Rotating Electric Machine

Abstract

An armature winding (431) of a rotating electrical machine (400) is configured from multiphase phase windings (431U, 431V, 431W), wherein: the phase winding of each phase is provided with a plurality of serially connected bodies (600) comprising partial windings, and are configured by connecting the serially connected bodies in parallel; the partial windings include a first partial winding (441A) and a second partial winding (441B) having mutually different coil resistances; and the serially connected bodies are each configured by connecting the first partial winding and the second partial winding in series.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is based on Japanese Application No. 2021-032026 filed on March 1, 2021, the contents of which are incorporated herein by reference. [Technical field]

[0002] The present disclosure relates to a rotating electric machine. [Background technology]

[0003] Conventionally, a rotating electric machine using a teeth-less, slot-less stator core has been proposed, as in Patent Document 1. In a teeth-less, slot-less rotating electric machine, cogging torque and torque ripple can be suppressed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-24296 A Summary of the Invention

[0005] However, when a teethless stator core is used as in Patent Document 1, the amount of magnetic flux passing through the stator winding increases, which poses a problem of increased loss due to circulating current.

[0006] The present disclosure has been made in consideration of the above circumstances, and has a primary object to provide a rotating electric machine capable of suppressing circulating current.

[0007] A first means for solving the above problem is a rotating electric machine comprising: an armature of a teethless structure having a field element having a plurality of magnetic poles, an armature winding including a plurality of partial windings, and a winding support member provided on the opposite side of the field element, either the radially inner side or the radially outer side of the armature winding, and supporting the plurality of partial windings, wherein either the field element or the armature is a rotor, wherein the armature winding is composed of a multi-phase phase winding, each of the phase windings has a plurality of series-connected bodies of the partial windings and is configured by connecting the series-connected bodies in parallel, the partial winding includes a first partial winding and a second partial winding having different coil resistances, and each of the series-connected bodies is configured by connecting the first partial winding and the second partial winding in series.

[0008] According to the above-mentioned means, a series-connected body is formed by connecting a first partial winding and a second partial winding having different coil resistances in series, and a phase winding for each phase is formed by connecting the series-connected bodies in parallel. This makes it possible to equalize the coil resistance of all the series-connected bodies connected in parallel, and to suppress circulating currents between the series-connected bodies. Furthermore, by connecting the series bodies, the number of turns can be increased, and field-weakening control can be performed. Furthermore, since the armature winding for each phase is not formed by connecting all the partial windings in series, eddy current loss can be suppressed.

[0009] In a second aspect, the first partial winding and the second partial winding are different in at least one of the shape, the number of turns, and the length of the wire that constitutes the partial winding.

[0010] The above-mentioned means increases the degree of freedom in terms of the shape, number of turns, length of the wire, etc., depending on the arrangement and space of the partial windings, and specifications, making design easier.

[0011] The third means is the first or second means, wherein the partial winding has a pair of intermediate conductor portions and transition portions at both axial ends of the pair of intermediate conductor portions, and is formed into a ring shape by these intermediate conductor portions and transition portions, the intermediate conductor portions of each partial winding are arranged side by side in the circumferential direction, and the first partial winding has the transition portion at one axial end of the armature winding bent radially inward, and the second partial winding has the transition portion at the other axial end bent radially outward.

[0012] According to the above-mentioned means, after assembling the partial windings to form the stator winding, it is possible to assemble cylindrical members to the radially inner and outer sides of the stator winding by moving the partial windings along the axial direction, which increases the degree of freedom in the assembly order during manufacturing, making assembly easier.

[0013] The fourth means is the third means, wherein in each partial winding, a pair of the intermediate conductor portions are arranged two coil pitches apart, and two of the intermediate conductor portions in the partial winding of the other phase are arranged between the pair of intermediate conductor portions, and the first partial winding is connected in series to the second partial winding of the same phase which is arranged at a position two coil pitches away via connecting wiring, and the connecting wiring is arranged so as to be lined up circumferentially at the same position in the axial direction.

