion of the winding 451. That is, the insulating cover 460 is provided with the support portion 465 sandwiched between two circumferentially separated conductor portions (i.e., conductor portions extending from each intermediate conductor portion toward the coil edge end side) in the overlapping portion 453.

[0305] In addition, such as Figure 47As shown, the inner cover 462 has an end plate portion 467 opposite to the axial inner end face of the overlapping portion 453 and two upright portions 468 extending axially from the end plate portion 467. The upright portions 468 are arranged such that they are respectively opposite to the radial inner side and the radial outer side at the front end of the overlapping portion 453.

[0306] When assembling the insulating cover 460 to the overlap portion 453 of the partial winding 451, an inner cover 462 is installed at the overlap portion 453, and an outer cover 461 is installed relative to the inner cover 462. The overlap portion 453 and each cover 461, 462 are preferably joined together by bonding or other joining methods. However, the installation order of the covers 461, 462 is arbitrary.

[0307] like Figure 48 As shown in (a), with the insulating cover 460 installed on the overlap 453, the overlap 453 is surrounded by the insulating cover 460 from both the axial and radial directions, and a portion of the support portion 465 protrudes. The insulating cover 460 is filled with a filler RE, for example, made of synthetic resin.

[0308] In addition, such as Figure 49 As shown in (a) and (b), the insulating cover 470 is configured to be axially separable, having an outer cover 471 that covers the overlapping portion 454 from the outer side of the axial direction and an inner cover 472 that covers the overlapping portion 454 from the inner side of the axial direction. The outer cover 471 has an end plate portion 473 opposite to the outer end face of the overlapping portion 454 and a peripheral wall portion 474 extending axially from the end plate portion 473. A support portion 475 made of metal plate is integrally provided on the end plate portion 473. For example, the support portion 475 is provided in a state where it is embedded in the end plate portion 473 (outer cover 471), which is a resin molded body.

[0309] The support portion 475 is a support member that supports the coil edge portion when the coil module 450 is assembled into the core assembly CB, and its structure is as follows: Figure 50 As shown in (b). Additionally, in Figure 50 In (b), the end plate portion 473 of the outer cover 471 is represented by an imaginary line.

[0310] A portion of the support portion 475 protrudes radially from the end plate portion 473 of the outer cover 471, and through holes 475a and 475b are provided in the protruding portion. More specifically, the support portion 475 protrudes radially inward from the outer side of the end plate portion 473 at the circumferential center of the end plate portion 473, and through holes 475a and 475b are provided in the protruding portion.

[0311] Furthermore, the support portion 475 has a flexed portion 475c that bends axially. The flexed portion 475c bends at the end of the insulating cover 470 on the radially opposite side of the protruding side of the support. In the assembled state of the insulating cover 470, the flexed portion 475c and the overlapping portion 454 are radially opposite each other. In this embodiment, the overlapping portion 454 of a portion of the winding 451 is bent radially outward, and the flexed portion 475c is radially opposite to the inner side of the radially protruding bent portion in the bent overlapping portion 454. Thus, the flexed portion 475c or the peripheral wall portion 474 integrated with the flexed portion 475c can engage with the overlapping portion 454 on the opposite side of the through holes 475a and 475b.

[0312] The bent portion 475c has bent portions 475d and 475e formed by bending at both ends in the circumferential direction in a radially inward manner. These bent portions 475d and 475e are engaging portions that can engage with the overlapping portion 454 from the inside of the bending direction when the insulating cover 470 is assembled to the overlapping portion 454 of a portion of the winding 451. That is, the insulating cover 470 is provided with the support portion 475 sandwiched between two circumferentially separated conductor portions (i.e., conductor portions extending from each intermediate conductor portion toward the coil edge end side) in the overlapping portion 454.

[0313] In addition, such as Figure 47 As shown, the inner cover 472 has an end plate portion 477 opposite to the axial inner end face of the overlapping portion 454 and two upright portions 478 extending axially from the end plate portion 477. The upright portions 478 are arranged such that they are respectively opposite to the radial inner side and the radial outer side at the front end of the overlapping portion 454.

[0314] When assembling the insulating cover 470 to the overlap portion 454 of the partial winding 451, an inner cover 472 is installed at the overlap portion 454, and an outer cover 471 is installed relative to the inner cover 472. The overlap portion 454 and each cover 471, 472 are preferably joined together by bonding or other joining methods. However, the installation order of the covers 471, 472 is arbitrary.

[0315] like Figure 49 As shown in (a), with the insulating cover 470 installed on the overlap 454, the overlap 454 is surrounded by the insulating cover 470 from both the axial and radial directions, and a portion of the support portion 475 protrudes. The insulating cover 470 is filled with a filler RE, for example, made of synthetic resin.

[0316] Figure 51Figures (a) and (b) are perspective views showing the positional relationship between a portion of the stator winding 451 and the support portions 465 and 475. For ease of explanation, these figures are shown as being in a state where the insulating covers 460 and 470 (outer covers 461 and 471 and inner covers 462 and 472) and the insulating sheath 455 have been removed from the coil module 450. Figure 51 (a) is a perspective view of the assembly state of the three windings 451 as seen from the radial inside. Figure 51 (b) is a perspective view of the assembly state of the three identical windings 451 viewed from the radial outside.

