Winding field magnet rotor

Abstract

To keep a joint portion of a wiring portion in an appropriate state in a winding field magnet rotor.SOLUTION: A rotor includes a rotor core, a field magnet winding, and a circuit module. The circuit module has a component holder 141 for holding an electrical component. On a first surface F1 side which is an opposite rotor core side out of the first surface side and a second surface side on both the sides in an axial direction in the component holder 141, wiring end portions which are end portions of a wiring portion extending from the field magnet winding and the electrical component extend in the axial direction from the component holder 141, and the wiring end portions are joined to each other. A support member 163 is provided on the first surface F1 side of the component holder 141 in a state where the support member surrounds a joint portion of the wiring end portions.SELECTED DRAWING: Figure 20

Description

[Technical Field]

[0001] The disclosure in this specification relates to a wound field rotor used in a wound field type rotating electric machine. [Background technology]

[0002] In a wound-field rotating electric machine, the rotor has a rotor core with a plurality of main poles (magnetic salient poles) arranged in the circumferential direction, and a field winding wound around the main poles. In the rotating electric machine described in Patent Document 1, a circuit module equipped with capacitors and diodes as electrical components is provided at an axial end of the rotor. The circuit module includes a component holder for holding the electrical components, and portions of wiring extending from the field winding and the electrical components are held by the component holder, with the ends of the wiring joined together. More specifically, the wiring is held in the component holder with its tip end extending in the axial direction, and the tip end of the wiring is joined together by welding or the like. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-124100 Summary of the Invention [Problem to be solved by the invention]

[0004] In the conventional configuration, the wiring portions protrude axially from the component holder, and the tips of the axially protruding wiring portions are joined together, which raises concerns that the joints at the tips of the wiring portions may peel off due to centrifugal force or rotational fluctuations during rotor rotation.

[0005] The present disclosure has been made in consideration of the above circumstances, and has an object to maintain the joints of wiring portions in a wound field rotor in an appropriate state. [Means for solving the problem]

[0006] The present disclosure provides: a rotor core having a plurality of main pole portions provided for each magnetic pole; a field winding formed by winding a conductor around the main pole portion; a circuit module disposed on one axial end side of the rotor core and having an electrical component connected to the field winding; A wound field rotor comprising: the circuit module has a component holder that holds the electrical component; of a first surface side and a second surface side on both sides in the axial direction of the component holder, on the first surface side opposite to the rotor core, wiring ends that are ends of wiring portions extending from the field winding and the electrical component extend from the component holder in the axial direction, and the wiring ends are joined to each other, A support member is provided on the first surface side of the component holder so as to surround the joint between the wiring end portions.

[0007] In the wound field rotor of the above configuration, the wiring ends, which are ends of the wiring portions extending from the field winding and the electrical components, extend from the first surface side, which is the side opposite the rotor core, of the first and second surfaces on both axial sides of the component holder. This configuration allows the work of joining the wiring ends to be performed efficiently. However, with a configuration in which the wiring ends extend from the first surface side, which is the side opposite the rotor core of the component holder, there is a concern that the centrifugal force and rotational fluctuations during rotor rotation may cause peeling of the joint at the extending portion of the wiring end.

[0008] In this regard, in the above configuration, the support member is provided on the first surface side of the component holder so as to surround the joint between the wire ends. This prevents the extensions of the wire ends from being displaced or deformed even when centrifugal force or rotational fluctuations occur during rotor rotation. This prevents problems such as peeling of the joints at the extensions of the wire ends. As a result, the joints of the wires in the wound field rotor can be maintained in an appropriate state. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an overall configuration diagram of a control system for a rotating electrical machine. [Figure 2] FIG. 2 is a diagram showing an inverter and its peripheral configuration. [Figure 3] FIG. [Figure 4] FIG. 3 is a diagram showing an electric circuit provided in the rotor. [Figure 5] FIG. 2 is a perspective view showing the overall configuration of the rotor. [Figure 6] FIG. 4 is a perspective view showing a state in which a covering portion and a coil end cover are removed from the rotor. [Figure 7] FIG. [Figure 8] FIG. [Figure 9] FIG. 4 is an exploded perspective view of a winding unit in the rotor main portion. [Figure 10] FIG. 3 is a cross-sectional view showing a cross-sectional structure of a part of a rotor main portion. [Figure 11] FIG. [Figure 12] FIG. 2 is a diagram showing the internal configuration of the bus bar module. [Figure 13] FIG. [Figure 14] FIG. 3 is a diagram showing the internal configuration of a part holder. [Figure 15] FIG. 4 is a perspective view showing the configuration of an axial end portion of the rotor main portion. [Figure 16] FIG. 2 is a perspective view showing a state in which the busbar module is assembled to the rotor main portion. [Figure 17] FIG. 4 is a perspective view showing a state in which the part holder is assembled to the rotor main portion. [Figure 18] FIG. 10 is a plan view of the bus bar module and the component holder stacked together, viewed from the bus bar module side. [Figure 19] FIG. 4 is an enlarged perspective view showing a portion of the component holder where wiring connections are made; [Figure 20] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 21]FIG. 3 is a diagram for explaining the configuration of a crossover wire of a field winding. [Figure 22] FIG. 4 is a diagram schematically showing the connection state of each of the first coil modules arranged in the circumferential direction. [Figure 23] FIG. 4 is a plan view of the bus bar module and the component holder as viewed from the second surface side. [Figure 24] FIG. 4 is a perspective view of the bus bar module and the component holder as viewed from the second surface side. [Figure 25] FIG. 4 is a vertical cross-sectional view showing the configuration of the vicinity of a coil end of a field winding. [Figure 26] FIG. 4 is an enlarged perspective view showing a portion of the component holder where wiring connections are made; [Figure 27] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 28] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 29] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 30] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 31] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 32] FIG. 4 is a longitudinal cross-sectional view showing the cross-sectional structure of a wiring connection portion in the component holder. [Figure 33] FIG. 10 is a schematic diagram showing a configuration in which the first coil module of each pole is continuously wound with a conductive wire. [Figure 34] 10A and 10B are diagrams illustrating a holding structure for a crossover wire in a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0010] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A wound-field rotating electric machine according to an embodiment of the present disclosure is used as a power source for driving electric vehicles such as electric vehicles and hybrid vehicles.

[0011] First, a control system including a rotating electric 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 electric machine 40. The rotating electric machine 40 is a self-excited wound field type synchronous machine. For example, the rotating electric machine 40, the inverter 20, and the control device 30 may be configured as an electromechanical integrated drive device, or the rotating electric machine 40, the inverter 20, and the control device 30 may each be configured with its own component.

[0012] The rotating electric machine 40 includes a housing 41, and a stator 50 and a rotor 60 housed in the housing 41. The rotating electric machine 40 of this embodiment is an inner rotor type rotating electric machine in which the rotor 60 is disposed radially inside the stator 50.

[0013] 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-, and W-phase windings 52U, 52V, and 52W that are arranged with an electrical angle offset of 120° from one another.

[0014] The rotor 60 includes a rotor core 61 and a field winding 70. The field winding 70 is preferably made of a conductor material such as aluminum wire, which has a low specific gravity and is easily formed. The conductor material of the field winding 70 is not limited to aluminum wire, and may be copper wire or CNT (carbon nanotube), for example. A rotating shaft 32 is assembled in the center hole of the rotor core 61. The rotating shaft 32 is rotatably supported in the housing 41 by bearings 42 and 43.