[0014] According to the above-mentioned means, the connection wire connects the first partial winding and the second partial winding that is arranged at a position two coil pitches away and constitutes the same phase. Therefore, the connection wire only needs to have a length of about two coil pitches, and it is possible to prevent the connection wires from overlapping each other in the circumferential direction. Therefore, by arranging the connection wires so that they are arranged in the same position in the axial direction, the axial dimension of the connection wires can be reduced, and the rotating electric machine can be made smaller. [Brief description of the drawings]

[0015] The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: [Figure 1] FIG. 1 is a perspective view showing an entire rotating electric machine according to a first embodiment; [Diagram 2] FIG. 2 is a plan view of a rotating electric machine; [Diagram 3] FIG. 3 is a vertical cross-sectional view of a rotating electric machine; [Figure 4] FIG. 4 is a cross-sectional view of a rotating electric machine; [Diagram 5] FIG. 5 is an exploded cross-sectional view of a rotating electric machine; [Figure 6] FIG. 6 is a cross-sectional view of a rotor; [Figure 7] FIG. 7 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit; [Figure 8] FIG. 8 is a diagram showing the relationship between the electrical angle and the magnetic flux density of the magnet according to the embodiment; [Figure 9] FIG. 9 is a diagram showing the relationship between electrical angle and magnetic flux density for a magnet of a comparative example; [Figure 10] FIG. 10 is a perspective view of a stator unit; [Figure 11] FIG. 11 is a vertical cross-sectional view of a stator unit; [Figure 12] FIG. 12 is a perspective view of the core assembly as viewed from one axial side; [Figure 13] FIG. 13 is a perspective view of the core assembly as viewed from the other axial side; [Figure 14] FIG. 14 is a cross-sectional view of a core assembly; [Figure 15] FIG. 15 is an exploded cross-sectional view of a core assembly; [Figure 16] FIG. 16 is a circuit diagram showing a connection state of partial windings in each of three phase windings; [Figure 17] FIG. 17 is a side view showing a first coil module and a second coil module arranged side by side for comparison; [Figure 18]FIG. 18 is a side view showing a first partial winding and a second partial winding arranged side by side for comparison; [Figure 19] FIG. 19 is a diagram showing a configuration of a first coil module; [Figure 20] FIG. 20 is a cross-sectional view taken along line 20-20 in FIG. 19(a); [Figure 21] FIG. 21 is a perspective view showing a configuration of an insulating cover; [Figure 22] FIG. 22 is a diagram showing a configuration of a second coil module; [Diagram 23] FIG. 23 is a cross-sectional view taken along line 23-23 in FIG. 22(a); [Figure 24] FIG. 24 is a perspective view showing a configuration of an insulating cover; [Diagram 25] FIG. 25 is a diagram showing overlap positions of film materials when the coil modules are arranged in the circumferential direction; [Figure 26] FIG. 26 is a plan view showing an assembled state of the first coil module to the core assembly; [Figure 27] FIG. 27 is a plan view showing an assembled state of the first coil module and the second coil module to the core assembly; [Figure 28] FIG. 28 is a vertical cross-sectional view showing a fixed state by a fixing pin; [Figure 29] FIG. 29 is a perspective view of a bus bar module; [Diagram 30] FIG. 30 is a cross-sectional view showing a portion of a vertical cross section of a bus bar module; [Diagram 31] FIG. 31 is a perspective view showing a state in which a bus bar module is assembled to a stator holder; [Diagram 32] FIG. 32 is a vertical cross-sectional view of a fixing portion for fixing a bus bar module; [Diagram 33] FIG. 33 is a vertical cross-sectional view showing a state in which a relay member is attached to a housing cover; [Diagram 34] FIG. 34 is a perspective view of a relay member; [Diagram 35]FIG. 35 is an electric circuit diagram showing a control system for a rotating electric machine; [Diagram 36] FIG. 36 is a functional block diagram showing a current feedback control process by a control device; [Figure 37] FIG. 37 is a functional block diagram showing a torque feedback control process by the control device; [Figure 38] FIG. 38 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modified example; [Figure 39] FIG. 39 is a diagram showing the configuration of a stator unit having an inner rotor structure. [Diagram 40] FIG. 40 is a plan view showing an assembled state of the coil module to the core assembly; [Diagram 41] FIG. 41 is a vertical sectional view of a rotating electric machine according to a second embodiment; [Diagram 42] FIG. 42 is a cross-sectional view of a rotating electric machine; [Diagram 43] FIG. 43 is a cross-sectional view of a rotating electric machine; [Diagram 44] FIG. 44 is an exploded cross-sectional view of a rotating electric machine; [Diagram 45] FIG. 45 is an exploded perspective view of a stator unit; [Figure 46] FIG. 46 is an exploded perspective view of a stator; [Figure 47] FIG. 47 is an exploded perspective view of the stator; [Figure 48] FIG. 48 is an exploded cross-sectional view of a stator unit; [Figure 49] FIG. 49 is a perspective view showing a configuration of partial windings; [Figure 50] FIG. 50 is an exploded perspective view showing an insulating cover in a partial winding; [Figure 51] FIG. 51 is a perspective view showing a configuration of partial windings; [Figure 52] FIG. 52 is an exploded perspective view showing an insulating cover in a partial winding; [Figure 53] FIG. 53 is a plan view showing a state in which partial windings are arranged side by side in the circumferential direction; [Figure 54] FIG. 54 is a cross-sectional view of a stator holder; [Figure 55] FIG. 55 is a perspective view of the stator unit as viewed from the wiring module side; [Figure 56] FIG. 56 is an exploded cross-sectional view showing a rotating electric machine divided into a fixed portion and a rotating portion, [Figure 57] FIG. 57 is a circuit diagram of a stator winding in the second embodiment; [Figure 58] Figure 58 is an exploded view of the stator windings and bus bars. [Figure 59] FIG. 59 is a circuit diagram of a stator winding in a comparative example; [Figure 60] FIG. 60 is a side view showing an outline of a first partial winding and a second partial winding in another example; [Figure 61] FIG. 61 is a perspective view showing an outline of a first partial winding and a second partial winding in another example; [Figure 62] FIG. 62 is a perspective view showing an outline of a first partial winding and a second partial winding in another example; [Figure 63] FIG. 63 is a side view showing an outline of a first partial winding and a second partial winding in another example; [Figure 64] FIG. 64 is a side view showing an outline of a first partial winding and a second partial winding in another example; [Figure 65] FIG. 65 is a perspective view showing an outline of a first partial winding and a second partial winding in another example; [Figure 66] FIG. 66 is a side view showing an outline of a first partial winding and a second partial winding in another example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] A number of embodiments will be described with reference to the drawings. In a number of embodiments, functionally and / or structurally corresponding and / or associated parts may be given the same reference numerals or reference numerals with different digits in the hundredths or more. For corresponding and / or associated parts, reference may be made to the description of other embodiments.

