Winding magnetic field type rotary electric machine

Abstract

To provide a winding magnetic field type rotary electric machine capable of reducing a size thereof.SOLUTION: A winding magnetic field type rotary electric machine 40 comprises: a stator 50 provided with a stator winding 52; a rotor 60 provided with a rotor core 61 and a magnetic field winding 70; and a circuit module 102 provided with an electrical component connected to the magnetic field winding 70, that is provided to the rotor 60 in an integrally rotatable manner. The magnetic field winding 70 comprises a plurality of pole coils formed by winding a conductive wire at each main-pole part of the rotor core 61, and the pole coils at each main pole part are electrically connected to each other via a conductive wire connection part CN. The circuit module 102 is provided on a first end X1 side that is one side in an axial direction of the rotor core 61, and on the other hand, the conductive wire connection part CN is provided on a second end X2 side that is the other side in the axial direction of the rotor core 61.SELECTED DRAWING: Figure 10

Description

Technical Field

[0001] The disclosure in this specification relates to a wound-field rotating electrical machine.

Background Art

[0002] In a wound-field rotating electrical machine, the rotor has a rotor core having a plurality of main pole portions (magnetic salient pole portions) arranged in the circumferential direction, and a field winding wound around the main pole portions. Also, a circuit module equipped with capacitors and diodes as electrical components is provided at an axial end portion of the rotor (see Patent Document 1). In the circuit module, capacitors and the like are held by a component holder.

[0003] In the wound-field rotating electrical machine described in Patent Document 1, in the component holder of the circuit module, a component housing portion for housing electrical components such as capacitors is provided so as to surround the rotation axis. Also, the field winding has a plurality of winding portions (pole coils) provided for each main pole portion. And, on the radially outer side of the component housing portion in the component holder, a winding fixing portion to which conductor end portions extending axially from each winding portion are fixed is provided, and the conductor end portions extending from the winding portions of each main pole portion are connected to each other by welding or the like at the winding fixing portion.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In a rotor of a wound-field type, when the electrical components mounted on the circuit module become larger or the number of electrical components increases, the area required for accommodating the electrical components in the component holder becomes larger, and the area for fixing the conductor end portions extending from the field winding cannot be secured. In this case, on one side of both axial sides of the rotor, a configuration in which the conductor end portions extending axially from each winding portion are connected in the region between the circuit module (component holder) and the field winding can be considered. However, in a configuration in which the connection portion between the conductor end portions of each winding portion is provided in the region between the circuit module and the field winding, it is necessary to expand the distance from the axial tip of the field winding to the circuit module in order to avoid interference between the circuit module and the conductor end portions of each winding portion. Therefore, there is a concern that the axial length of one side of the rotor becomes longer, and as a result, the size of the rotating electrical machine increases.

[0006] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a wound-field type rotating electrical machine capable of reducing the size.

Means for Solving the Problems

[0007] The present disclosure is a stator having a stator winding, a rotor having a rotor core having a plurality of main pole portions protruding radially provided for each pole arranged in the circumferential direction, and field windings wound around each of the main pole portions, a circuit module provided rotatably integrally with the rotor and having electrical components connected to the field winding, and a wound-field type rotating electrical machine having the field winding has a plurality of pole coils formed by winding a conductor material for each of the main pole portions, and the pole coils of each of the main pole portions are electrically connected via a conductor connecting portion, the circuit module is provided on a first end side which is one axial side of the rotor core, while the conductor connecting portion is provided on a second end side which is the other axial side of the rotor core.

[0008] In a wound-field type rotating electrical machine, in the rotor, pole coils are provided for each main pole portion of the rotor core, and for example, adjacent pole coils in the circumferential direction are connected to each other via a conductor connecting portion. Further, a circuit module is provided on the rotor so as to be integrally rotatable. In this case, in a configuration in which the conductor connecting portion of the pole coil and the circuit module are provided on one axial side of the rotor core, it is necessary to avoid interference between the circuit module and the conductor connecting portion, and there is a concern that the axial length on one side of the rotor becomes long.

[0009] In this regard, by adopting a configuration in which the circuit module is provided on the first end side which is one axial side of the rotor core, and the conductor connecting portion is provided on the second end side which is the other axial side of the rotor core, interference between the circuit module and the conductor connecting portion can be avoided. Further, in a configuration in which the conductor connecting portion of the pole coil and the circuit module are provided separately on both axial sides of the rotor, in a rotating electrical machine in which the rotor and the stator are arranged to face each other radially inside and outside, the circuit module protruding axially outside the stator winding is suppressed. As described above, the physical size of the wound-field type rotating electrical machine can be reduced.

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

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Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Mode for Carrying Out the Invention

[0011] Hereinafter, embodiments in which the wound-field type rotating electrical machine according to the present disclosure is embodied will be described with reference to the drawings. The rotating electrical machine is used, for example, as a driving power source in electric vehicles such as electric automobiles and hybrid automobiles.