[0317] like Figure 51 As shown in (a), at one axial end of the stator winding 411, a support portion 465 is provided such that a bent portion 465c faces the radially inner side of the overlapping portion 453 of a portion of the winding 451, and extends radially outward from the bent portion 465c. Additionally, as... Figure 51 As shown in (b), at the other axial end of the stator winding 411, a support portion 475 is provided such that a bent portion 475c is opposite to the radially outer side of the overlapping portion 454 of a portion of the winding 451, and extends radially inward from the bent portion 475c.

[0318] Here, the specific structure for fixing the various windings 451 (each coil module 450) implemented by the support parts 465 and 475 will be described. Figure 52 This is a top view showing the configuration of three partial windings 451 on the stator retainer 420 (core assembly CB). The view shows one partial winding 451 positioned in the upper section (i.e., near the front of the paper) and two partial windings 451 positioned in the lower section (i.e., inside the paper). Additionally, with... Figure 51 Similarly, in (a) and (b), Figure 52 The image shows the state in which the insulating covers 460 and 470 (outer covers 461 and 471 and inner covers 462 and 472) and the insulating covering 455 are removed from the coil module 450.

[0319] exist Figure 52 In this configuration, the overlapping portions 453 and 454 of multiple partial windings 451 overlap axially. In this overlapping state, every two support portions 465 and 475 (i.e., the insulating covers 460 and 470 including the support portions 465 and 475) are mechanically engaged with the stator retainer 420 by connecting members 481 and 482. Thus, each insulating cover 460 and 470 can be fixed relative to the stator retainer 420.

[0320] Specifically, on one axial end side, in the two axially overlapping support portions 465, the through holes 465a and 465b formed in each of the support portions 465 are located at the same position along the axial direction. That is, through holes 465a and 465b are formed at two different circumferential positions in the support portion 465, and when the two support portions 465 overlap along the axial direction, the position of the through hole 465a in one support portion 465 coincides with the position of the through hole 465b in the other support portion 465. In addition, as described above, a recess 427 (see reference) is formed in the flange 423 of the stator retainer 420. Figure 45 With each portion of the winding 451 arranged relative to the stator retainer 420, the positions of the through holes 465a and 465b of each bracket portion 465 coincide with the positions of the recesses 427 of the stator retainer 420. Then, by inserting the connecting member 481 into the through holes 465a and 465b of each bracket portion 465 and the recesses 427 of the stator retainer 420, each bracket portion 465 (each insulating cover 460) is mechanically connected to the stator retainer 420.

[0321] The connecting member 481 on the overlapping part 453 side is, for example, a metal fixing pin, which is fixed to the recess 427 on the stator retainer 420 side by pressing or screwing. Then, by inserting the connecting member 481 through the through holes 465a and 465b of each bracket part 465, the bracket parts 465 are engaged in a snap-fit ​​state.

[0322] Furthermore, on the other axial end side, in the two axially overlapping support portions 475, the through holes 475a and 475b formed in each support portion 475 are located at the same position along the axial direction. That is, through holes 475a and 475b are formed at two different circumferential positions in the support portion 475, and when the two support portions 475 overlap along the axial direction, the position of the through hole 475a of one support portion 475 coincides with the position of the through hole 475b of the other support portion 475. In addition, as described above, a recess 428 (see reference) is formed in the bottom 422 of the stator retainer 420. Figure 45 With each portion of the winding 451 arranged relative to the stator retainer 420, the positions of the through holes 475a and 475b of each bracket portion 475 coincide with the positions of the recesses 428 of the stator retainer 420. Then, by inserting the connecting member 482 into the through holes 475a and 475b of each bracket portion 475 and the recesses 427 of the stator retainer 420, each bracket portion 475 (each insulating cover 470) is mechanically connected to the stator retainer 420.

[0323] The connecting member 482 on the overlapping portion 454 side has a connecting structure capable of separating and joining along the axial direction. Its specific structure is as follows: Figure 53As shown. The connecting member 482 is made of metal and consists of two connecting bolts 482a and 482b that can be separated and joined axially. One connecting bolt 482a can be screwed into a recess 428 formed in the bottom 422 of the stator retainer 420, and the other connecting bolt 482b can be screwed into relative to the connecting bolt 482a. Furthermore, an internal thread is formed in the recess 428. In this case, the support portion 475 of the lower section insulating cover 470 is fixed by the connecting bolt 482a, and the support portion 475 of the upper section insulating cover 470 is fixed by the connecting bolt 482b. Alternatively, the connecting member 482 can also be configured such that the two members, which can be separated and joined axially, are fixed by pressing in.

[0324] Each connecting member 481, 482 can be modified to other ways, instead of making the connecting structure different on one end and the other end in the axial direction, or the connecting structure can be the same on one end and the other end in the axial direction. In addition, welding or bonding can also be used as the connecting method.