[0017] The rotating electric machine in this embodiment is used, for example, as a vehicle power source. However, the rotating electric machine can be widely used in industries, vehicles, aircraft, home appliances, office automation equipment, game machines, etc. In the following embodiments, the same reference numerals are used in the drawings to designate the same or equivalent parts, and the explanations of the parts with the same reference numerals are incorporated herein.

[0018] (First embodiment) The rotating electric machine 10 according to this embodiment is a synchronous multi-phase AC motor and has an outer rotor structure. The rotating electric machine 10 is generally shown in Figs. 1 to 5. Fig. 1 is a perspective view showing the entire rotating electric machine 10, Fig. 2 is a plan view of the rotating electric machine 10, Fig. 3 is a longitudinal sectional view (sectional view taken along line 3-3 in Fig. 2) of the rotating electric machine 10, Fig. 4 is a transverse sectional view (sectional view taken along line 4-4 in Fig. 3) of the rotating electric machine 10, and Fig. 5 is an exploded sectional view showing components of the rotating electric machine 10 in an exploded manner. In the following description, in the rotating electric machine 10, the direction in which the rotating shaft 11 extends is defined as the axial direction, the direction extending radially from the center of the rotating shaft 11 is defined as the radial direction, and the direction extending circumferentially around the rotating shaft 11 is defined as the circumferential direction.

[0019] The rotating electric machine 10 is roughly divided into a rotating electric machine main body having the rotor 20, the stator unit 50, and the busbar module 200, and a housing 241 and a housing cover 242 provided so as to surround the rotating electric machine main body. All of these members are arranged coaxially with the rotating shaft 11 provided integrally with the rotor 20, and the rotating electric machine 10 is configured by assembling them in the axial direction in a predetermined order. The rotating shaft 11 is supported by a pair of bearings 12, 13 provided on the stator unit 50 and the housing 241, respectively, and is rotatable in this state. The bearings 12, 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between them. The rotation of the rotating shaft 11 rotates, for example, an axle of a vehicle. The rotating electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle frame or the like.