[0015] As shown in FIG. 2, the inverter 20 includes a series connection of upper-arm switches SUp, SVp, and SWp for U, V, and W phases and lower-arm switches SUn, SVn, and SWn for U, V, and W phases. First ends of U, V, and W-phase windings 52U, 52V, and 52W are connected to the connection points between the upper-arm switches SUp, SVp, and SWp and the lower-arm switches SUn, SVn, and SWn for each phase. Second ends of the U, V, and W-phase windings 52U, 52V, and 52W are connected at the neutral point. That is, in this embodiment, the stator winding 52 is star-connected. However, the stator winding 52 may also be delta-connected. In this embodiment, each of the switches SUp to SWn is, for example, an IGBT. A freewheel diode is connected in antiparallel to each of the switches SUp to SWn.

[0016] The collectors of the upper arm switches SUp, SVp, SWp of each phase are connected to the positive terminal of a DC power supply 10. The emitters of the lower arm switches SUn, SVn, SWn of each phase are connected to the negative terminal of the DC power supply 10. A smoothing capacitor 11 is connected in parallel to the DC power supply 10.

[0017] Next, the stator 50 and the rotor 60 will be described with reference to FIG.

[0018] The stator 50 and the rotor 60 are both arranged coaxially with the rotating shaft 32. In the following description, the direction in which the rotating shaft 32 extends is referred to as the axial direction, the direction extending radially from the center of the rotating shaft 32 is referred to as the radial direction, and the direction extending circumferentially around the rotating shaft 32 is referred to as the circumferential direction.

[0019] The stator core 51 is made of laminated steel plates made of a soft magnetic material and has an annular back yoke 51a and multiple teeth 51b protruding radially inward from the back yoke 51a. Multiple slots 54 are formed between adjacent teeth 51b in the circumferential direction. The stator winding 52 is formed by accommodating the phase windings of each phase in a predetermined order in each of these slots 54. For example, the stator 50 may employ a segment coil structure using multiple conductor segments. However, the structure of the stator winding 52 is arbitrary.

[0020] The rotor core 61 is made of a soft magnetic material, for example, laminated steel plates. The rotor core 61 has a cylindrical portion 61a and a plurality of main pole portions 62 that protrude radially outward from the cylindrical portion 61a. A field winding 70 is wound around the main pole portions 62 by concentrated winding. In this embodiment, eight main pole portions 62 are provided at equal intervals in the circumferential direction.

[0021] The field winding 70 includes a first winding portion 71 and a second winding portion 72. The first winding portion 71 is wound radially outward around each main pole portion 62, and the second winding portion 72 is wound radially inward relative to 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. Furthermore, of circumferentially adjacent main pole portions 62, 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. Therefore, the magnetization directions of circumferentially adjacent main pole portions 62 are opposite to each other. In the rotor 60, the main pole portions 62 in the rotor core 61 and the field winding 70 wound around each main pole portion 62 form a plurality of magnetic poles (field poles) arranged in the circumferential direction.

[0022] FIG. 4 is a diagram illustrating an electric circuit including the first and second winding portions 71 and 72 in the rotor 60. The first winding portion 71 and the second winding portion 72 are connected in series by connecting the second end 71b of the first winding portion 71 to the first end 72a of the second winding portion 72. A diode 91 and a capacitor 92 are connected to the second end 71b of the first winding portion 71 in parallel with the second winding portion 72. A diode 93 and a capacitor 94 are connected in series to the series connection of the first winding portion 71 and the second winding portion 72. In the following description, the diode 91 and the capacitor 92 connected in parallel with the second winding portion 72 are also referred to as the parallel diode 91 and the parallel capacitor 92, respectively. The diode 93 and the capacitor 94 connected in series to the series connection of the first winding portion 71 and the second winding portion 72 are also referred to as the series diode 93 and the series capacitor 94, respectively. The capacitors 92 and 94 are, for example, ceramic capacitors or film capacitors.

[0023] The parallel diode 91 has a cathode connected to the first end 72a of the second winding portion 72 and an anode connected to the second end 72b of the second winding portion 72. As a result, in a closed circuit including the second winding portion 72 and the parallel diode 91, current flows in one direction, from the anode side to the cathode side of the parallel diode 91. Furthermore, the series diode 93 has a cathode connected to the first end 71a of the first winding portion 71 and an anode connected to the second end 72b of the second winding portion 72. As a result, the field current flowing through each winding portion 71, 72 is rectified. In this embodiment, the number of turns of the second winding portion 72 is greater than the number of turns of the first winding portion 71.

[0024] Returning to the description of FIG. 2 , the control device 30 is an electronic control unit (EC) primarily composed of a microcomputer 31. The microcomputer 31 includes a central processing unit (CPU). The functions provided by the microcomputer 31 can be provided by software stored in a physical memory device and a computer executing the software, software alone, hardware alone, or a combination thereof. For example, if the microcomputer 31 is provided by hardware electronic circuits, the functions can be provided by digital circuits including multiple logic circuits or analog circuits. For example, the microcomputer 31 executes programs stored in a non-transitory tangible storage medium (NSS) that serves as its own storage unit. The programs include programs for controlling the rotating electric machine 40. A method corresponding to the programs is performed by executing a set of instructions that constitute the programs. The storage unit is, for example, a non-volatile memory. The programs stored in the storage unit can be updated via a communication network such as the Internet, for example, via OTA (Over The Air) or other means.

[0025] Control device 30 generates drive signals that turn on and off each of switches SUp to SWn that constitute inverter 20. Specifically, control device 30 generates drive signals that turn on and off each of switches SUp to SWn and outputs the generated drive signals to the gates of each of switches SUp to SWn in order to convert DC power output from DC power supply 10 into AC power and supply it to U-, V-, and W-phase windings 52U, 52V, and 52W. As a result, in each phase, the upper arm switches and the lower arm switches are alternately turned on with dead times therebetween.

[0026] Control device 30 turns on and off each of switches SUp to SWn so as to pass a composite current of a fundamental current and a high-frequency current (specifically, a high-frequency excitation current) having a frequency higher than that of the fundamental current through each of phase windings 52U, 52V, 52W. The fundamental current is a current that mainly serves to generate torque in rotating electric machine 40. The high-frequency current is a current that mainly serves to excite first and second winding portions 71 and 72 that constitute field winding 70, thereby inducing a field current in field winding 70. The phase currents flowing through phase windings 52U, 52V, 52W are shifted by 120 electrical degrees.

[0027] The high-frequency current flowing through the stator winding 52 may be a harmonic current whose fluctuating frequency is N times (N is an integer greater than or equal to 2) the frequency of the fundamental current, or may be a current whose fluctuating frequency is different from N times the frequency of the fundamental current.

[0028] When a high-frequency current flows through the stator winding 52, a voltage is induced in the first and second winding portions 71 and 72, causing a field current to flow. The induced voltages in the first and second winding portions 71 and 72 are, for example, in phase. The currents IL1 and IL2 flowing through the first and second winding portions 71 and 72 contain frequency components of the high-frequency current.

[0029] 4, when the first and second winding portions 71, 72 are excited by energizing the stator winding 52, a current flows from the first winding portion 71 to the second winding portion 72. Furthermore, when the voltage across the second winding portion 72 exceeds the forward voltage of the parallel diode 91, a current IL2, which is greater than the current IL1 flowing through the first winding portion 71, flows through the closed circuit including the second winding portion 72 and the parallel diode 91. The flow of a current through the closed circuit including the second winding portion 72 and the parallel diode 91 increases the DC component of the field current. This increases the DC component of the magnetic flux of the rotor 60, thereby increasing the torque of the rotating electric machine 40.

[0030] Furthermore, when a current flows through the closed circuit including the second winding portion 72 and the parallel diode 91, a portion of the current flows through the first winding portion 71. In this case, the direction of the current IL1 flowing through the first winding portion 71 and the direction of the current IL2 flowing through the second winding portion 72 are opposite to each other. This reduces the pulsation of the field current, which is the sum of the currents IL1 and IL2, and ultimately reduces the torque pulsation of the rotating electric machine 40.