[0325] like Figure 52 As shown, in each partial winding 451, the overlapping portions 453 and 454 are configured to overlap axially with the overlapping portions 453 and 454 of the partial windings 451 that are different from each other at one circumferential end and the other circumferential end, respectively. Furthermore, the combination of two partial windings 451 fixed relative to the stator retainer 420 by the connecting members 481 and 482 differs at one axial end and the other axial end. That is, in this embodiment, the pair of partial windings 451 joined by the connecting member 481 at the overlapping portion 453 side is different from the pair of partial windings 451 joined by the connecting member 482 at the overlapping portion 454 side. Figure 52 Specifically, on the overlap portion 453 side, the pair of "left and middle" partial windings 451 of the three partial windings 451 of the left, middle and right is coupled by the coupling member 481, and on the overlap portion 454 side, the pair of "middle and right" partial windings 451 of the three partial windings 451 of the left, middle and right is coupled by the coupling member 482.

[0326] Regarding the completed state of stator unit 400, such as Figure 42As shown in (a), at twelve circumferential locations in each axially overlapping insulating cover 460, the through holes 465a and 465b of each insulating cover 460 overlap vertically, and connecting members 481 are joined at each through hole 465a and 465b that are spaced apart circumferentially. Similarly, at twelve circumferential locations in each axially overlapping insulating cover 470, the through holes 475a and 475b of each insulating cover 470 overlap vertically, and connecting members 482 are joined at each through hole 475a and 475b that are spaced apart circumferentially. In this case, as described above, the pair of coil modules 450 joined by connecting members 481 on the insulating cover 460 side (overlapping portion 453 side) is different from the pair of coil modules 450 joined by connecting members 482 on the insulating cover 470 side (overlapping portion 454 side).

[0327] However, the pair of coil modules 450 joined by the connecting member 481 on the insulating cover 460 side can be the same as the pair of coil modules 450 joined by the connecting member 482 on the insulating cover 470 side. Alternatively, the connecting member 481 can be joined using circumferential through holes 465a and 465b on the insulating cover 460 side, or the connecting member 482 can be joined using circumferential through holes 475a and 475b on the insulating cover 470 side.

[0328] Next, the structure of each coil module 450 assembled relative to the core assembly CB will be described.

[0329] When assembling the coil modules 450, the six coil modules 450 on the lower side are arranged circumferentially relative to the core assembly CB. This state is as follows: Figure 54 The top view is shown. In this case, multiple (six in this embodiment) insulating covers 460 are arranged circumferentially at the same position in the axial direction. In this state, the recess 427 (see reference 420) of the stator retainer 420 is positioned relative to the recess 427 of the stator retainer 420. Figure 44 , Figure 45 Align the positions of the through holes 465a and 465b on the side of the insulating cover 460. For example... Figure 44 As shown, when the number of recesses 427 is half the total number of coil modules 450, for example, for through holes 465b in through holes 465a and 465b, the position of the recesses 427 relative to the stator retainer 420 is aligned.

[0330] Furthermore, before assembling the coil module 450, the connecting member 481 is fixed to the recess 427 of the stator retainer 420 by pressing or screwing. In this state, it is preferable to arrange each coil module 450 while inserting the through hole 465b of the bracket portion 465 into the connecting member 481.

[0331] Furthermore, multiple (six in this embodiment) insulating covers 470 are arranged circumferentially at the same position in the axial direction. In this state, the recess 428 (see reference 420) of the stator retainer 420 is positioned relative to the recess 428 of the stator retainer 420. Figure 45 Align the positions of the through holes 475a and 475b on the side of the insulating cover 470. At this time, fix each insulating cover 470 by inserting the connecting bolt 482a through the through hole 475a of the bracket part 475.

[0332] Next, the six coil modules 450 on the upper side are assembled. This state is... Figure 42 The states shown in (a) and (b) are as follows. In this state, insulating covers 460 and 470 are respectively disposed on the upper and lower layers at one end and the other end along the axial direction. Furthermore, the intermediate conductor portions 452 of each coil module 450 are arranged in a row along the circumferential direction. In this state, each insulating cover 460 of the upper and lower layers is coupled to the stator retainer 420 with the connecting member 481 inserted through the through holes 465a and 465b. Similarly, each insulating cover 470 of the upper and lower layers is coupled to the stator retainer 420 with the connecting member 482 inserted through the through holes 475a and 475b.

[0333] exist Figures 41-43 In the completed stator unit 400 shown, the support portions 465 and 475 of the insulating covers 460 and 470 of the coil modules 450 are mechanically connected to the core assembly CB via connecting members 481 and 482, thereby fixing each coil module 450. In this case, in each coil module 450, the insulating covers 460 and 470 enable phase-to-phase insulation between some windings 451 and insulation to ground of the stator core 412.