[0020] In the rotating electric machine 10, the stator unit 50 is provided to surround the rotating shaft 11, and the rotor 20 is disposed radially outside the stator unit 50. The stator unit 50 has a stator 60 and a stator holder 70 attached to its radially inside. The rotor 20 and the stator 60 are disposed facing each other in the radial direction with an air gap therebetween, and the rotor 20 rotates integrally with the rotating shaft 11, causing the rotor 20 to rotate radially outside the stator 60. The rotor 20 corresponds to the "field element," and the stator 60 corresponds to the "armature."

[0021] FIG. 6 is a longitudinal sectional view of the rotor 20. As shown in FIG. 6, the rotor 20 has a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. The rotor carrier 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23, which are integrated together. The rotor carrier 21 functions as a magnet holding member, and the magnet unit 22 is fixed annularly to the radially inner side of the cylindrical portion 23. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt in a state where it is inserted into the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal to) the axial direction, and the rotor carrier 21 is fixed to the rotating shaft 11 in a state where the flange 11a and the end plate portion 24 are surface-jointed.

[0022] The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner peripheral surface of the magnet holder 31, and an end plate 33 fixed to one of the axial sides opposite the end plate portion 24 of the rotor carrier 21. The magnet holder 31 has the same length dimension in the axial direction as the magnet 32. The magnet 32 ​​is provided in a state in which it is surrounded by the magnet holder 31 from the radial outside. The magnet holder 31 and the magnet 32 ​​are fixed in a state in which they abut against the end plate 33 at one end on the axial side. The magnet unit 22 corresponds to the "magnet portion".

[0023] Fig. 7 is a partial cross-sectional view showing the cross-sectional structure of the magnet unit 22. In Fig. 7, the direction of the axis of easy magnetization of the magnet 32 ​​is indicated by an arrow.

[0024] In the magnet unit 22, the magnets 32 are arranged so that their polarities alternate along the circumferential direction of the rotor 20. This gives the magnet unit 22 a plurality of magnetic poles in the circumferential direction. The magnets 32 are polar anisotropic permanent magnets, and are constructed using sintered neodymium magnets with an intrinsic coercive force of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more.

[0025] The peripheral surface of the magnet 32 ​​on the radially inner side (the stator 60 side) is the magnetic flux action surface 34 where the magnetic flux is exchanged. The magnet unit 22 generates magnetic flux intensively in the region near the d-axis, which is the magnetic pole center, on the magnetic flux action surface 34 of the magnet 32. Specifically, the magnet 32 ​​has different orientations of the magnetization easy axis on the d-axis side (part closer to the d-axis) and the q-axis side (part closer to the q-axis), and the magnetization easy axis on the d-axis side is parallel to the d-axis, and the magnetization easy axis on the q-axis side is perpendicular to the q-axis. In this case, an arc-shaped magnetic flux path is formed along the direction of the magnetization easy axis. In short, the magnet 32 ​​is configured so that the magnetization easy axis is oriented parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.

[0026] In magnet 32, the magnetic flux path is formed in an arc shape, so that the magnetic flux path length is longer than the radial thickness dimension of magnet 32. This increases the permeance of magnet 32, making it possible to exert the same performance as a magnet with a larger amount of magnet, despite the same amount of magnet.

[0027] The magnets 32 are arranged in pairs, two adjacent magnets in the circumferential direction, to form one magnetic pole. That is, the magnets 32 arranged in the circumferential direction in the magnet unit 22 have cut surfaces on the d-axis and the q-axis, and the magnets 32 are arranged in contact with or in close proximity to each other. As described above, the magnets 32 have an arc-shaped magnetic flux path, and the N pole and S pole of the magnets 32 adjacent to each other in the circumferential direction face each other on the q-axis. This makes it possible to improve the permeance near the q-axis. In addition, the magnets 32 on both sides of the q-axis attract each other, so that the magnets 32 can maintain a contact state with each other. This also contributes to improving the permeance.

[0028] In the magnet unit 22, the magnetic flux flows in an arc shape between the adjacent N and S poles due to each magnet 32, so the magnetic path is longer than that of a radially anisotropic magnet, for example. For this reason, as shown in FIG. 8, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of a radially anisotropic magnet shown as a comparative example in FIG. 9, the magnetic flux can be concentrated on the center side of the magnetic pole, making it possible to increase the torque of the rotating electric machine 10. In addition, in the magnet unit 22 of this embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution compared to the conventional Halbach array magnet. In addition, in FIG. 8 and FIG. 9, the horizontal axis indicates the electrical angle, and the vertical axis indicates the magnetic flux density. In addition, in FIG. 8 and FIG. 9, 90° on the horizontal axis indicates the d-axis (i.e., the magnetic pole center), and 0° and 180° on the horizontal axis indicate the q-axis.