[0012] First, a control system including a rotating electrical machine will be described with reference to FIG. 1. The control system includes a DC power supply 10, an inverter 20, a control device 30, and a rotating electrical machine 40. The rotating electrical machine 40 is a self-excited wound-field type synchronous machine. For example, the rotating electrical machine 40, the inverter 20, and the control device 30 may be configured as an integrated electromechanical drive device, or each of the rotating electrical machine 40, the inverter 20, and the control device 30 may be composed of respective components.

[0013] The rotating electrical machine 40 includes a housing 41, a stator 50 and a rotor 60 housed in the housing 41. The rotating electrical machine 40 of the present embodiment is an inner rotor type rotating electrical machine in which the rotor 60 is arranged radially inside the stator 50.

[0014] The stator 50 includes a stator core 51 and a stator winding 52. The stator winding 52 is made of, for example, copper wire and includes U, V, W-phase windings 52U, 52V, 52W arranged in a state of being shifted from each other by 120° in electrical angle.

[0015] The rotor 60 includes a rotor core 61 and a field winding 70. The field winding 70 may be formed of, for example, an aluminum wire having a small specific gravity and being easy to form. Note that the field winding 70 is not limited to an aluminum wire, and may be, for example, a copper wire or a CNT (carbon nanotube). A rotating shaft 32 is assembled in a central hole of the rotor core 61. The rotating shaft 32 is rotatably supported by bearings 42 and 43 in a housing 41.

[0016] As shown in FIG. 2, the inverter 20 includes a series connection body of upper arm switches SUp, SVp, SWp of U, V, and W phases and lower arm switches SUn, SVn, SWn of U, V, and W phases. At connection points between the upper arm switches SUp, SVp, SWp and the lower arm switches SUn, SVn, SWn in each phase, first ends of U, V, and W phase windings 52U, 52V, 52W are connected. Second ends of the U, V, and W phase windings 52U, 52V, 52W are connected at a neutral point. That is, in the present embodiment, the stator winding 52 is star-connected. However, the stator winding 52 may be delta-connected. In the present embodiment, each of the switches SUp to SWn is, for example, an IGBT. A freewheel diode is connected in anti-parallel to each of the switches SUp to SWn.

[0017] The positive terminal of the DC power supply 10 is connected to the collectors of the upper arm switches SUp, SVp, SWp of each phase. The negative terminal of the DC power supply 10 is connected to the emitters of the lower arm switches SUn, SVn, SWn of each phase. A smoothing capacitor 11 is connected in parallel to the DC power supply 10.

[0018] Subsequently, the stator 50 and the rotor 60 will be described with reference to FIG. 3.

[0019] Both the stator 50 and the rotor 60 are arranged coaxially with the rotating shaft 32. In the following description, the direction in which the rotating shaft 32 extends is defined as the axial direction, the direction extending radially from the center of the rotating shaft 32 is defined as the radial direction, and the direction extending circumferentially around the rotating shaft 32 is defined as the circumferential direction.

[0020] The stator core 51 is composed of a laminated steel sheet made of a soft magnetic material, and has an annular back yoke 51a and a plurality of teeth 51b protruding radially inward from the back yoke 51a. A plurality of slots 54 arranged in the circumferential direction are formed between adjacent teeth 51b. By accommodating the phase windings of each phase in these slots 54 in a predetermined order, the stator winding 52 is constituted. For example, in the stator 50, a segment coil structure using a plurality of conductor segments may be adopted. However, the structure of the stator winding 52 is arbitrary.

[0021] The rotor core 61 is made of a soft magnetic material and is constituted by, for example, a laminated steel sheet. The rotor core 61 has a cylindrical cylindrical portion 61a and a plurality of main pole portions 62 protruding radially outward from the cylindrical portion 61a. The field winding 70 is wound around the main pole portion 62 by concentrated winding. In the present embodiment, eight main pole portions 62 are provided at equal intervals in the circumferential direction.

[0022] The field winding 70 includes a first winding portion 71 and a second winding portion 72. The first winding portion 71 is wound around each main pole portion 62 on the radially outer side, and the second winding portion 72 is wound around the radially inner side of the first winding portion 71. In each main pole portion 62, the winding directions of the first winding portion 71 and the second winding portion 72 are the same as each other. Also, among the main pole portions 62 adjacent to each other in the circumferential direction, the winding directions of the winding portions 71, 72 wound around one are opposite to the winding directions of the winding portions 71, 72 wound around the other. For this reason, the magnetization directions of the main pole portions 62 adjacent to each other in the circumferential direction are opposite to each other. In the rotor 60, a plurality of magnetic poles (field poles) arranged in the circumferential direction are formed by each main pole portion 62 in the rotor core 61 and the field winding 70 wound around each main pole portion 62.

[0023] FIG. 4 shows an electric circuit on the rotor 60 side including winding portions 71 and 72 wound around the main pole portion 62. The first winding portion 71 and the second winding portion 72 are connected in series. A first capacitor 91 is connected between both ends of the second winding portion 72, and a second capacitor 92 is connected between both ends of the series connection of the first winding portion 71 and the second winding portion 72. The capacitors 91 and 92 are, for example, ceramic capacitors or film capacitors.