[0031] Next, the configuration of the rotor 60 will be described in more detail. Fig. 5 is a perspective view showing the overall configuration of the rotor 60, and Fig. 6 is a perspective view showing the rotor 60 with the outer covering portion 102 that covers the rotor main portion 101 and the coil end covers 103, 104 removed. Fig. 7 is an exploded perspective view of the rotor 60, and Fig. 8 is a vertical cross-sectional view of the rotor 60.

[0032] The rotor 60 is broadly divided into a rotor main section 101, a cylindrical outer covering section 102 provided to surround the outer periphery of the rotor main section 101, coil end covers 103 and 104 attached to one and the other axial ends of the rotor main section 101, and a busbar module 105 and a circuit module 106 provided at one end of both axial sides of the rotor main section 101. The rotor main section 101 includes a rotor core 61 and a field winding 70, and the rotating shaft 32 is attached to the center hole of the rotor core 61. The field winding 70 is made up of a plurality of winding units 110 arranged in the circumferential direction.

[0033] The busbar module 105 and the circuit module 106 are fixed to the rotating shaft 32 with the rotating shaft 32 inserted through each hollow portion. As a result, the busbar module 105 and the circuit module 106 are provided at positions axially facing the coil end portions of the field winding 70. The outer circumferential covering portion 102 is formed by using, for example, a string-like yarn and winding the yarn in multiple layers around the outer circumferential sides of the plurality of winding units 110 assembled to the rotor core 61.

[0034] FIG. 9 is an exploded perspective view of the winding unit 110 in the rotor main section 101, and FIG. 10 is a cross-sectional view showing the cross-sectional structure of a part of the rotor main section 101.

[0035] The rotor main section 101 has a plurality of winding units 110, one for each magnetic 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 section 62 of the rotor core 61 inserted into its hollow section. In this embodiment, the winding units 110 form a "pole coil."

[0036] The winding unit 110 has a first coil module 111 that is on the radially outer side when attached to the main pole section 62, and a second coil module 112 that is on the radially inner side. The first coil module 111 is a coil module that corresponds to the first winding section 71, and the second coil module 112 is a coil module that corresponds to the second winding section 72.

[0037] The first coil module 111 has an annular coil body 121 formed by winding a conductor material made of a rectangular 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 that extends circumferentially and covers the outer peripheral portions on the radially outer and inner sides of the coil body 121, and a portion that extends radially and covers the hollow portion of the coil body 121. In other words, the outer peripheral portion on the radially outer side, the inner peripheral portion on the radially inner side, and the hollow portion of the coil body 121 are insulated and coated with the insulator 122.

[0038] The second coil module 112 has an annular coil body 123 formed by winding a conductor material made of a rectangular 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 that extends circumferentially and covers the outer peripheral portions on the radially outer and inner sides of the coil body 123, and a portion that extends radially and covers the hollow portion of the coil body 123. In other words, the outer peripheral portion on the radially outer side and the inner peripheral portion and hollow portion of the coil body 123 are insulated and coated with the insulator 124.

[0039] The coil body 121 of the first coil module 111 is, for example, an α-winding coil in which a conductive wire is wound in an α-winding manner. The coil body 123 of the second coil module 112 is a continuously wound coil in which a conductive wire is continuously wound in a predetermined circumferential direction. In the first coil module 111, two conductive wire ends 125 are drawn out in the axial direction, and in the second coil module 112, two conductive wire ends 126 are drawn out in the axial direction. In each of the winding units 110 arranged in the circumferential direction, the conductive wire ends 125, 126 are connected to each other, so that the multiple first coil modules 111 provided on each main pole part 62 are connected in series, and the multiple second coil modules 112 provided on each main pole part 62 are connected in series. In each of the coil modules 111, 112, the portion where the conductor is wound around the main pole portion 62 is the "winding portion," and the end of the conductor extending from the winding portion is the "conductor end portion 125, 126."

[0040] The conductor wire used for the coil bodies 121, 123 is, for example, a flat wire having a substantially rectangular cross section (specifically, a substantially rectangular shape). The flat wire is composed of a conductor portion made of aluminum or the like and an insulating layer covering the conductor portion. However, a round wire having a circular cross section can also be used as the conductor wire. Note that the coil structure of each coil module 111, 112 is optional; for example, the coil bodies 121, 123 can both be continuous wound coils.

[0041] As shown in Fig. 10, the first coil module 111 has two radially wound layers of conductive wire, while the second coil module 112 has twelve radially wound layers of conductive wire. The number of layers in each of the coil modules 111, 112 is arbitrary, but it is preferable that the number of layers in the second coil module 112 is greater than the number of layers in the first coil module 111. The coil modules 111, 112 have different numbers of circumferential windings (in other words, the number of rows of conductive wire in the circumferential direction), with the number of windings being greater on the radially outer side than on the radially inner side. This improves the space factor of the field winding 70.

[0042] Next, the bus bar module 105 and the circuit module 106 will be described. Fig. 11 is a perspective view of the bus bar module 105, and Fig. 12 is a diagram showing the internal configuration of the bus bar module 105. Fig. 13 is a perspective view showing the circuit module 106 exploded into a component holder 141 and a heat sink 151, and Fig. 14 is a diagram showing the internal configuration of the component holder 141.

[0043] 11 and 12, busbar module 105 has main body 131 made of a resin molded body, and has a center hole 132 at the center thereof. A highly rigid cylindrical member 133 made of, for example, metal is assembled in center hole 132. Busbar module 105 is assembled to rotating shaft 32 with rotating shaft 32 inserted into the inner periphery of cylindrical member 133.

[0044] A plurality of bus bars 134 for electrically connecting the coil modules 111, 112 for each magnetic pole are embedded in the main body 131. In the main body 131, each bus bar 134 is arranged to extend circumferentially around the central hole 132, and both longitudinal ends of each bus bar 134 form arm portions 134a that extend radially. The arm portions 134a protrude radially outward from the outer circumferential surface of the main body 131, and their tip portions are bent in the axial direction.

[0045] The bus bar 134 of the bus bar module 105 has: Seven bus bars 134 that connect the first coil modules 111 for eight magnetic poles in series; Seven bus bars 134 that connect the second coil modules 112 for eight magnetic poles in series; The arm portions 134a of each bus bar 134 are connected to the conductor ends of the coil modules 111, 112, one by one. The bus bars 134 also include bus bars 134 that form both ends of a series-connected body of first coil modules 111 with eight magnetic poles, and bus bars 134 that form both ends of a series-connected body of second coil modules 112 with eight magnetic poles.

[0046] 13 and 14, the circuit module 106 has a component holder 141 that houses electrical components, and a heat sink 151 that is placed on the component holder 141. The component holder 141 and the heat sink 151 are both disk-shaped and have the same outer diameter. The component holder 141 and the heat sink 151 are integrated with their axial end faces joined together (see FIG. 7).

[0047] Component holder 141 is made of a resin molded body and has a center hole 142 at its center. A highly rigid cylindrical member 143 made of, for example, metal is attached to center hole 142. Component holder 141 is attached to rotating shaft 32 with rotating shaft 32 inserted into the inner periphery of cylindrical member 143.

[0048] Component holder 141 has electrical components that configure the electrical circuit described in Fig. 4, and also has a plurality of bus bars 145 electrically connected to each of these electrical components. These electrical components and bus bars 145 are provided in component holder 141 in a state where they are embedded in resin.

[0049] The component holder 141 holds the diodes 91 and 93 and the capacitors 92 and 94 as electrical components around the central hole 142. A bus bar 145 is connected to each of these electrical components. In this embodiment, three bus bars 145_1, 145_2, and 145_3 are used as the bus bar 145. In the component holder 141, the periphery of each electrical component may be sealed with a sealing material.