[0334] Furthermore, each coil module 450 is connected to the stator retainer 420, which has a refrigerant passage 425, via connecting members 481 and 482. Therefore, some of the heat generated in the windings 451 is directly transferred from the overlaps 453 and 454 via the support portions 465 and 475 and the connecting members 481 and 482 to the vicinity of the refrigerant passage 425 in the stator retainer 420. In this case, a portion of the support portions 465 and 475 is exposed outside the cover and is connected thereby via the connecting members 481 and 482, thus promoting heat dissipation. Additionally, since the support portions 465 and 475, and the connecting members 481 and 482 are all made of metal, heat transfer is excellent.

[0335] Furthermore, because the insulating covers 460 and 470 are filled with filler RE (refer to...) Figure 48 of (a), Figure 49Therefore, the gaps between the overlapping portions 453, 454 (partial windings 451) and the insulating covers 460, 470 are filled, improving thermal conductivity. Furthermore, by filling the gaps within the insulating covers 460, 470 with filler RE, it is also expected that the bonding strength of each coil module 450 will be improved.

[0336] Based on the implementation method described above, the following effects can be obtained.

[0337] In the rotary electric machine MG with the above-described structure, a portion of the stator winding 411, 451, has a pair of intermediate conductor portions 452 and overlapping portions 453 and 454. Multiple portion windings 451 are arranged circumferentially such that the intermediate conductor portions 452 are arranged circumferentially. In this case, by assembling each portion winding 451 (coil module 450) to the core assembly CB, the stator winding 411 can be assembled regardless of whether the stator 410 has poleless teeth. Furthermore, by installing insulating covers 460 and 470 at the overlapping portions 453 and 454 of the portion windings 451, the circumferentially arranged portion windings 451 can be ideally insulated from each other.

[0338] Furthermore, in this structure, bracket portions 465 and 475, which are provided in a state of protruding from the insulating covers 460 and 470, are used to mechanically engage the bracket protruding portions from the insulating covers 460 and 470 with the core assembly CB (stator retainer 420). In this case, the mounting of multiple partial windings 451 (coil modules 450) relative to the core assembly CB can be easily and reliably implemented. When using a manufacturing apparatus such as a winding machine to manufacture the stator, the manufacturing apparatus can be miniaturized. As a result, the assembly of the stator windings 411 can be easily achieved.

[0339] In the support portions 465 and 475, bent portions 465c and 475c are provided at the ends on the radially opposite side to the protruding side, and these bent portions 465c and 475c are radially opposite to the overlapping portions 453 and 454. In this case, the overlapping portions 453 and 454 and the support portions 465 and 475 can be radially engaged by the bent portions 465c and 475 on the opposite side of the protrusion in the support portions 465 and 475. In this state, the protruding portions of the support portions 465 and 475 are mechanically engaged with the core assembly CB. As a result, radial positional displacement of some windings 451 can be suppressed, and the assembly state of each winding 451 relative to the core assembly CB can be maintained in an appropriate state.

[0340] In a structure where the overlapping portions 453 and 454 of a portion of the winding 451 are bent radially and overlap with the core assembly CB axially, insulating covers 460 and 470 are arranged at the axial end of the core assembly CB, overlapping with the core assembly CB axially. In this structure, by making the bent portions 465c and 475c of the support portions 465 and 475 face each other radially to the inner side of the bent portions of the overlapping portions 453 and 454, the insulating covers 460 and 470 can be ideally mechanically engaged with the axial end of the core assembly CB.

[0341] The overlapping portions 453 and 454 of the partial winding 451 have two circumferentially separated conductor portions (i.e., conductor portions extending from each intermediate conductor portion 452 toward the coil edge end side). With the support portions 465 and 475 sandwiched between these conductor portions, the circumferential positional displacement of the overlapping portions 453 and 454 is limited by the support portions 465 and 475. Therefore, according to the above structure, in addition to suppressing radial positional displacement of the partial winding 451, circumferential positional displacement can also be suppressed. Furthermore, since the support portions 465 and 475 are positioned axially outward relative to the overlapping portions 453 and 454, positional displacement of the partial winding 451 can be suppressed in any of the axial, radial, and circumferential directions.

[0342] In the overlapping portions 453 and 454 of the partial windings 451, in order to achieve insulation between the partial windings 451 and between the partial windings 451 and the core assembly CB (particularly the stator core 412), it is desirable to provide insulating covers 460 and 470 that surround the overlapping portions 453 and 454 from both the axial and radial directions. In this case, by configuring the insulating covers 460 and 470 to include multiple segmented covers that are axially mounted relative to the overlapping portions 453 and 454, the mounting of the insulating covers 460 and 470 relative to the overlapping portions 453 and 454 can be easily implemented. In addition, by adopting a structure in which a support portion 465 and 475 is integrally provided on any one of the multiple segmented covers, the support portion 465 and 475 can be mounted simultaneously with the mounting of each segmented cover. Thus, it is possible to ideally provide insulating covers 460 and 470 that surround the overlapping portions 453 and 454 circumferentially from both the axial and radial directions.