[0024] A diode 93 as a rectifying element is connected between both ends of the series connection formed by the winding portions 71 and 72. That is, the first end of the first winding portion 71 is connected to the cathode of the diode 93, and the first end of the second winding portion 72 is connected to the second end of the first winding portion 71. The anode of the diode 93 is connected to the second end of the second winding portion 72. Note that the electric circuit in FIG. 4 can be changed. For example, the capacitor can be arranged at another position in parallel with each of the winding portions 71 and 72, or the diode can be arranged at another position in parallel with each of the winding portions 71 and 72.

[0025] When a high-frequency exciting current flows through the stator winding 52, a variation due to a high-frequency component of the main magnetic flux occurs in the magnetic circuit including the stator core 51 and the rotor core 61. Due to the occurrence of the variation of the main magnetic flux, an induced voltage is generated in each of the winding portions 71 and 72, and a current is induced in each of the winding portions 71 and 72. When induced voltages having the same polarity are generated in the winding portions 71 and 72, the induced currents in the winding portions 71 and 72 are not canceled out, so the induced current increases. Also, the diode 93 rectifies the current flowing through each of the winding portions 71 and 72 in one direction. As a result, a field current flows through the field winding 70 in the direction rectified by the diode 93, and the field winding 70 is excited.

[0026] Returning to the description of FIG. 2, the control device 30 is mainly composed of a microcomputer (equivalent to a computer), and the microcomputer includes a processor and a memory. The control device 30 generates drive signals for turning on and off the switches SUp to SWn that constitute the inverter 20. Specifically, the control device 30 generates drive signals for turning on and off the switches SUp to SWn in order to convert the DC power output from the DC power supply 10 into AC power and supply it to the U, V, and W phase windings 52U, 52V, and 52W, and supplies the generated drive signals to the gates of the switches SUp to SWn.

[0027] The control device 30 turns on and off the switches SUp to SWn so that a combined current of a fundamental wave current and a high-frequency exciting current flows through each of the phase windings 52U, 52V, and 52W. The fundamental wave current is mainly a current that generates torque in the rotating electrical machine 40. The high-frequency exciting current is a high-frequency current having a higher frequency than the fundamental wave current, and is mainly a current that excites the field winding 70. It is also possible to use a harmonic current as the high-frequency current. The phase currents flowing through the phase windings 52U, 52V, and 52W are shifted by 120° in electrical angle.

[0028] Next, the configuration of the rotor 60 will be described in more detail. FIG. 5 is an exploded perspective view of the rotor 60. FIG. 6 is a perspective view showing the winding unit 110 disassembled in the rotor main body 101, and FIG. 7 is a cross-sectional view showing the cross-sectional structure of a part of the rotor main body 101.

[0029] The rotor 60 includes a rotor main body 101 and a circuit module 102 provided on one end side of both axial ends of the rotor main body 101. The rotor main body 101 includes a rotor core 61 and a field winding 70 as described with reference to FIG. 3, and a rotating shaft 32 is assembled in the central hole of the rotor core 61. The field winding 70 is composed of a plurality of winding units 110 arranged side by side in the circumferential direction. The circuit module 102 is fixed to the rotating shaft 32 with the rotating shaft 32 inserted through the hollow portion. The circuit module 102 is provided at a position axially opposed to the coil end on the axially outer side of the rotor core 61 in the field winding 70.

[0030] The rotor main body 101 has a plurality of winding units 110 provided for each pole of the rotor 60. Each winding unit 110 is formed in an annular shape with the axial direction as the longitudinal direction, and is assembled to the rotor core 61 with the main pole portion 62 of the rotor core 61 inserted into its hollow portion. In the present embodiment, the "pole coil" is constituted by the winding unit 110.

[0031] The winding unit 110 has a first coil module 111 on the outer side in the radial direction and a second coil module 112 on the inner side in the radial direction in a state of being attached to the main pole portion 62. The first coil module 111 is a coil module corresponding to the first winding portion 71, and the second coil module 112 is a coil module corresponding to the second winding portion 72.

[0032] The first coil module 111 has an annular coil body 121 formed by winding a conductor made of a flat wire multiple times in the circumferential and radial directions, and a thin plate-like insulator 122 provided integrally with the coil body 121. The insulator 122 has a portion extending in the circumferential direction and covering the outer peripheral portions on the outer and inner sides in the radial direction of the coil body 121, and a portion extending in the radial direction and covering the hollow portion of the coil body 121. That is, the outer peripheral portion on the outer side in the radial direction, the inner peripheral portion on the inner side in the radial direction, and the hollow portion of the coil body 121 are insulated and covered by the insulator 122.