[0050] The bus bar 145_1 is connected to the diode 93 and the capacitor 94, and in terms of the electrical circuit of Fig. 4, is a bus bar connected to the first end 71a of the first winding portion 71. The bus bar 145_2 is connected to the diode 91 and the capacitor 92, and in terms of the electrical circuit of Fig. 4, is a bus bar connected to the second end 71b of the first winding portion 71 and the first end 72a of the second winding portion 72. The bus bar 145_3 is connected to the diodes 91, 93 and the capacitors 92, 94, and in terms of the electrical circuit of Fig. 4, is a bus bar connected to the second end 72b of the second winding portion 72.

[0051] In the component holder 141, each bus bar 145 is arranged to extend circumferentially around the central hole 142, and each has an arm portion 145a extending radially. The arm portion 145a extends radially, with its tip portion bent axially. The tip portion of the arm portion 145a is exposed to the outside of the holder and serves as a connection end portion where connection to the first winding portion 71 and the second winding portion 72 is made.

[0052] As shown in FIG. 13 , heat sink 151 is fixed to one of the axially opposite sides of component holder 141 on the side opposite rotor core 61 (the right side in the figure). By fixing heat sink 151 to component holder 141, the entire end face of component holder 141 on the side opposite the rotor core is covered by heat sink 151. Heat sink 151 is made of aluminum, for example. However, heat sink 151 may be made of other materials with excellent heat dissipation properties, such as aluminum alloy or copper. A central hole 152 is provided in the center of heat sink 151. A cylindrical member 143 integrated with component holder 141 is assembled into central hole 152.

[0053] By fixing the heat sink 151 to the axial end face of the component holder 141, heat generated in the diodes 91 and 93 and the capacitors 92 and 94 when current is applied to the component holder 141 is released via the heat sink 151.

[0054] Component holder 141 is provided with a plurality of through holes 146 that penetrate in the plate thickness direction. Heat sink 151 is provided with a plurality of through holes 153 that penetrate in the plate thickness direction. These through holes 146, 153 are provided at positions that communicate with each other in the axial direction.

[0055] Here, the wiring structure at the coil end of the field winding 70 will be described with reference to Figs. 15 to 17. Fig. 15 is a perspective view showing the configuration of the axial end of the rotor main section 101. Fig. 16 is a perspective view showing a state in which a busbar module 105 is assembled to one axial side of the rotor main section 101, and Fig. 17 is a perspective view showing a state in which a component holder 141 of a circuit module 106 is assembled to one axial side of the rotor main section 101. In other words, Fig. 16 is a perspective view showing a state in which a busbar module 105 is assembled to the configuration shown in Fig. 15, and Fig. 17 is a perspective view showing a state in which a component holder 141 of a circuit module 106 is assembled to the configuration shown in Fig. 16.

[0056] 15, eight winding units 110 are arranged circumferentially in the rotor main section 101, and in each winding unit 110, two conductor end portions 125 are drawn out from the first coil module 111 and two conductor end portions 126 are drawn out from the second coil module 112. The conductor end portions 125, 126 are drawn out so that their tip portions converge at a position toward the radial center on the axial outside of the field winding 70.

[0057] 16, in the bus bar module 105, arm portions 134a of the bus bar 134 extending from the outer circumferential surface of the main body portion 131 are joined to the conductor ends 125, 126 of the field winding 70, respectively. In this case, by assembling the bus bar module 105 to the rotating shaft 32, the bus bar module 105 is disposed on one axial end side of the rotor main portion 101, and the tip ends of the conductor ends 125, 126 and the arm portion 134a are closely opposed to each other. In this state, the tip ends of the conductor ends 125, 126 and the arm portion 134a are joined to each other by welding or the like.

[0058] 17, component holder 141 is assembled to bus bar module 105 so as to overlap in the axial direction. In this case, by assembling component holder 141 to rotating shaft 32, component holder 141 is positioned facing the axial end face of bus bar module 105. A recess 161 recessed in the axial direction is provided on the axial end face of component holder 141, and this recess 161 is configured to join bus bar 145 extending from the electric circuit of circuit module 106 to the field winding 70 side.

[0059] 18 is a plan view of the bus bar module 105 and the component holder 141 stacked on top of each other, viewed from the bus bar module 105 side. As can be seen from the drawing, the component holder 141 has a larger radial dimension than the bus bar module 105 and has a portion that is radially outward of the bus bar module 105. In this case, the arm portions 134a of the bus bar 134 protrude radially outward from the outer periphery of the bus bar module 105, and the tip ends of the conductor ends 125, 126 and the arm portions 134a are joined to each other at a position radially outward from the main body portion 131 and axially facing the axial end face of the component holder 141 (see FIG. 16).

[0060] Component holder 141 has a plurality of through holes 153 at positions radially outward of busbar module 105. This allows through holes 153 to communicate with both sides in the axial direction even when busbar module 105 and component holder 141 are stacked on top of each other.

[0061] Next, the structure of wiring connections in the component holder 141 will be described. Fig. 19 is an enlarged perspective view showing a portion of the component holder 141 where wiring connections are made. Fig. 20 is a longitudinal cross-sectional view showing the cross-sectional structure of the wiring connection portion in the component holder 141, taken along line 20-20 in Fig. 19. Note that in this case, of the two axial sides of the component holder 141, the side opposite the rotor core (upper side in Fig. 20) is referred to as a first surface F1, and the side facing the rotor core (lower side in Fig. 20) is referred to as a second surface F2.

[0062] The component holder 141 has a recess 161 on the first surface F1, which is the side opposite the rotor core, and a tip portion of the arm portion 134a of the bus bar 145 is drawn into the recess 161. The component holder 141 also has a through-hole 162 that extends axially from the bottom surface of the recess 161 and opens the recess 161 to the second surface F2 side of the component holder 141. Another bus bar 147, which is a connection partner of the bus bar 145, is inserted into the through-hole 162, and the arm portion 147a of the bus bar 147 is drawn into the recess 161. The bus bar 147 is an intermediate bus bar, one end of which is connected to the conductor ends 125, 126 of the field winding 70. Note that instead of the bus bar 147, either the conductor ends 125, 126 of the field winding 70 may be used as the connection partner of the bus bar 145.

[0063] Then, in the recess 161, the arm portions 145a, 147a of the bus bars 145, 147 are joined together, thereby electrically connecting the bus bars 145, 147 to each other. That is, the arm portions 145a, 147a extend axially from the component holder 141 on the first surface F1 side, and are joined to each other by welding or the like in the recess 161. In the configuration of FIG. 20, the arm portions 145a, 147a correspond to the "wiring end portions."

[0064] Each arm portion 145a, 147a is provided so as not to protrude outside the recess 161, i.e., so as not to be axially outward of the first surface F1 of the component holder 141. This prevents interference between each arm portion 145a, 147a and the heat sink 151 when the heat sink 151 is placed on the component holder 141.

[0065] A support member 163 formed by filling a filler material is housed within the recess 161. The support member 163 is made of, for example, a resin material. The support member 163 is provided within the recess 161 so as to surround the joint between the arm portions 145a and 147a. In this configuration in which the arm portions 145a and 147a extend axially from the component holder 141, centrifugal force and the like acts on the arm portions 145a and 147a during rotation of the rotor 60, raising concerns about peeling of the joint. However, by providing the support member 163 as described above, the occurrence of problems such as peeling of the joint due to centrifugal force and the like is suppressed.