[0343] In the stator winding 411 of the above structure, the circumferentially arranged partial windings 451 are configured such that a portion overlaps circumferentially, and at the coil edge end CE, the overlapping portions 453 and 454 of the partial windings 451 of different phases overlap each other axially. In this state, in the insulating covers 460 and 470 installed on each overlapping portion 453 and 454, the protruding portions of each overlapping support portion 465 and 475 are connected to the core assembly CB by connecting members 481 and 482. Therefore, the installation of multiple partial windings 451 relative to the core assembly CB can be easily implemented. In addition, since the heat transfer path between each support portion 465 and 475 and the core assembly CB is formed by the connecting members 481 and 482, the desired structure can also be achieved from the viewpoint of heat dissipation of the stator winding 411.

[0344] The combination of the two partial windings 451, which are connected to the core assembly CB by connecting members 481 and 482, differs at one axial end and the other axial end. This allows for the connection of adjacent partial windings 451 arranged circumferentially to each other while minimizing the required connection area relative to the core assembly CB. This reduces the manufacturing burden of the rotary electric machine MG.

[0345] The support portions 465 and 475, which are configured as insulating covers 460 and 470, are combined with the core assembly CB, which has a cooling section. In this case, some of the heat generated in the winding 451 is directly transferred to the vicinity of the cooling section via the support portions 465 and 475, thereby improving the cooling performance of the stator winding 411.

[0346] The core assembly CB is configured to include a stator core 412 and a stator retainer 420 radially outward from the stator core 412. The support portions 465 and 475 of the insulating covers 460 and 470 are fixed relative to the stator retainer 420, which is located beyond the stator core 412, by connecting members 481 and 482. In this case, since it is not necessary to connect the connecting members 481 and 482 relative to the stator core 412, it is not necessary to provide recesses or the like on the stator core 412 for connecting the connecting members 481 and 482, thus suppressing undesirable conditions such as cogging torque.

[0347] The refrigerant passage 425 is provided in the stator retainer 420 within a region including the cylindrical portion 421 and the bottom portion 422. Therefore, in a structure where the support portions 465 and 475 are mechanically connected to the bottom portion 422 of the stator retainer 420, heat transfer from the support portions 465 and 475 to the refrigerant passage 425 of the stator retainer 420 can be ideally implemented.

[0348] In the above structure, the radially extending bottom 422 and flange 423 of the core assembly CB are designed as connection points for the mechanical connection of the support portions 465 and 475. This makes it easy to ensure that the connection points allow for the ideal connection of the support portions 465 and 475.

[0349] The winding 451 is configured such that each insulating cover 460, 470 is mechanically engaged with the core assembly CB at both axial ends. This allows for proper fixation of the winding 451, preventing, for example, undesirable situations such as inconsistent axial air gap dimensions caused by the intermediate conductor portion 452 being non-parallel to the axial direction. Furthermore, the engagement methods of the engaging members 481, 482 at both axial ends of the winding 451 are different. Specifically, one is a threaded engagement, and the other is a snap-fit ​​engagement. This allows for different engagement margins (clearance) at one and the other axial ends, facilitating dimensional adjustments in the assembled state.

[0350] The structure is configured such that an insulating cover 455 made of thin film material covers the middle conductor portion 452 (coil side portion) of a portion of the winding 451. In this structure, insulating covers 460 and 470 are used to insulate the coil edge portion of the portion of the winding 451, and the insulating cover 455 is used to insulate the coil side portion. Compared with structures that use the same insulating members in each of the above-mentioned portions, the insulation structure of each portion can be simplified.

[0351] (A variation of the second embodiment)

[0352] • As long as the support portions 465 and 475 of the insulating covers 460 and 470 are integrally provided in the end plate portions 463 and 473, in addition to the structure embedded in the end plate portions 463 and 473, it can also be a structure fixed to the plate surface of the end plate portions 463 and 473 by adhesive or the like.

[0353] The support portions 465 and 475 can also be made of materials other than metal, such as high-strength and non-stretchable resin. Preferably, the support portions 465 and 475 are made of a material with higher strength than the insulating covers 460 and 470. Furthermore, the support portions 465 and 475 are preferably made of a material with high thermal conductivity.

[0354] • Alternatively, the mechanical coupling mechanism can be provided only on one of the insulating covers 460 and 470 located on both axial sides. For example, the mechanical coupling mechanism can be provided only on the bottom 422 side of the stator retainer 420. Furthermore, in this case, it can also be configured to be pressed on the opposite axial side using a busbar or terminal block, housing, etc. (not shown).

[0355] • On one axial end side and the other axial end side of the partial winding 451, the engagement directions of the engaging members 481 and 482 can also be the same. For example, the two sides can be configured as threaded engagement or as snap-fit ​​engagement.

[0356] In the second embodiment described above, the winding support member is configured using a core assembly CB that includes a stator core 412 and a stator retainer 420. However, it is also possible to modify the configuration to use the stator retainer 420 as the winding support member, i.e., to exclude the stator core 412. The cooling section provided on the core assembly CB (winding support member) may also be configured differently from the refrigerant passage 425. For example, the cooling section may employ a structure in which heat dissipation fins are provided on the outer periphery of the cylindrical portion 421.