[0033] The second coil module 112 has an annular coil body 123 formed by winding a conductor made of a flat wire multiple times in the circumferential and radial directions, and a thin plate-like insulator 124 provided integrally with the coil body 123. The insulator 124 has a portion extending in the circumferential direction and covering the outer peripheral portions on the outer and inner sides in the radial direction of the coil body 123, and a portion extending in the radial direction and covering the hollow portion of the coil body 123. That is, the outer peripheral portion on the outer side in the radial direction, the inner peripheral portion on the inner side in the radial direction, and the hollow portion of the coil body 123 are insulated and covered by the insulator 124.

[0034] The coil bodies 121 and 123 are air-core coils configured as, for example, α-wound coils. Note that the rectangular wire used for the coil bodies 121 and 123 has a substantially rectangular cross-sectional shape (specifically, a substantially rectangular shape), and the rectangular wire is composed of a conductor portion made of aluminum or the like and an insulating layer that covers the conductor portion. However, it is also possible to use round wire with a circular cross-section as the conductor wire.

[0035] As shown in FIG. 7, in the first coil module 111, as an example, the conductor wires are wound in two layers in the radial direction, and in the second coil module 112, the conductor wires are wound in six layers in the radial direction. Also, in each of the coil modules 111 and 112, the number of winding turns in the circumferential direction (in other words, the number of arrangements of the conductor wires in the circumferential direction) is different, and the number of winding turns is larger on the outer side in the radial direction than on the inner side in the radial direction. Thereby, an improvement in the space factor in the field winding 70 is achieved. Note that if the space factor is disregarded, it is also possible to make the number of winding turns in the circumferential direction the same for each of the coil bodies 121 and 123 arranged in the radial direction.

[0036] Also, in the rotor main body 101, between the main pole portions 62 of the rotor core 61, holding plates 125 and 126 for holding the assembled states of the first coil module 111 and the second coil module 112 are provided in a state where these coil modules 111 and 112 are assembled to each main pole portion 62. The holding plate 125 is attached to the outer side in the radial direction of the first coil module 111, and the holding plate 126 is attached between the first coil module 111 and the second coil module 112.

[0037] As shown in FIG. 6, in the winding unit 110 of each pole, two conductor wire ends 127 are drawn out axially from the first coil module 111, and six conductor wire ends 128 are drawn out axially from the second coil module 112. Then, in each winding unit 110 arranged in the circumferential direction, the respective conductor wire ends 127 and 128 are joined to each other by welding or the like, so that a plurality of first coil modules 111 provided on each main pole portion 62 are connected in series, and a plurality of second coil modules 112 provided on each main pole portion 62 are connected in series.

[0038] In addition, the configuration for connecting the windings (coil modules 111 and 112) of the main pole portions 62 arranged in the circumferential direction may be other than the configuration in which the conductor ends 127 and 128 of the coil modules 111 and 112 are joined by welding or the like as described above. For example, a configuration in which a conductor material is continuously wound around a plurality of main pole portions 62 so as to straddle the plurality of main pole portions 62 (a continuous winding configuration) may be adopted.

[0039] FIG. 8 is a perspective view showing a configuration example of the circuit module 102. The circuit module 102 has a component holder 130 made of a material having electrical insulation properties. Specifically, the component holder 130 is a resin molded body made of a resin material. The component holder 130 has a substantially disk shape with a central hole 131 at the center. The component holder 130 is configured to be assembled to the rotary shaft 32 with the rotary shaft 32 inserted through the central hole 131.

[0040] The component holder 130 is provided with a plurality of accommodating portions 132 for accommodating the capacitors 91 and 92 and the diode 93 so as to surround the central hole 131. In the configuration of FIG. 8, for example, the capacitors 91 and 92 are accommodated in 5 of the 6 accommodating portions 132, and the diode 93 is accommodated in the remaining 1 accommodating portion 132. In the component holder 130, the capacitors 91 and 92 and the diode 93 are electrically connected by a bus bar (not shown). Further, in the component holder 130, the winding end portions of the first coil module 111 that are the both ends of the first winding portion 71 in the first winding portion 71 and the winding end portions of the second coil module 112 that are the both ends of the second winding portion 72 in the second winding portion 72 are electrically connected to an electric circuit composed of the capacitors 91 and 92 and the diode 93 (see FIG. 4).

[0041] By the way, a configuration can be considered in which the connection part between the conductor ends extending from each winding unit 110 is provided in the region between the circuit module 102 (component holder 130) and the field winding 70. In this case, in order to avoid interference between the circuit module 102 and the conductor ends of each winding unit 110, it is necessary to extend the distance from the axial tip of each winding unit 110 (field winding 70) to the circuit module 102, and there is a concern that the size of the rotating electrical machine 40 will increase.

[0042] For example, in the rotor 60, when the electrical components mounted on the circuit module 102 become larger or the number of electrical components increases, the area required for accommodating the electrical components in the component holder 130 becomes larger, and the area for fixing the conductor ends extending from the field winding 70 cannot be secured. Therefore, a configuration is adopted in which the connection part between the conductor ends of each winding unit 110 is provided in the region between the circuit module 102 and the field winding 70. This configuration will be described with reference to FIG. 9, which is a schematic diagram of the rotating electrical machine 40.