[0066] When heat sink 151 is joined to component holder 141, it is preferable that the axial end face (the end face on the first surface F1 side) of support member 163 abuts against heat sink 151. However, when heat sink 151 is joined to component holder 141, it is preferable that arm portions 145a and 147a and heat sink 151 are insulated from each other.

[0067] Note that Figure 19 shows a state in which the recess 161 is not filled with resin, and when resin is filled into the recess 161, each arm portion 145a, 147a is surrounded by the support member 163.

[0068] During the manufacture of rotor 60, arm portions 145a and 147a are pulled out into recess 161 of component holder 141, and welding or other operations are performed using the space within recess 161 to join arm portions 145a and 147a to each other. After that, a filler material is filled into recess 161, and as the filler material solidifies, support member 163 is formed within recess 161. In this case, recess 161 of component holder 141 serves as a joining space for each bus bar, ensuring the space required for the joining operation while realizing a configuration in which arm portions 145a and 147a do not protrude toward first surface F1 (the side opposite the rotor core) of component holder 141. Furthermore, the simple operation of filling recess 161 with resin allows for favorable support of the bus bar joints.

[0069] 19 shows two joints X and Y, each representing a joint formed by combining and joining arm portions 145a and 147a. At joint X, the arm portions 145a and 147a are drawn out while aligned radially, and the arm portions 145a and 147a aligned radially are joined to each other. In contrast, at joint Y, the arm portions 145a and 147a are drawn out while aligned circumferentially, and the arm portions 145a and 147a aligned circumferentially are joined to each other. In this case, at joint Y, the possibility of damage due to centrifugal force during rotor rotation is reduced compared to joint X.

[0070] In the component holder 141, all of the joints between the arm portions 145a and 147a may be configured as joints Y. Alternatively, in the component holder 141, all of the joints between the arm portions 145a and 147a may be configured as joints X.

[0071] Next, a description will be given of the configuration of the crossover wires that connect the winding units 110 (pole coils) for each magnetic pole in the field winding 70. In this embodiment, the crossover wires of the field winding 70 are formed by the conductor ends 125, 126 of each coil module 111, 112 and the bus bar 134 of the bus bar module 105, and the crossover wire configuration is shown in Fig. 21. For ease of explanation, Fig. 21 shows only the crossover wire of the first winding section 71 (first coil module 111).

[0072] 21, in each of the winding units 110 arranged in the circumferential direction, two conductor end portions 125 are drawn out from the radially outer first coil module 111, and the conductor end portions 125 extend from a radially outer position toward the radially inner side. In other words, the conductor end portions 125 extend in a direction intersecting the axial direction (i.e., in the radial direction) at the axially outer side of the field winding 70. A bus bar 134 is connected to the tip end of each conductor end portion 125, so that the first coil modules 111 of each pole are connected in series. In this case, the conductor end portions 125 and the bus bar 134 form a crossover wire W that connects the first coil modules 111 of each pole.

[0073] 22 is a diagram schematically illustrating the connection state of each of the first coil modules 111 lined up in the circumferential direction. As shown in the figure, each of the first coil modules 111 lined up in the circumferential direction has two conductor end portions 125, and the conductor end portions 125 are connected to the bus bars 134 of the bus bar module 105, thereby connecting them in series via the bus bars 134. In this case, in each of the first coil modules 111 adjacent in the circumferential direction, the conductor end portions 125 on the same circumferential side of both sides in the circumferential direction (the left-right direction in the figure) are connected via the bus bars 134, so that the winding directions of the conductor material are staggered.

[0074] 21, in the second coil module 112 on the radially inner side of the winding unit 110, similarly, a conductor end 126 extends in a direction intersecting the axial direction on the axially outer side of the field winding 70, and the conductor end 126 and the bus bar 134 form a crossover wire W that connects the second coil modules 112 of each pole. Note that in the second coil module 112, one of the two conductor end portions 126 extends in the radial direction and the other extends in the circumferential direction (see FIG. 15).

[0075] In the above-described configuration in which the conductor ends 125, 126 extend in a direction intersecting the axial direction (radially or circumferentially), there is a concern that the conductor ends 125, 126 may be unintentionally displaced due to centrifugal force or rotational force caused by rotation fluctuations during rotation of the rotor 60. To address this issue, the part holder 141 is provided with a protrusion 171 on the second surface F2 side, which is the rotor core side, that protrudes in the axial direction and faces the conductor ends 125, 126 in a direction perpendicular to the axial direction. The specific configuration will be described below.

[0076] 23A and 23B are diagrams showing the configuration of protrusions 171 provided on component holder 141, with Fig. 23A being a plan view of busbar module 105 and component holder 141 viewed from the second surface F2 side, and Fig. 23B being a cross-sectional view taken along line 23B-23B in Fig. 23A. Fig. 24 is a perspective view of busbar module 105 and component holder 141 viewed from the second surface F2 side. Note that Figs. 23A and 24 show wire ends 125 and 126 superimposed on component holder 141.

[0077] The component holder 141 is provided with a plurality of protrusions 171 extending from the second surface F2 toward the rotor core (the front side of the paper in FIG. 23(a)) at positions radially outward of the busbar module 105. The protrusions 171 are provided in positions aligned side by side (adjacent positions) with the conductor ends 125, 126 in a plan view. That is, the protrusions 171 face the conductor ends 125, 126 in a direction perpendicular to the axial direction.

[0078] More specifically, radially extending protrusions 171A are provided at positions adjacent to the radially extending conductor ends 125, 126 of each coil module 111, 112 as protrusions 171. The protrusions 171A are provided at positions sandwiching each conductor end 125, 126 from both sides in the circumferential direction. In other words, a radially extending groove 172 is formed between the protrusions 171A on both sides sandwiching each conductor end 125, 126, and each conductor end 125, 126 is positioned within the groove 172.

[0079] Furthermore, a circumferentially extending protrusion 171B is provided as the protrusion 171 adjacent to the circumferentially extending conductor end 126 (conductor end 126X in FIG. 23(a)). The protrusion 171B is provided at a position radially outward of the conductor end 126X. The protrusions 171B may be provided at positions that sandwich the circumferentially extending conductor end 126X from both sides in the radial direction. In other words, a groove 172 may be formed between the protrusions 171B on both sides that sandwich the conductor end 126X, and the conductor end 126X may be positioned within the groove 172.

[0080] The protrusions 171 (171A, 171B) suppress displacement and deformation of the conductor ends 125, 126 due to centrifugal force or rotational fluctuations during rotor rotation. At this time, even if the conductor ends 125, 126 are deflected radially or circumferentially due to centrifugal force or rotational fluctuations during rotor rotation, excessive displacement of the conductor ends 125, 126 is restricted. This suppresses problems such as damage to the conductor ends 125, 126 or breakage of the joints between the conductor ends 125, 126 and the bus bar 134.

[0081] Protrusion 171 is provided as part of component holder 141 and is made of an insulating resin molding. Therefore, even if protrusion 171 comes into contact with conductor ends 125, 126, it does not cause problems such as a short circuit between conductor ends 125, 126. Note that protrusion 171 may be manufactured separately from component holder 141 and integrated with component holder 141 by adhesion, welding, or the like.

[0082] The joints between the conductor ends 125, 126 and the bus bar 134 (arm portion 134a) may be disposed in the grooves 172 between the protrusions 171. In this case, the joints between the conductor ends 125, 126 and the arm portion 134a may be press-formed. Press-forming reduces the thickness in the joining direction, making it easier to arrange the parts in the grooves 172 and improving productivity.

[0083] As shown in Fig. 23(b), it is preferable that the groove 172 is filled with a filler. In this case, the gap between the protrusion 171 and the conductor ends 125, 126 is filled with the filler 173 formed in the groove 172. This more appropriately suppresses the displacement of the conductor ends 125, 126. Furthermore, a heat transfer path is formed in the middle of the conductor ends 125, 126, improving the heat dissipation of the conductor ends 125, 126.