[0357] (Third Implementation)

[0358] The structure of the stator unit 500 in this embodiment will now be described. The stator unit 500 in this embodiment modifies a portion of the stator unit 400 in the second embodiment; the differences from the second embodiment will be primarily described below. Furthermore, components common to the second embodiment will be labeled with the same symbols, and their descriptions will be omitted.

[0359] Figure 55 This is a top view of stator unit 500. Figure 56 This is a longitudinal sectional view of stator unit 500. Figure 57 This is an exploded perspective view showing the core assembly CB and stator winding 411 in stator unit 500. Furthermore, Figure 56 Is it through Figure 55 A sectional view at line 56-56 of the stator center point C.

[0360] Compared to the second embodiment, the stator unit 500 in this embodiment differs in its structure for fixing each coil module 450 relative to the core assembly CB. Specifically, the coil modules 450 are fixed using pins on the bottom 422 side of the stator retainer 420, and fixed using bolts on the flange 423 side of the stator retainer 420. Therefore, the forms of the recess 427 provided on the flange 423 and the recess 428 provided on the bottom 422 are changed in the stator retainer 420.

[0361] As described above, the stator winding 411 has multiple coil modules 450, each of which has a generally Z-shaped partial winding 451. However, the forms of the insulating covers 460 and 470 are different compared to the second embodiment. Furthermore, in this embodiment, the structures of the insulating covers 460 and 470 at the upper and lower sections of each coil module 450, arranged in two layers along the axial direction, are different. Therefore, for convenience, in the following description, the coil module 450 at the lower section will be referred to as "lower section module 450A," and the coil module 450 at the upper section will be referred to as "upper section module 450B." Additionally, to clearly distinguish the structural differences between the lower section module 450A and the upper section module 450B, the insulating covers 460 and 470 of the lower section module 450A will be referred to as "insulating covers 460A and 470A," and the insulating covers 460 and 470 of the upper section module 450B will be referred to as "insulating covers 460B and 470B." The structures of the outer covers 461, 471 and inner covers 462, 472 in each of the insulating covers 460, 470 are the same as those in the second embodiment described above.

[0362] Figure 58 (a) is a 3D view of the lower module 450A. Figure 58 (b) is a 3D view of the upper module 450B.

[0363] like Figure 58 As shown in (a), a support portion 501 is provided on the insulating cover 460A of the lower module 450A, with a portion protruding circumferentially. A bushing portion 502 extending axially is provided on the support portion 501, and a through hole 503 is provided in the bushing portion 502. Furthermore, a support portion 504 is provided on the insulating cover 470A of the lower module 450A, with a portion protruding radially inward. A through hole 505 is provided in the protruding portion of the support portion 504.

[0364] In addition, such as Figure 58 As shown in (b), a support portion 511 is provided on the insulating cover 460B of the upper module 450B, with a portion protruding radially outward. A bushing portion 512 extending axially is provided on the support portion 511, and a through hole 513 is provided in the bushing portion 512. Furthermore, a support portion 514 is provided on the insulating cover 470B of the upper module 450B, with a portion protruding radially inward. A through hole 515 is provided in the protruding portion of the support portion 514.

[0365] In addition, Figure 58In (a) and (b), a portion of the support portions 501, 504, 511, and 514 is hidden within the insulating covers 460 and 470 and cannot be observed. However, similar to the structure described above, each of the support portions 501, 504, 511, and 514 has a bent portion at its end that is radially opposite to the protruding side.

[0366] Figure 59 Images (a) and (b) are perspective views showing the positional relationship between portions of winding 451 of modules 450A and 450B in stator winding 411 and support portions 501, 504, 511, and 514. Figure 59 (a) is a perspective view of the assembly state of the three windings 451 as seen from the radial inside. Figure 59 (b) is a perspective view of the assembly state of the three identical windings 451 viewed from the radial outside.

[0367] like Figure 59 As shown in (a) and (b), on one axial end side (upper side of the figure), in each of the axially overlapping support portions 501 and 511, the bushing portions 502 and 512 are joined together, and the through holes 503 and 513 of each of the bushing portions 502 and 512 are connected. Furthermore, on the other axial end side (lower side of the figure), in each of the axially overlapping support portions 504 and 514, the through holes 505 and 515 of each of the support portions 504 and 514 are positioned in the same direction.

[0368] Moreover, such as Figure 55 As shown, on one axial end side, the axially overlapping support portions 501, 511 are engaged with the stator retainer 420 via a connecting member 521. More specifically, the support portions 501, 511 are engaged with the connecting member 521 inserted into the through holes 503, 513 of each bushing portion 502, 512. The connecting member 521 is, for example, a metal bolt, which is screwed into the internal thread formed in the through hole 513 of each bushing portion 512 while communicating with the through holes 503, 513 of each bushing portion 502 from the bushing portion 502 side.

[0369] Furthermore, the bushing portions 502 and 512 are preferably designed with concave and convex mating surfaces, and are positioned relative to each other through the interlocking of these surfaces. This facilitates the positioning of each coil module 450 during assembly.