[0043] In FIG. 9, on one side of both axial sides of the rotor 60, in the region between the circuit module 102 and the field winding 70, the conductor ends of the coil modules 111, 112 of each pole are joined. And by joining these conductor ends, the coil modules 111, 112 of each pole are electrically connected to each other. In FIG. 9, the portion where the coil modules 111, 112 are electrically connected to each other, that is, the portion including the conductor ends of the coil modules 111, 112 and the joining portion of the conductor ends is referred to as the "conductor connection portion CN". The coil modules 111, 112 provided for each main pole portion 62 are connected to each other via the conductor connection portion CN.

[0044] In the configuration of FIG. 9, in order to avoid interference between the circuit module 102 and the conductor connection portion CN, it is necessary to extend the distance from the axial tip of the field winding 70 to the circuit module 102. Therefore, there is a concern that the axial length on one side of the rotor 60 will become longer, and as a result, the size of the rotating electrical machine 40 will increase.

[0045] Therefore, in the present embodiment, as shown in FIG. 10, the circuit module 102 is provided on the first end X1 side (the left side in the figure), which is one axial side of the rotor core 61, and the conductor connection part CN is provided on the second end X2 side (the right side in the figure), which is the other axial end side of the rotor core 61. And thereby, while avoiding the interference between the circuit module 102 and the conductor connection part CN, the physical size of the rotating electrical machine 40 is reduced. The following will describe the specific configuration.

[0046] FIG. 11 is a diagram schematically showing the configuration regarding the connection between the field winding 70 (winding parts 71, 72) and the circuit module 102 in the comparative example. Further, FIG. 12 is a diagram schematically showing the configuration regarding the connection between the field winding 70 (winding parts 71, 72) and the circuit module 102 in the present embodiment. In FIGS. 11 and 12, a plurality of first coil modules 111 constituting the first winding part 71 and a plurality of second coil modules 112 constituting the second winding part 72 are shown arranged side by side left and right. Also, in FIGS. 11 and 12, the vertical direction is the axial direction of the rotor 60, the upper side of each winding part 71, 72 is the first end X1 side, and the lower side of each winding part 71, 72 is the second end X2 side.

[0047] In FIG. 11 which is a comparative example, in the coil modules 111, 112 of each main pole part 62, the conductor end parts are drawn out to the first end X1 side which is one axial side, and the conductor end parts of different coil modules 111, 112 are connected to each other to form the conductor connection part CN. Also, the circuit module 102 is provided on the first end X1 side as well.

[0048] In this comparative example, the rotating electrical machine 40 has the configuration shown in FIG. In this case, since the conductor connection part CN of each coil module 111, 112 and the circuit module 102 are provided on the first end X1 side of the rotor 60, the conductor connection part CN of each coil module 111, 112 and the circuit module 102 are arranged so as to be aligned in the axial direction. Therefore, there is a concern that the circuit module 102 may protrude axially with respect to the first coil end SE1 among the stator coil ends at both axial ends of the stator winding 52.

[0049] In contrast, in FIG. 12, in the coil modules 111 and 112 of each main pole portion 62, the circuit module 102 is provided on the first end X1 side which is one axial side. Further, the conductor end portions are drawn out to the second end X2 side which is the other axial side, and the conductor end portions of the different coil modules 111 and 112 are connected to each other to form a conductor connection portion CN. In this case, among the conductor end portions of each coil module 111 and 112 provided for each main pole portion 62, only the conductor end portions that are the both ends of the first winding portion 71 and the conductor end portions that are the both ends of the second winding portion 72 are drawn out to the first end X1 side (the side opposite to the conductor connection portion CN in the axial direction) and connected to the circuit module 102.

[0050] In the present embodiment, the rotating electrical machine 40 has the configuration shown in FIG. 10. In this case, the circuit module 102 and the conductor connection portion CN of each coil module 111 and 112 are provided separately on the first end X1 side and the second end X2 side of the rotor 60. Therefore, an increase in the axial length on one axial side of the rotor 60 is suppressed.

[0051] Here, on the first end X1 side, when the axial dimension from the axial end face of the rotor core 61 to the tip portion on the counter-rotor-core side of the circuit module 102 is L1 and the axial height of the first coil end SE1 of the stator winding 52 is H1, these L1 and H1 satisfy L1 ≤ H1. Thereby, the circuit module 102 is suppressed from protruding axially with respect to the first coil end SE1 of the stator 50.

[0052] Note that the tip portion on the counter-rotor-core side of the circuit module 102 is, for example, the axial end face on the counter-rotor-core side in the component holder 130. Further, a plate-shaped cover (a cover that covers electrical components) may be attached to the axial end face on the counter-rotor-core side of the component holder 130. When a cover is attached to the component holder 130, the tip portion on the counter-rotor-core side of the circuit module 102 is preferably the axial end face on the counter-rotor-core side in the cover.