[0084] The protrusions 171 (171A, 171B) may have any shape in plan view. For example, the protrusions 171 may be provided as pillars extending from the second surface F2.

[0085] 25 is a longitudinal cross-sectional view showing the configuration near the coil end of the field winding 70. In the field winding 70, the winding units 110 of each magnetic pole have a larger number of turns of conductor wire on the radially outer side than on the radially inner side, and therefore the coil end height of the field winding 70 is higher on the radially outer side than on the radially inner side. In this case, a substantially conical inner space S is formed on the inner circumferential side of the coil end of the field winding 70 at the position where the coil end height is highest, and the bus bar module 105 is disposed in this inner space S. In addition, in the inner space S, the conductor wire ends 125, 126 of the coil modules 111, 112 and the arm portion 134a extending from the bus bar module 105 are connected to each other.

[0086] A protrusion 171 that protrudes in the axial direction from the component holder 141 is provided on the radially outer side of the busbar module 105. In the inner space S, the conductor ends 125, 126 and the protrusion 171 face each other in a direction perpendicular to the axial direction. The protrusion 171 suppresses displacement of the conductor ends 125, 126 of the coil modules 111, 112 in the inner space S on the inner circumferential side of the coil end of the field winding 70.

[0087] The configuration in which the busbar module 105 is disposed in the inner space S on the inner circumferential side of the coil end of the field winding 70 makes it possible to reduce the axial length of the axial end of the rotor 60. Furthermore, in a configuration in which the conductor ends 125, 126 of the coil modules 111, 112 extend radially, it is conceivable that the conductor ends 125, 126 would be prone to displacement due to a force generated in the rotational direction due to rotational fluctuations of the rotor 60. However, the protrusions 171 provided on the component holder 141 suitably suppress displacement of the conductor ends 125, 126.

[0088] Furthermore, the leading ends of the conductor ends 125, 126 of each coil module 111, 112 extend radially inward and are connected to the bus bar 134 at a radially inner position. Therefore, compared to a configuration in which the conductor ends 125, 126 and the bus bar 134 are connected to each other at a radially outer position, radial or circumferential (rotational) forces generated by centrifugal force or rotational fluctuations are smaller at the joints between the conductor ends 125, 126 and the bus bar 134. This makes it possible to make the joints less susceptible to damage, etc.

[0089] According to the present embodiment described above in detail, the following excellent effects can be obtained.

[0090] In the rotor 60, a support member 163 is provided on the first surface F1 side of the component holder 141, which is the side opposite the rotor core, so as to surround the joint between the arm portions 145a, 147a (wiring ends) of the bus bars 145, 147. In this case, even if centrifugal force or rotational fluctuation occurs during rotation of the rotor 60, displacement or deformation of the extending portions of the wiring ends extending from the component holder 141 is suppressed. This suppresses the occurrence of problems such as peeling at the joints of the wiring ends. As a result, the joints of the wiring portions in the rotor 60 can be maintained in an appropriate state.

[0091] A recess 161 is provided on the first surface F1 side of the component holder 141, and the arm portions 145a, 147a (wiring ends) are joined together within the recess 161. A filler material is filled into the recess 161, and a support member 163 is formed from the filler material. In this case, the component holder 141 ensures a space within the recess 161 that allows the wiring ends to be joined together, while allowing the wiring ends to be covered with the filler material after joining. This allows the wiring ends to be joined together appropriately and maintains the wiring ends in an appropriate state after joining.

[0092] The wire ends drawn out from the part holder 141 are joined together while lined up in the circumferential direction (joint Y in FIG. 19 ). In this case, the possibility of damage to the joint due to centrifugal force during rotor rotation can be reduced compared to a configuration in which the wire ends are joined together while lined up in the radial direction.

[0093] Furthermore, the rotor 60 is configured to have a protrusion 171 that protrudes in the axial direction and faces the conductor ends 125, 126 (crossover wires W) in a direction perpendicular to the axial direction on the second surface F2 side of the part holder 141, which is the rotor core side. This prevents the conductor ends 125, 126 from unintentionally displacing even if centrifugal force or rotational fluctuations occur during rotation of the rotor 60. As a result, the conductor ends 125, 126 of the coil modules 111, 112 in the field winding 70 can be maintained in an appropriate state.

[0094] In the field winding 70, if the conductor ends 125, 126 of the coil modules 111, 112 extend in a direction that intersects the axial direction (i.e., in the radial or circumferential direction), the conductor ends 125, 126 will be affected by centrifugal force and rotational fluctuations during rotor rotation. In this regard, by providing the protrusions 171 so as to face the conductor ends 125, 126 in a direction perpendicular to the axial direction, the displacement of the conductor ends 125, 126 can be appropriately suppressed.

[0095] In each winding unit 110 of the field winding 70, the number of turns of the conductor wire material is increased on the radially outer side compared to the radially inner side, thereby increasing the space factor of the field winding 70. Furthermore, the connection portions between the conductor wire ends 125, 126 and the bus bar 134 are provided in the inner space S, which is located on the inner circumferential side of the coil end of the field winding 70 at the location where the coil end has the highest coil end height, thereby shortening the axial length of the rotor 60. Furthermore, in a configuration in which the connection portions between the conductor wire ends 125, 126 and the bus bar 134 are provided in the inner space S, the conductor wire ends 125, 126 extend from the radially outer side toward the radially inner side, but the provision of the protrusions 171 on the second surface F2 side of the component holder 141 suitably suppresses displacement of the conductor wire ends 125, 126. In this case, in the inner space S, the conductor ends 125, 126 (crossover wire W) and the protrusion 171 are configured to face each other in a direction perpendicular to the axial direction, thereby enabling the axial length of the rotor 60 to be shortened while effectively suppressing displacement of each conductor end 125, 126.

[0096] The conductor ends 125, 126 of each coil module 111, 112 are configured so that their tip ends extend radially inward and are connected to the bus bar 134 of the bus bar module 105 at their radially inner tip ends. In this case, the conductor ends 125, 126 and the bus bar 134 are connected to each other at positions closer to the inside in the radial direction, and therefore, compared to a configuration in which the conductor ends 125, 126 and the bus bar 134 are connected to each other at positions closer to the outside in the radial direction, a force acting in the radial or circumferential direction (rotational direction) at the joint between the conductor ends 125, 126 and the bus bar 134 is smaller. As a result, damage to the joint can be suppressed.

[0097] Groove 172 is formed on the second surface F2 side of component holder 141 by protrusions 171 on both sides of conductor ends 125, 126, and a filler material is filled in groove 172. This makes it possible to more appropriately suppress displacement of conductor ends 125, 126 (crossover wire W).

[0098] (Other embodiments) The above embodiment may be modified as follows, for example.

[0099] 19 and 20, the following configurations may be used as the wiring connection structure of the component holder 141. FIG. 26 is an enlarged perspective view of a portion of the component holder 141 where wiring connections are made. FIG. 27 is a longitudinal cross-sectional view showing the cross-sectional structure of the wiring connection portion of the component holder 141, taken along line 27-27 in FIG. 26.

[0100] The component holder 141 has a recess 161 on a first surface F1, which is the side opposite the rotor core, and an arm portion 145a of the bus bar 145 is drawn into the recess 161. The component holder 141 also has an arm portion 147a of another bus bar 147 drawn into the recess 161 through a through hole 162. The arm portions 145a and 147a are joined to each other on the first surface F1 side, extending axially from the component holder 141.