[0029] That is, with each magnet 32 ​​configured as described above, the magnetic flux on the d-axis is strengthened and the magnetic flux change near the q-axis is suppressed in the magnet unit 22. This makes it possible to preferably realize the magnet unit 22 in which the surface magnetic flux change from the q-axis to the d-axis is smoothed at each magnetic pole.

[0030] The sine wave matching rate of the magnetic flux density distribution may be, for example, 40% or more. In this way, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to the use of radially aligned magnets or parallel aligned magnets, which have a sine wave matching rate of about 30%. Furthermore, if the sine wave matching rate is 60% or more, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to a magnetic flux concentration array such as a Halbach array.

[0031] In the radially anisotropic magnet shown in FIG. 9, the magnetic flux density changes sharply near the q-axis. The sharper the change in magnetic flux density, the more eddy currents increase in the stator winding 61 of the stator 60, which will be described later. The magnetic flux changes sharply on the stator winding 61 side. In contrast, in this embodiment, the magnetic flux density distribution has a magnetic flux waveform that is close to a sine wave. Therefore, the change in magnetic flux density near the q-axis is smaller than that of the radially anisotropic magnet. This makes it possible to suppress the generation of eddy currents.

[0032] Magnet 32 ​​has a recess 35 formed in a predetermined range including the d-axis on its radially outer outer peripheral surface, and a recess 36 formed in a predetermined range including the q-axis on its radially inner inner peripheral surface. In this case, according to the direction of the easy magnetization axis of magnet 32, the magnetic flux path becomes short near the d-axis on the outer peripheral surface of magnet 32, and the magnetic flux path becomes short near the q-axis on the inner peripheral surface of magnet 32. Therefore, in consideration of the fact that it is difficult to generate sufficient magnetic flux in places in magnet 32 ​​where the magnetic flux path length is short, magnets are removed in places where the magnetic flux is weak.

[0033] The magnet unit 22 may be configured to use magnets 32 in the same number as the magnetic poles. For example, the magnets 32 may be provided between two circumferentially adjacent magnetic poles, each of which is located between the d-axes that are the centers of the magnetic poles. In this case, the magnet 32 ​​is configured so that the circumferential center is the q-axis and has a cut surface on the d-axis. The magnet 32 ​​may also be configured so that the circumferential center is the d-axis, rather than the q-axis. Instead of using magnets twice the number of magnetic poles or the same number of magnets as the number of magnetic poles, the magnet 32 ​​may be configured to use a ring magnet connected in a ring shape.

[0034] 3, a resolver 41 serving as a rotation sensor is provided on one of both axial ends of the rotating shaft 11 opposite the joint with the rotor carrier 21 (the upper end in the figure). The resolver 41 includes a resolver rotor fixed to the rotating shaft 11, and a resolver stator disposed radially outside the resolver rotor to face it. The resolver rotor is in the shape of a disk ring, and is provided coaxially with the rotating shaft 11 with the rotating shaft 11 inserted therethrough. The resolver stator has a stator core and a stator coil, and is fixed to the housing cover 242.

[0035] Next, a description will be given of the configuration of the stator unit 50. Fig. 10 is a perspective view of the stator unit 50, and Fig. 11 is a vertical cross-sectional view of the stator unit 50. Fig. 11 is a vertical cross-sectional view taken at the same position as Fig. 3.

[0036] The stator unit 50 generally comprises a stator 60 and a stator holder 70 located radially inside the stator 60. The stator 60 comprises a stator winding 61 and a stator core 62. The stator core 62 and the stator holder 70 are integrated together to form a core assembly CA, and a plurality of partial windings 151 constituting the stator winding 61 are assembled to the core assembly CA. The stator winding 61 corresponds to the "armature winding", the stator core 62 corresponds to the "armature core", and the stator holder 70 corresponds to the "armature holding member". The core assembly CA corresponds to the "support member".

[0037] Here, the core assembly CA will be described first. Fig. 12 is a perspective view of the core assembly CA seen from one axial side, Fig. 13 is a perspective view of the core assembly CA seen from the other axial side, Fig. 14 is a transverse cross-sectional view of the core assembly CA, and Fig. 15 is an exploded cross-sectional view of the core assembly CA.