[0053] Also, on the second end X2 side, if the axial dimension from the axial end face of the rotor core 61 to the tip of the conductor connection part CN on the side opposite to the rotor core is L2, and the axial height of the second coil end SE2 of the stator winding 52 is H2, then these L2 and H2 satisfy L2 ≤ H2. As a result, the conductor connection part CN is suppressed from protruding axially with respect to the second coil end SE2 of the stator 50.

[0054] The stator 50 has a stator winding 52 with a segment structure, and its configuration will be described with reference to FIG. 13. In the stator 50, a stator winding 52 composed of a plurality of conductor segments 151 is wound around the stator core 51. As shown in FIG. 14, the conductor segment 151 is formed by folding a conductor wire into a substantially U shape, and two tip portions on the side opposite to the folded portion are bent in the circumferential direction. In the conductor segment 151, the folded tip side is the turn portion 152, and both ends on the side opposite to the turn portion 152 are the conductor wire end portions 153. The conductor segment 151 corresponds to the "conductor wire for the stator winding".

[0055] The conductor segment 151 is inserted into the slot 54 with the turn portion 152 as one axial end side, and in this state, different conductor segments are connected to each other at the conductor wire end portions 153 on the side opposite to the turn portion 152. As a result, on one side (the lower side in FIG. 13) of both axial ends of the stator winding 52, the second coil end SE2 is formed by the turn portion 152 of the conductor segment 151, and on the other side (the upper side in FIG. 13), the first coil end SE1 is formed by the joining of the conductor wire end portions 153 of the conductor segment 151. That is, the first coil end SE1 has a joint portion where the end portions of the conductor segment 151 are joined, and the second coil end SE2 has a configuration without a joint portion where the end portions of the conductor segment 151 are joined.

[0056] In this case, at each coil end SE1, SE2, the coil end height from the axial end face of the stator core 51 is different, and on the side of the first coil end SE1, the coil end height is relatively high. Assuming that the axial height of the first coil end SE1 is H1 and the axial height of the second coil end SE2 is H2 as described in FIG. 10, these H1, H2 satisfy H1 > H2.

[0057] On the other hand, it is assumed that the axial thickness dimension of the circuit module 102 is larger than the axial dimension of the wire connection portion CN. For example, when the size of the electrical components in the circuit module 102 is increased or the number of components is increased, it is considered that the thickness dimension of the circuit module 102 will increase.

[0058] In the rotor 60 shown in FIG. 10, the first end X1 side where the circuit module 102 is provided becomes the side of the first coil end SE1 of the stator winding 52, and the second end X2 side where the wire connection portions CN of the coil modules 111, 112 are provided becomes the side of the second coil end SE2 of the stator winding 52. In this case, by arranging the circuit module 102 on the inner circumferential side of the first coil end SE1, which is the higher one of the coil end heights of the coil ends SE1, SE2 of the stator winding 52, the axial protrusion of the circuit module 102 with respect to the first coil end SE1 of the stator 50 is preferably suppressed.

[0059] The configuration of the wire connection portion CN on the second end X2 side of the rotor 60 will be further described with reference to FIGS. 15 and 16. FIG. 15 is a side view of the winding unit 110, and FIG. 16 is a view of the rotor main body 101 as seen from the second end X2 side in the axial direction.

[0060] In the field magnet winding 70, in the coil modules 111 and 112 (winding units 110) that constitute the pole coils, the number of turns of the conductor material is larger on the radially outer side than on the radially inner side (see Fig. 7). Therefore, as shown in Fig. 15, when the winding unit 110 is viewed from the side, on the radially outer side (the left side in the figure) of the field magnet winding 70, the coil end height from the axial end face of the rotor core 61 is relatively high, and on the radially inner side (the right side in the figure), the coil end height is relatively low. That is, the coil end portion CE of the field magnet winding 70 has a higher coil end height on the radially outer side than on the radially inner side.

[0061] Also, as shown in Fig. 16, on the second end X2 side of the rotor main body 101, for each magnetic pole, the conductor end portion 127 of the first coil module 111, for example, is arranged from the radially outer side toward the radially inner side.

[0062] Due to these circumstances, as shown in Fig. 15, in the coil end portion CE on the second end X2 side, it is preferable that the conductor connection portion CN is arranged using the inner space on the inner peripheral side of the portion where the coil end height is the highest. That is, in the winding unit 110, the conductor end portion 127 extends along the inclination of the axial end face of the coil end portion CE and is provided so as to incline toward the axial center side more on the radially inner side when viewed in the axial direction. Further, the radially innermost portion of the conductor end portion 127 is bent in the axial direction, and the bent portion serves as a joint portion joined to other conductor end portions 127 and the like. In this case, the conductor connection portion CN that connects the coil modules 111 and 112 of different magnetic poles to each other is preferably arranged in the inner space that is recessed in a substantially conical shape in the coil end portion CE on the second end X2 side. Thereby, on the second end X2 side, it is possible to reduce the axial dimension from the axial end face of the rotor core 61 to the tip portion on the side opposite to the rotor core of the conductor connection portion CN.