[0101] Furthermore, a support member 181 is provided on the first surface F1 side of the component holder 141 and fixed to the recess 161. The support member 181 has a fixing portion 182 that is fixed to the recess 161 and a protruding portion 183 that extends axially from the fixing portion 182 and protrudes from the first surface F1. The support member 181 is also provided with an insertion portion 184 that extends axially, and the joint portions of the arm portions 145a, 147a are inserted into the insertion portion 184.

[0102] It is preferable that fixing portion 182 of support member 181 is fixed to recess 161 of component holder 141 by ultrasonic welding. However, any fixing means may be used for supporting member 181, and it is also possible to fix fixing portion 182 of support member 181 to recess 161 by bonding with an adhesive, or to fix fixing portion 182 of support member 181 to recess 161 by press-fitting.

[0103] The support member 181 may be a resin molded body, similar to the component holder 141. However, the support member 181 may also be made of a metal such as aluminum. The support member 181 may be separable into a plurality of parts. For example, the support member 181 may be divided into two parts in the radial direction at a position where the insertion portion 184 is divided, and may be configured with one part located on the radially outer side of the busbar joint and the other part located on the radially outer side. Alternatively, the support member 181 may be divided into two parts in the circumferential direction at a position where the insertion portion 184 is divided, and may be configured with one part located on one circumferential side of the busbar joint and the other part located on the other circumferential side.

[0104] Support member 181 is provided to surround the joint portion of arm portions 145 a, 147 a. Support member 181 restricts displacement of arm portions 145 a, 147 a even if centrifugal force or the like acts on arm portions 145 a, 147 a when rotor 60 rotates, thereby suppressing problems such as peeling of the joint portion.

[0105] 26 and 27, unlike the configurations in FIGS. 19 and 20, the joints of the arm portions 145a and 147a protrude outside the recess 161. This simplifies the busbar joining process on the first surface F1 side of the component holder 141. Furthermore, because the support member 181 is fixed to the recess 161 of the component holder 141, tilting of the support member 181 due to centrifugal force during rotor rotation is prevented. Even if the arm portions 145a and 147a protrude axially outward from the first surface F1 of the component holder 141, the busbar joints can be appropriately supported.

[0106] 26 and 27, it is preferable that heat sink 151 be provided with an insertion portion made of a through-hole or recess extending in the axial direction, and that heat sink 151 be assembled to component holder 141 with support member 181 inserted into the insertion portion. In this case, interference between support member 181 and heat sink 151 is avoided by inserting support member 181 into the insertion portion of heat sink 151. It is preferable that support member 181 be in contact with heat sink 151. When heat sink 151 is provided with a recess as the insertion portion, it is preferable that support member 181 is not exposed at the axial end face of heat sink 151 on the opposite side from component holder 141.

[0107] 28, the support member 181 preferably has a facing portion 185 facing the first surface F1 of the component holder 141 outside the recess 161. The facing portion 185 is integrally formed with a protruding portion 183 of the support member 181 that protrudes axially from the recess 161, and the surface facing the first surface F1 is capable of being seated on the first surface F1. The facing portion 185 preferably has at least one of a configuration facing the first surface F1 on the radially outer side of the recess 161 and a configuration facing the first surface F1 on both circumferential sides of the recess 161. The facing portion 185 preferably has a flange-shaped portion extending in a direction perpendicular to the axial direction.

[0108] By providing the opposing portion 185 on the support member 181, it is possible to increase the resistance to centrifugal force and the like that occurs when the rotor rotates, and to realize a configuration that is more suitable for maintaining the wiring end in an appropriate state.

[0109] The shape of the facing portion 185 of the support member 181 can be changed. For example, as shown in Fig. 29, the facing portion 185 may have a tapered shape that becomes wider toward the first surface F1 in a vertical cross section. The tapered surface of the facing portion 185 may also be a concave curved surface (R-shaped).

[0110] A configuration shown in FIG. 30 is also possible. In FIG. 30, the annular portion 103b of the coil end cover 103 is disposed facing the radially outer side of the support member 181. Specifically, the coil end cover 103 has an end plate portion 103a fixed to the rotating shaft 32 and an annular portion 103b extending axially from the outer edge of the end plate portion 103a and centered on the rotating shaft 32. The end plate portion 103a has a hole 103c in its radial center, and is fitted and fixed to the rotating shaft 32 in the hole 103c. The annular portion 103b of the coil end cover 103 faces radially the outer peripheral surface of the component holder 141 and the radially outer surface of the support member 181. The annular portion 103b, the outer peripheral surface of the component holder 141, and the radially outer surface of the support member 181 preferably contact each other.

[0111] According to the configuration of FIG. 30, the displacement of the support member 181 due to centrifugal force or the like when the rotor rotates is suppressed by the coil end cover 103, and the resistance to centrifugal force or the like can be further increased.

[0112] As shown in FIG. 31, the joints of the arm portions 145a, 147a may be bent in a direction intersecting the axial direction. In FIG. 31, the axial tips of the arm portions 145a, 147a are bent radially inward (or radially outward), and the bent portions extending radially are the locations where joining is performed by welding or the like. In this case, the axial height of the arm portions 145a, 147a can be reduced, thereby increasing the resistance of the joints to centrifugal force. Note that, at the tips of the arm portions 145a, 147a, the joints between the arm portions 145a, 147a may be bent radially after welding or the like. The joints between the arm portions 145a, 147a may also be bent circumferentially.

[0113] 32, it is also possible to fix the support member 181 on the first surface F1 of the component holder 141 without providing the recess 161 on the first surface F1 side of the component holder 141. The support member 181 may be fixed to the first surface F1 of the component holder 141 by adhesive or welding.

[0114] In the above embodiment, the joint between the wiring end portions is surrounded by the support members 163, 181 from four sides, namely, both circumferential and radial directions, but this may be modified. For example, the joint between the wiring end portions may be surrounded by the support members 163, 181 from three sides, namely, both circumferential directions and the outer radial direction.

[0115] In the above embodiment, the bus bar 145 extending from an electrical component and another bus bar 147 are extended onto the first surface F1 of the component holder 141, and the arm portions 145a, 147a of the bus bars 145, 147 are joined together. However, this configuration may be modified. The conductor ends 125, 126 of the coil modules 111, 112 may be extended onto the first surface F1 of the component holder 141, and the conductor ends 125, 126 may be joined together. Alternatively, one of the conductor ends 125, 126 may be joined to the arm portion 145a. In other words, the combination of interconnection ends may not only be a combination of bus bars, but also a combination of a bus bar and an interconnection end, or a combination of interconnection end. In these cases, similar to the above, the support members 163, 181 may be configured to support the interconnection ends on the first surface F1 side of the component holder 141.

[0116] 21 and 22, for example, the conductor end portion 125 and the bus bar 134 of the bus bar module 105 are configured as a crossover wire W connecting the first coil modules 111 of each pole, but this configuration may be changed. That is, the crossover wire W may be configured by connecting the conductor end portions 125, 126 of the coil modules 111, 112 of each pole via the bus bar 134, or by directly connecting the conductor end portions 125, 126 to each other.

[0117] In the field winding 70, the first and second winding portions 71, 72 do not have to be configured in such a way that the conductor ends 125, 126 are connected to each other using the coil modules 111, 112, and may have a different configuration.

[0118] FIG. 33 is a schematic diagram showing a configuration in which the pole coils 191 of each pole in the first winding portion 71 are continuously wound with conductor material C. In FIG. 33, the pole coils 191 of each pole are formed as air-core wound coils, and the conductor material C between each pole coil 191, i.e., the conductor material C that forms the intermediate portion between the magnetic poles, serves as a crossover wire W. The first winding portion 71 is preferably formed so that a plurality of air-core wound coils are connected together, and then assembled to each main pole portion 62 of the rotor core 61. However, a configuration in which the conductor material C is directly wound around each main pole portion 62 of the rotor core 61 may also be used.