[0038] As described above, the core assembly CA has the stator core 62 and the stator holder 70 assembled to the radially inner side of the stator core 62. In other words, the stator core 62 is integrally assembled to the outer peripheral surface of the stator holder 70.

[0039] The stator core 62 is configured as a core sheet laminate in which core sheets 62a made of magnetic steel sheets are laminated in the axial direction, and has a cylindrical shape with a predetermined thickness in the radial direction. The stator winding 61 is assembled to the radially outer side of the stator core 62, which is the rotor 20 side. The outer peripheral surface of the stator core 62 is curved without unevenness. The stator core 62 functions as a back yoke. The stator core 62 is configured by laminating a plurality of core sheets 62a, which are punched into an annular plate shape, in the axial direction. However, the stator core 62 may have a helical core structure. In the stator core 62 with a helical core structure, a strip-shaped core sheet is used, and the core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 62 as a whole.

[0040] In this embodiment, the stator 60 has a slotless structure that does not have teeth for forming slots, but the configuration may be any of the following (A) to (C). (A) In the stator 60, inter-conductor members are provided between each conductor portion (intermediate conductor portion 152 described later) in the circumferential direction, and the inter-conductor member is made of a magnetic material that satisfies the relationship Wt×Bs≦Wm×Br, where Wt is the circumferential width of the inter-conductor member at one magnetic pole, Bs is the saturation magnetic flux density of the inter-conductor member, Wm is the circumferential width of the magnet 32 ​​at one magnetic pole, and Br is the residual magnetic flux density of the magnet 32. (B) In the stator 60, inter-conductor members are provided between each of the conductor portions (intermediate conductor portions 152) in the circumferential direction, and a non-magnetic material is used for the inter-conductor members. (C) In the stator 60, no inter-conductor members are provided between the conductor portions (intermediate conductor portions 152) in the circumferential direction.

[0041] 15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, and is configured by assembling them together with the outer cylinder member 71 on the radial outside and the inner cylinder member 81 on the radial inside. Each of these members 71, 81 is configured from a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

[0042] The outer tube member 71 is a cylindrical member whose outer and inner circumferential surfaces are both perfectly circular curved surfaces, and an annular flange 72 extending radially inward is formed on one axial end side. A plurality of protrusions 73 extending radially inward are formed on this flange 72 at predetermined intervals in the circumferential direction (see FIG. 13). Furthermore, facing surfaces 74, 75 that axially face the inner tube member 81 are formed on one and the other axial ends of the outer tube member 71, and annular grooves 74a, 75a extending annularly are formed on the facing surfaces 74, 75.

[0043] The inner tube member 81 is a cylindrical member having an outer diameter smaller than the inner diameter of the outer tube member 71, and its outer circumferential surface is a perfectly circular curved surface concentric with the outer tube member 71. An annular flange 82 extending radially outward is formed on one axial end of the inner tube member 81. The inner tube member 81 is assembled to the outer tube member 71 in a state where it abuts against the opposing surfaces 74, 75 of the outer tube member 71 in the axial direction. As shown in FIG. 13, the outer tube member 71 and the inner tube member 81 are assembled to each other by a fastener 84 such as a bolt. Specifically, a plurality of protrusions 83 extending radially inward are formed at a predetermined interval in the circumferential direction on the inner peripheral side of the inner tube member 81, and the protrusions 73, 83 are fastened to each other by the fastener 84 in a state where the axial end faces of the protrusions 83 and the protrusions 73 of the outer tube member 71 are overlapped.

[0044] As shown in FIG. 14, when the outer tube member 71 and the inner tube member 81 are assembled together, an annular gap is formed between the inner peripheral surface of the outer tube member 71 and the outer peripheral surface of the inner tube member 81, and the gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows. The refrigerant passage 85 is provided in an annular shape in the circumferential direction of the stator holder 70. More specifically, the inner tube member 81 is provided with a passage forming portion 88 that protrudes radially inward on its inner peripheral side and has an inlet side passage 86 and an outlet side passage 87 formed therein, and each of these passages 86, 87 opens to the outer peripheral surface of the inner tube member 81. In addition, a partition portion 89 is provided on the outer peripheral surface of the inner tube member 81 to partition the refrigerant passage 85 into an inlet side and an outlet side. As a result, the refrigerant flowing in from the inlet side passage 86 flows in the circumferential direction through the refrigerant passage 85, and then flows out from the outlet side passage 87.