[0063] Note that only a part of the conductor connection portion CN may be arranged in the inner space that is recessed in a substantially conical shape in the coil end portion CE, or the entire conductor connection portion CN may be arranged in the inner space that is recessed in a substantially conical shape in the coil end portion CE.

[0064] According to the embodiment described in detail above, the following excellent effects can be obtained.

[0065] The circuit module 102 is provided on the first end X1 side which is one axial side of the rotor core 61, and the wire connection part CN is provided on the second end X2 side which is the other axial end side of the rotor core 61. Thereby, interference between the circuit module 102 and the wire connection part CN can be avoided. Further, in the configuration in which the wire connection part CN of the coil modules 111 and 112 and the circuit module 102 are provided separately on both axial sides of the rotor 60, in the rotating electric machine 40 in which the rotor 60 and the stator 50 are arranged to face each other radially inside and outside, the circuit module 102 is suppressed from protruding axially outside the stator winding 52. As described above, the size reduction of the rotating electric machine 40 can be achieved.

[0066] On the first end X1 side of the rotor 60, the axial dimension from the axial end face of the rotor core 61 to the tip portion on the side opposite to the rotor core of the circuit module 102 is set to be equal to or less than the axial height of the stator coil end (SE1) on the first end X1 side. Thereby, size reduction on the first end X1 side of the rotor 60 can be realized.

[0067] On the second end X2 side of the rotor 60, the axial dimension from the axial end face of the rotor core 61 to the tip portion on the side opposite to the rotor core of the wire connection part CN is set to be equal to or less than the axial height of the stator coil end (SE2) on the second end X2 side. Thereby, size reduction on the second end X2 side of the rotor 60 can be realized.

[0068] The stator winding 52 has a joint at the first coil end SE1 of the stator 50 where the ends of the conductor segments 151 are joined, and is configured not to have a joint at the second coil end SE2 where the ends of the conductor segments 151 are joined. Then, the rotor 60 is oriented such that the first end X1 side of the rotor core 61 faces the first coil end SE1 side of the stator winding 52, and the second end X2 side of the rotor core 61 faces the second coil end SE2 side of the stator winding 52. In this case, in the stator winding 52, the axial heights (axial length dimensions) of the first coil end SE1 and the second coil end SE2 are different, and the axial height of the first coil end SE1 is higher. However, considering this difference in axial height, the circuit module 102 and the conductor connection part CN of the field winding 70 can be suitably arranged respectively.

[0069] In each winding unit 110 of the field winding 70, the occupation ratio of the field winding 70 can be increased by increasing the number of turns of the conductor material on the radially outer side compared to the radially inner side. In this case, the coil end height of the coil end of the field winding 70 is higher on the radially outer side than on the radially inner side. And, a configuration is adopted in which the conductor connection part CN is arranged in at least a part of the inner space on the inner peripheral side of the coil end at the second end X2 side of the field winding 70, which is closer to the inner periphery than the part where the coil end height is the highest. Thereby, a reduction in size at the second end X2 side in the rotor 60 can be realized.

[0070] (Other embodiments) The above embodiment may be modified as follows, for example.

[0071] · In the above embodiment, in the rotor 60, the conductor connection part CN is formed by joining the conductor ends extending from each coil module 111, 112, but this may be changed. For example, in the rotor 60, it is possible to configure the field winding 70 by continuously winding the conductor material around each main pole part 62 arranged in the circumferential direction. In this case, pole coils are wound around each main pole part 62 by continuous winding, and the crossing part of the conductor material connecting the pole coils for each main pole part 62 becomes the "conductor connection part CN".

[0072] In addition, when the conductor end portions extending from each of the coil modules 111 and 112 are joined to form a conductor connection portion CN, the conductor connection portion CN can be referred to as a "winding connection portion". Further, when the jumper wire connecting the winding portions for each main pole portion 62 becomes the conductor connection portion CN, the conductor connection portion CN can be referred to as a "winding jumper portion".

[0073] · The field winding 70 is not limited to a configuration including a first winding portion 71 and a second winding portion 72. For example, the field winding 70 may be configured such that each winding portion (pole coil) for each main pole portion 62 is connected in series without being divided into the first and second winding portions 71 and 72. Further, a configuration in which diodes are connected to both ends of the field winding 70, or a configuration in which a diode and a capacitor are connected in parallel may also be used.

[0074] That is, in the above embodiment, the pole coil of each pole is constituted by a winding unit 110 composed of two coil modules (a first coil module 111 and a second coil module 112) for each pole, but this may be changed, and the pole coil of each pole may be constituted by one coil module for each pole.

[0075] · In the stator 50, the stator core may be a stator core provided without teeth.

[0076] · The rotating electrical machine is not limited to a rotating electrical machine used as an in-vehicle main machine, and for example, a rotating electrical machine used as an ISG (Integrated Starter Generator) which is a motor-generator may also be used.

[0077] · The moving body on which the rotating electrical machine system is mounted is not limited to a vehicle, and for example, an aircraft or a ship may also be used. Further, the rotating electrical machine system is not limited to a system mounted on a moving body, and may be a stationary system.