[0119] The first winding portion 71 is configured such that the conductor wire C is wound continuously around all of the pole coils 191 arranged circumferentially. However, this configuration can be changed so that all of the pole coils 191 are divided into multiple groups and the conductor wire C is wound continuously around each group. In other words, it is sufficient that the conductor wire C is wound continuously around at least two pole coils 191 arranged circumferentially. Although not shown, the same applies to the second winding portion 72.

[0120] Fig. 34 is a diagram illustrating the holding structure of the crossover wire W when the pole coils 191 of each pole are continuously wound. Fig. 34 is a plan view of eight pole coils 191 lined up in the circumferential direction in the first winding section 71 as seen from the axial direction, with the component holder 141 indicated by a dashed line. Points A and B on both circumferential sides of each pole coil 191 are the start and end points of the pole coil 191 (the start and end of the winding of the conductor wire), and the part connecting point B (the end of the winding) and point A (the start of the winding) between circumferentially adjacent pole coils 191 is the crossover wire W.

[0121] When the pole coil 191 of each pole is configured by continuous winding, excess wire W between the poles may be generated, and this excess wire may become slack. If slack occurs in the crossover wire W, there is a concern that the crossover wire W may come into contact with surrounding components or be damaged when the rotor rotates.

[0122] In this regard, in the configuration of FIG. 34, a protrusion 171 is provided on the component holder 141, and the jumper wire W is laid over the protrusion 171. As described above, the protrusion 171 is provided on the second surface F2 side of the component holder 141 so as to protrude in the axial direction. This configuration suppresses sagging of the jumper wire W, thereby preventing problems caused by sagging of the jumper wire W. The shape and number of the protrusions 171 are arbitrary, and the jumper wire W between poles may be laid over multiple protrusions 171. For example, if the excess jumper wire W is long, it is preferable to lay the jumper wire W over the multiple protrusions 171 in a zigzag or spiral pattern.

[0123] 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 the pole coils of each magnetic pole are connected in series rather than being divided into the first and second winding portions 71, 72. That is, in the above embodiment, the pole coils of each magnetic pole are configured by winding units 110 each including two coil modules 111, 112 for each magnetic pole. However, this may be modified so that the pole coils of each magnetic pole are configured by one coil module for each magnetic pole. In this case, it is preferable to configure the electric circuit of the rotor 60 so that a diode is connected to both ends of the field winding 70, or so that a diode and a capacitor are connected in parallel to both ends of the field winding 70.

[0124] In the stator 50, the stator core may not be provided with teeth.

[0125] The rotating electric machine is not limited to a rotating electric machine used as an in-vehicle main engine in a vehicle, but may be, for example, a rotating electric machine used as an ISG (Integrated Starter Generator) that doubles as a motor and generator.

[0126] The moving body on which the rotating electric machine system is mounted is not limited to a vehicle, but may be, for example, an aircraft or a ship. Furthermore, the rotating electric machine system is not limited to a system mounted on a moving body, but may be a stationary system.

[0127] The technical ideas extracted from the above-described embodiments will be described below. [Configuration 1] a rotor core (61) having a plurality of main pole portions (62) provided for each magnetic pole; a field winding (70) formed by winding a conductive wire around the main pole portion; a circuit module (106) disposed on one axial end side of the rotor core and having electrical components connected to the field winding; A wound field rotor (60) comprising: The circuit module has a component holder (141) for holding the electrical component, of a first surface side and a second surface side on both sides in the axial direction of the component holder, on the first surface side opposite to the rotor core, wiring ends that are ends of wiring portions extending from the field winding and the electrical component extend from the component holder in the axial direction, and the wiring ends are joined to each other, A wound field rotor, wherein a support member (163, 181) is provided on the first surface side of the component holder so as to surround the joint between the wiring end portions. [Configuration 2] The component holder has a recess (161) on the first surface side, and the wiring end is drawn into the recess. 2. The wound field rotor according to configuration 1, wherein the wire ends are joined together in the recess, and the support member is formed by a filler material filled in the recess. [Configuration 3] The component holder has a recess (161) on the first surface side, and the wiring end is drawn into the recess. 2. The wound field rotor according to claim 1, wherein the support member is provided on the first surface side of the component holder, the support member being fixed to the recess and partially protruding from the recess in the axial direction. [Configuration 4] 4. The wound field rotor according to configuration 3, wherein the support member has a facing portion (185) that faces the first surface of the component holder outside the recess. [Configuration 5] a coil end cover (103) for covering a coil end portion of the field winding that is axially outer than the rotor core; The coil end cover has an annular portion (103b) centered on the rotor rotation shaft (32), 5. The wound field rotor according to configuration 3 or 4, wherein the annular portion of the coil end cover is disposed to face the radially outer side of the portion of the support member that protrudes from the recess. [Configuration 6] The wound field rotor according to any one of configurations 1 to 5, wherein the wiring ends of the combined wiring members to be joined together are drawn out in a circumferentially aligned state on the first surface side of the component holder, and the respective wiring members are joined to each other and surrounded by the support member. [Configuration 7] the wiring ends extend in the axial direction toward the first surface side of the component holder, and the tip portions of the wiring ends form joints between the wiring ends; 7. The wound field rotor according to any one of configurations 1 to 6, wherein the joints between the wire ends are bent in a direction that intersects the axial direction and extends in the radial direction. [Explanation of symbols]

[0128] 60... rotor, 61... rotor core, 62... main pole portion, 70... field winding, 106... circuit module, 134, 145... bus bars, 141... component holder, 163... support member.

Claims

1. a rotor core (61) having a plurality of main pole portions (62) provided for each magnetic pole; a field winding (70) formed by winding a conductor around the main pole portion; a circuit module (106) disposed on one axial end side of the rotor core and having electrical components connected to the field winding; A wound field rotor (60) comprising: The circuit module has a component holder (141) for holding the electrical component, On the first surface side, which is opposite to the rotor core, of a first surface side and a second surface side on both sides of the component holder in the axial direction, wiring ends that are ends of wiring portions extending from the field winding and the electrical component extend from the component holder in the axial direction, and the wiring ends are joined to each other, A wound field rotor, wherein a support member (163, 181) is provided on the first surface side of the component holder in a state surrounding the joint portion between the wiring end portions.

2. The component holder has a recess (161) on the first surface side, and the wiring end is drawn into the recess, 2. The wound field rotor according to claim 1, wherein the wire ends are joined together within the recess, and the support member is formed by a filler material filled in the recess.

3. The component holder has a recess (161) on the first surface side, and the wiring end is drawn into the recess, 2. The wound field rotor according to claim 1, wherein the support member is provided on the first surface side of the part holder, the support member being fixed to the recess and partially protruding from the recess in the axial direction.

4. The wound field rotor according to claim 3 , wherein the support member has a facing portion (185) facing the first surface of the component holder outside the recess.

5. a coil end cover (103) for covering a coil end portion of the field winding that is axially outer than the rotor core; The coil end cover has an annular portion (103b) centered on the rotor rotation shaft (32), 4. The wound field rotor according to claim 3, wherein the annular portion of the coil end cover is disposed radially outwardly of a portion of the support member that protrudes from the recess.

6. 6. The wound field rotor according to claim 1, wherein the wiring ends of the combined wiring members to be joined together are drawn out in a circumferentially aligned state on the first surface side of the component holder, and the respective wiring members are joined to each other and surrounded by the support member.

7. the wiring ends extend in the axial direction toward the first surface side of the component holder, and the tip portions of the wiring ends form joints between the wiring ends; 6. The wound field rotor according to claim 1, wherein the joints between the wire ends are bent in a direction intersecting the axial direction.

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