[0045] The inlet side passage 86 and the outlet side passage 87 have one end extending radially and opening into the outer circumferential surface of the inner cylindrical member 81, and the other end extending axially and opening into the axial end surface of the inner cylindrical member 81. Fig. 12 shows an inlet opening 86a communicating with the inlet side passage 86 and an outlet opening 87a communicating with the outlet side passage 87. The inlet side passage 86 and the outlet side passage 87 communicate with an inlet port 244 and an outlet port 245 (see Fig. 1) attached to the housing cover 242, and the refrigerant flows in and out via these ports 244, 245.

[0046] Seals 101, 102 are provided at the joint between the outer cylinder member 71 and the inner cylinder member 81 to prevent leakage of refrigerant from the refrigerant passage 85 (see FIG. 15). Specifically, the seals 101, 102 are, for example, O-rings, and are accommodated in the annular grooves 74a, 75a of the outer cylinder member 71 and are provided in a compressed state by the outer cylinder member 71 and the inner cylinder member 81.

[0047] As shown in FIG. 12, the inner tube member 81 has an end plate portion 91 at one axial end, and the end plate portion 91 is provided with a hollow cylindrical boss portion 92 extending in the axial direction. The boss portion 92 is provided so as to surround an insertion hole 93 for inserting the rotating shaft 11. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242. The end plate portion 91 is provided with a plurality of support portions 95 extending in the axial direction on the radial outside of the boss portion 92. The support portions 95 are portions that serve as fixing portions for fixing the busbar module 200, and will be described in detail later. The boss portion 92 is a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on the inner periphery of the boss portion 92 (see FIG. 3).

[0048] As shown in FIGS. 12 and 13, the outer cylindrical member 71 and the inner cylindrical member 81 are formed with recesses 105, 106 used to fix a plurality of coil modules 150, which will be described later.

[0049] Specifically, as shown in Fig. 12, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of the inner tube member 81, more specifically, on the axially outer end face of the end plate portion 91 which surrounds the boss portion 92. Also, as shown in Fig. 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end face of the outer tube member 71, more specifically, on the axially outer end face of the flange 72. These recesses 105, 106 are arranged to be aligned on an imaginary circle concentric with the core assembly CA. The recesses 105, 106 are each provided at the same position in the circumferential direction, and the intervals and numbers thereof are also the same.

[0050] Incidentally, the stator core 62 is assembled in a state where a radial compressive force is generated against the stator holder 70 in order to ensure the strength of assembly to the stator holder 70. Specifically, the stator core 62 is fitted and fixed to the stator holder 70 with a predetermined tightening margin by shrink fitting or press fitting. In this case, it can be said that the stator core 62 and the stator holder 70 are assembled in a state where one of them generates a radial stress on the other. In addition, in order to increase the torque of the rotating electric machine 10, for example, it is considered to increase the diameter of the stator 60, and in such a case, the tightening force of the stator core 62 is increased to strengthen the connection of the stator core 62 to the stator holder 70. However, if the compressive stress (in other words, the residual stress) of the stator core 62 is increased, there is a concern that the stator core 62 may be damaged.

[0051] In this embodiment, in a configuration in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined tightening margin, a restricting portion is provided at a radially opposing portion of the stator core 62 and the stator holder 70, which restricts the circumferential displacement of the stator core 62 by engaging with the circumferential direction. That is, as shown in Figs. 12 to 14, a plurality of engaging members 111 as restricting portions are provided at a predetermined interval in the circumferential direction between the stator core 62 and the outer tubular member 71 of the stator holder 70 in the radial direction, and the engaging members 111 suppress the circumferential positional deviation between the stator core 62 and the stator holder 70. In this case, it is preferable to provide a recess in at least one of the stator core 62 and the outer tubular member 71, and to engage the engaging members 111 in the recess. Instead of the engaging members 111, a convex portion may be provided in either the stator core 62 or the outer tubular member 71.

[0052] In the above configuration, the stator core 62 and the stator holder 70 (outer cylinder member 71) are fitted and fixed with a predetermined interference, and are provided in a state in which their mutual circumferential displacement is restricted by the restriction of the engaging member 111. Therefore, even if the interference between the stator core 62 and the stator holder 70 is relatively small, the circumferential displacement of the stator core 62 can be suppressed. Furthermore, since the desired displacement suppression effect can be obtained even if the interference is relatively small, damage to the stator core 62 caused by an excessively large interference can be suppressed. As a result, the displacement of the stator core 62 can be appropriately suppressed.