[0078] The technical idea extracted from the above embodiment will be described below. [Configuration 1] A stator (50) having a stator winding (52), a rotor (60) having a rotor core (61) with a plurality of main pole portions (62) provided for each of the circumferentially arranged magnetic poles and protruding in the radial direction, and field windings (70) wound around each of the main pole portions, a circuit module (102) provided rotatable integrally with the rotor and having electrical components connected to the field windings, A wound-field rotating electrical machine (40) having: The field winding has a plurality of pole coils (110) each formed by winding a conductor around each main pole portion, and the pole coils of each main pole portion are electrically connected to each other via conductor connection portions (CN). The circuit module is provided on a first end side which is one axial side of the rotor core, while the conductor connection portion is provided on a second end side which is the other axial side of the rotor core. A wound-field rotating electrical machine. [Configuration 2] Both axial sides of the stator winding are stator coil ends. On the first end side of the rotor, the axial dimension from the axial end face of the rotor core to the tip of the circuit module on the side opposite to the rotor core is equal to or less than the axial height of the stator coil end (SE1) on the first end side. The wound-field rotating electrical machine according to Configuration 1. [Configuration 3] Both axial sides of the stator winding are stator coil ends. On the second end side of the rotor, the axial dimension from the axial end face of the rotor core to the tip of the conductor connection portion on the side opposite to the rotor core is equal to or less than the axial height of the stator coil end (SE2) on the second end side. The wound-field rotating electrical machine according to Configuration 1 or 2. [Configuration 4] In the stator winding, one of the stator coil ends at both axial ends is a first coil end (SE1) and the other is a second coil end (SE2). The first coil end has a joint portion where the ends of the conductor wires for the stator winding are joined, and the second coil end does not have a joint portion where the ends of the conductor wires for the stator winding are joined. The rotor is oriented such that the first end side of the rotor core is on the side of the first coil end of the stator winding and the second end side of the rotor core is on the side of the second coil end of the stator winding, the wound-field type rotating electrical machine according to any one of Configurations 1 to 3. [Configuration 5] In the field winding, the pole coil has a larger number of turns of the conductor wire on the radially outer side than on the radially inner side, and the coil end of the field winding has a higher coil end height on the radially outer side than on the radially inner side. In the coil end of the second end side of the field winding, the wire connection portion is disposed in at least a part of the inner space that is on the inner peripheral side of the portion where the coil end height is the highest, the wound-field type rotating electrical machine according to any one of Configurations 1 to 4.

Description of Reference Numerals

[0079] 40... rotating electrical machine, 50... stator, 52... stator winding, 60... rotor, 61... rotor core, 62... main pole portion, 70... field winding, 102... circuit module, 111, 112... coil module, CN... wire connection portion.

Claims

1. A stator (50) having a stator winding (52), a rotor (60) having a rotor core (61) provided with a plurality of main pole portions (62) protruding radially for each of the circumferentially arranged magnetic poles, and field windings (70) wound around each of the main pole portions, a circuit module (102) provided rotatable integrally with the rotor and having electrical components connected to the field windings, A wound-field rotating electrical machine (40) having: The field winding has a plurality of pole coils (110) formed by winding a conductor around each of the main pole portions, and the pole coils of each main pole portion are electrically connected to each other via a conductor connection portion (CN), A wound-field rotating electrical machine, wherein the circuit module is provided on a first end side which is one axial end side of the rotor core, and the conductor connection portion is provided on a second end side which is the other axial end side of the rotor core.

2. Both axial ends of the stator winding are stator coil ends, The wound-field rotating electrical machine according to claim 1, wherein, on the first end side of the rotor, an axial dimension from an axial end face of the rotor core to a tip portion on the side opposite to the rotor core of the circuit module is equal to or less than an axial height of the stator coil end (SE1) on the first end side.

3. Both axial ends of the stator winding are stator coil ends, The wound-field rotating electrical machine according to claim 1 or 2, wherein, on the second end side of the rotor, an axial dimension from an axial end face of the rotor core to a tip portion on the side opposite to the rotor core of the conductor connection portion is equal to or less than an axial height of the stator coil end (SE2) on the second end side.

4. In the stator winding, one of the stator coil ends at both axial ends is a first coil end (SE1), and the other is a second coil end (SE2), The first coil end has a joint portion where ends of the conductor for the stator winding are joined, and the second coil end does not have a joint portion where ends of the conductor for the stator winding are joined, The wound-field rotating electrical machine according to claim 1, wherein the rotor is oriented such that the first end side of the rotor core is on the side of the first coil end of the stator winding, and the second end side of the rotor core is on the side of the second coil end of the stator winding.

5. In the field winding, the number of turns of the conductor material in the pole coil is larger on the radially outer side than on the radially inner side, and the coil end height of the field winding is higher on the radially outer side than on the radially inner side. The winding field type rotating electrical machine according to claim 1, wherein the wire connection portion is disposed in at least a part of an inner space on the inner peripheral side of a portion where the coil end height is highest at the coil end on the second end side of the field winding.

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