[0370] Additionally, on the other axial end side, the axially overlapping bracket portions 504 and 514 are engaged with the stator retainer 420 via a connecting member 522. More specifically, the bracket portions 504 and 514 are engaged when the connecting member 522 is inserted into the through holes 505 and 515 of each bracket portion 504 and 514. The connecting member 522 is, for example, a metal retaining pin.

[0371] During the assembly of coil modules 450, the six coil modules 450 on the lower section side are arranged circumferentially relative to the core assembly CB, and then the six coil modules 450 on the upper section side are arranged circumferentially. The lower section coil modules 450 are then configured as follows: Figure 60 As shown in the diagram, the upper section coil module 450 is then configured as follows: Figure 55 The state shown. In Figure 55 In the shown configuration, the bracket portions 501 and 511, located on one axial end of each insulating cover 460A and 460B, are mechanically connected to the core assembly CB via a connecting member 521. Conversely, the bracket portions 504 and 514, located on the other axial end of each insulating cover 470A and 470B, are mechanically connected to the core assembly CB via a connecting member 522. This secures each coil module 450 relative to the core assembly CB.

[0372] In this embodiment, in the support portions 501 and 511 of the insulating covers 460A and 460B, the bushing portions 502 and 512 are axially joined together, and the connecting member 521 is inserted into the hollow portion of each bushing portion 502 and 512 to join the support portions 501 and 511. In this case, by joining the bushing portions 502 and 512, the relative distance between the insulating covers 460A and 460B in the axial direction can be maintained at a certain level, while the insulating covers 460 and 470 are joined to the core assembly CB in an appropriate state.

[0373] The following describes variations of the second and third embodiments.

[0374] For example, in the second embodiment, the structure in which the support portions 465 and 475 of the insulating covers 460 and 470 are mechanically connected to the core assembly CB can also be configured without using the connecting members 481 and 482, which are separate from the support portions 465 and 475. For example, as... Figure 61 As shown, in the structure where each insulating cover 460 overlaps along the axial direction and has a support portion 465X, 465Y, it is preferable to provide a bent portion 531 formed by bending along the axial direction at the front end of the support portion 465X on the outer side, and fix the bent portion 531 to the recess 427 on the stator retainer 420 side in a state of being inserted into the through hole of the support portion 465Y.

[0375] In the above structure, each winding 451 is configured to have a roughly Z-shaped form when viewed from the side, and this winding 451 is arranged in overlapping upper and lower layers along the axial direction. However, this structure can be modified. For example, in Figure 62In the structure, some windings 451 are arranged in two different ways: one is roughly I-shaped when viewed from the side, and the other is roughly C-shaped when viewed from the side. Furthermore, these windings 451 are assembled into the core assembly CB. Additionally, in... Figure 62 The bracket portions 465 and 475 and connecting members 481 and 482 included in the insulating covers 460 and 470 are shown in a simplified manner.

[0376] exist Figure 62 In this configuration, one portion of the winding 451 is in the shape of overlapping portions 453 and 454 without being bent radially. Furthermore, similar to the overlapping portions 453 and 454 in the bent state, in the overlapping portions 453 and 454 in the non-bent state, the bent portions 465c and 475c of the support portions 465 and 475 are also in a state where they are radially opposite to the overlapping portions 453 and 454.

[0377] · Figure 63 The structure of a stator suitable for an external rotor configuration is shown. Figure 63 As described above, the support portions 465 and 475, which are provided in a state of protruding from the insulating covers 460 and 470, are mechanically combined with the core assembly CB.

[0378] • As a rotating electric motor (MG), 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.

[0379] The disclosure in 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.

Claims

1. A rotary motor, the rotary motor comprising: An excitation element having multiple magnetic poles; A multiphase armature winding, wherein the armature winding has a phase winding for each phase, and the phase winding has multiple partial windings; as well as A winding support member is disposed on one of the radially inner and radially outer sides of the armature winding, opposite to the excitation element, and supports the plurality of partial windings. The excitation element and the armature winding are arranged to be radially opposite each other. The partial winding includes: a pair of intermediate conductor portions extending axially and spaced apart circumferentially at predetermined intervals; and an overlap portion disposed at one end and the other end axially, connecting the pair of intermediate conductor portions in a ring shape. The plurality of said partial windings are arranged circumferentially such that the intermediate conductor portion is arranged circumferentially. In the partial windings, an insulating member is installed at the overlapping portion to achieve insulation between the partial windings. A support portion is provided on the insulating member, protruding from the insulating member. The support portion has a bent portion that bends axially at its end in the insulating member on the radially opposite side to the protruding side. The insulating member is arranged such that the bent portion is radially opposite to the overlapping portion, and the protruding portion of the support portion protruding from the insulating member is mechanically connected to the winding support member.

2. The rotary motor as described in claim 1, characterized in that, In the aforementioned partial winding, the overlapping portion is bent radially while overlapping the winding support member axially. The insulating member is provided such that the folded portion is radially opposite to the inner side of the radially protruding bent portion in the overlapping portion in the bent state.

3. The rotary motor as described in claim 1 or 2, characterized in that, The insulating member is configured such that the support portion is sandwiched between two circumferentially separated conductor portions within the overlapping portion.

4. The rotary motor as described in claim 1 or 2, characterized in that, The insulating member is an insulating cover that surrounds the overlapping portion from both the axial and radial directions. The insulating cover includes a plurality of segmented cover members mounted axially or radially relative to the overlapping portion, each of the plurality of segmented cover members having the support portion integrally provided thereon.

5. The rotary motor as described in claim 1 or 2, characterized in that, By arranging the intermediate conductor portion of one of the pairs of intermediate conductor portions of the partial windings of other phases between the pairs of intermediate conductor portions of the partial windings, the intermediate conductor portions of each phase are arranged in a predetermined order along the circumference, and at the coil edge ends of the armature winding, the overlapping portions of the partial windings of different phases overlap each other axially. In the insulating members respectively installed on the overlapping portions along the axial direction, the protruding portions of the support portions provided on each of the insulating members overlap along the axial direction, and the protruding portions of each of the support portions in the overlapping state are connected to the winding support member by a connecting member.

6. A rotary motor, the rotary motor comprising: An excitation element having multiple magnetic poles; A multiphase armature winding, wherein the armature winding has a phase winding for each phase, and the phase winding has multiple partial windings; as well as A winding support member is disposed on one of the radially inner and radially outer sides of the armature winding, opposite to the excitation element, and supports the plurality of partial windings. The excitation element and the armature winding are arranged to be radially opposite each other. The partial winding includes: a pair of intermediate conductor portions extending axially and spaced apart circumferentially at predetermined intervals; and an overlap portion disposed at one end and the other end axially, connecting the pair of intermediate conductor portions in a ring shape. By arranging the intermediate conductor portion of one of the pairs of intermediate conductor portions of the partial windings of other phases between the pairs of intermediate conductor portions of the partial windings, the intermediate conductor portions of each phase are arranged in a predetermined order along the circumference, and at the coil edge ends of the armature winding, the overlapping portions of the partial windings of different phases overlap each other axially. In the partial windings, an insulating member is installed at the overlapping portion to achieve insulation between the partial windings. A support portion is provided on the insulating member, protruding from the insulating member, wherein the portion of the support portion protruding from the insulating member is a protruding portion. In the insulating members respectively installed on the overlapping portions along the axial direction, the protruding portions of the support portions provided on each of the insulating members overlap along the axial direction, and the protruding portions of each of the support portions in the overlapping state are connected to the winding support member by a connecting member.

7. The rotary motor as described in claim 5, characterized in that, In each of the aforementioned partial windings, the overlapping portion overlaps axially with the overlapping portions of the different partial windings at one circumferential end and the other circumferential end. The combination of the two partial windings connected by the connecting member and the winding support member differs at one axial end and the other axial end.

8. The rotary electric motor as described in claim 5, characterized in that, The support portion has an axially extending bushing portion in the protruding portion that protrudes from the insulating member. In each of the axially overlapping support portions, the bushing portions are joined together, and the connecting member is inserted into the hollow portion of each bushing portion. In this state, each of the support portions is joined to the winding support member by the connecting member.

9. The rotary electric motor as described in claim 7, characterized in that, The support portion has an axially extending bushing portion in the protruding portion that protrudes from the insulating member. In each of the axially overlapping support portions, the bushing portions are joined together, and the connecting member is inserted into the hollow portion of each bushing portion. In this state, each of the support portions is joined to the winding support member by the connecting member.

10. The rotary electric motor as described in any one of claims 7 to 9, characterized in that, The winding support member has a cooling section for cooling the armature winding. The bracket portion is connected to the axial end face of the winding support member through the connecting member.

11. The rotary electric motor as claimed in claim 10, characterized in that, The winding support member includes: an armature core assembled on the radially inner or radially outer side of the armature winding; and an armature retaining member disposed on the opposite side of the armature winding in the radially inner or outer direction of the armature core, and having the cooling portion. The bracket portion is connected to the axial end face of the armature retaining member via the connecting member.

12. The rotary electric motor as claimed in claim 10, characterized in that, The winding support member has a cylindrical portion and a base portion extending radially from the axial end of the cylindrical portion, the bracket portion being mechanically coupled to the base portion of the winding support member. The winding support member has an annular refrigerant passage in the cylindrical portion to serve as the cooling section. The refrigerant passage is provided within the area including the cylindrical portion and the base portion.

13. The rotary electric motor as claimed in claim 11, characterized in that, The winding support member has a cylindrical portion and a base portion extending radially from the axial end of the cylindrical portion, the bracket portion being mechanically coupled to the base portion of the winding support member. The winding support member has an annular refrigerant passage in the cylindrical portion to serve as the cooling section. The refrigerant passage is provided within the area including the cylindrical portion and the base portion.

14. The rotary electric motor as described in any one of claims 1, 2, 7 to 9, 11, characterized in that, The winding support member has a cylindrical portion and a base portion extending radially from the axial end of the cylindrical portion. The bracket portion is mechanically connected to the base portion of the winding support member.

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