[0053] An annular internal space is formed on the inner periphery side of the inner cylinder member 81 so as to surround the rotating shaft 11, and an electrical component constituting, for example, an inverter as a power converter may be disposed in the internal space. The electrical component is, for example, an electrical module in which a semiconductor switching element and a capacitor are packaged. By disposing the electrical module in contact with the inner periphery surface of the inner cylinder member 81, it is possible to cool the electrical module by the refrigerant flowing through the refrigerant passage 85. It is also possible to eliminate the multiple protrusions 83 on the inner periphery side of the inner cylinder member 81 or to reduce the protruding height of the protrusions 83, thereby expanding the internal space on the inner periphery side of the inner cylinder member 81.

[0054] Next, the configuration of the stator winding 61 to be assembled to the core assembly CA will be described in detail. The state in which the stator winding 61 is assembled to the core assembly CA is as shown in Figures 10 and 11, where a plurality of partial windings 151 constituting the stator winding 61 are assembled in a state lined up in the circumferential direction on the radial outside of the core assembly CA, i.e., on the radial outside of the stator core 62.

[0055] The stator winding 61 has a plurality of phase windings, and is formed into a cylindrical (annular) shape by arranging the phase windings of each phase in a predetermined order in the circumferential direction. In this embodiment, the stator winding 61 has a three-phase winding by using U-phase, V-phase, and W-phase windings.

[0056] 11, the stator 60 has, in the axial direction, a portion corresponding to the coil side CS radially facing the magnet unit 22 of the rotor 20, and a portion corresponding to the coil end CE that is axially outside the coil side CS. In this case, the stator core 62 is provided in a range corresponding to the coil side CS in the axial direction.

[0057] In the stator winding 61, each phase winding has a plurality of partial windings 151 (see FIG. 16), and the partial windings 151 are individually provided as coil modules 150. That is, the coil module 150 is configured by integrally providing the partial windings 151 in the phase winding of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 according to the number of poles. The coil modules 150 (partial windings 151) of each phase are arranged in a predetermined order in the circumferential direction, so that the conductor parts of each phase are arranged in a predetermined order on the coil side CS of the stator winding 61. FIG. 10 shows the order of the conductor parts of the U phase, V phase, and W phase on the coil side CS. In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.

[0058] In the stator winding 61, partial windings 151 of each coil module 150 are connected in parallel or in series for each phase to form a phase winding. Fig. 16 is a circuit diagram showing a connection state of the partial windings 151 in each of the three phase windings. Fig. 16 shows a state in which the partial windings 151 in the phase windings of each phase are connected in parallel.

[0059] 11, the coil module 150 is assembled to the radially outer side of the stator core 62. In this case, the coil module 150 is assembled in a state in which both axial end portions thereof protrude axially outward (i.e., toward the coil end CE) from the stator core 62. In other words, the stator winding 61 has a portion corresponding to the coil end CE protruding axially outward from the stator core 62, and a portion corresponding to the coil side CS on the axially inner side thereof.

[0060] The coil module 150 has two types of shapes. In one, the partial winding 151 is bent radially inward at the coil end CE, i.e., toward the stator core 62, and in the other, the partial winding 151 is not bent radially inward at the coil end CE and extends linearly in the axial direction. In the following description, for convenience, the partial winding 151 having a bent shape at both axial ends is also referred to as the "first partial winding 151A," and the coil module 150 having the first partial winding 151A is also referred to as the "first coil module 150A." In addition, the partial winding 151 not having a bent shape at both axial ends is also referred to as the "second partial winding 151B," and the coil module 150 having the second partial winding 151B is also referred to as the "second coil module 150B."

[0061] FIG. 17 is a side view showing the first coil module 150A and the second coil module 150B arranged side by side for comparison, and FIG. 18 is a side view showing the first partial winding 151A and the second partial winding 151B arranged side by side for comparison. As shown in these figures, the coil modules 150A and 150B and the partial windings 151A and 151B have different axial lengths and different end shapes on both axial sides. The first partial winding 151A is substantially C-shaped in side view, and the second partial winding 151B is substantially I-shaped in side view. The first partial winding 151A is fitted with insulating covers 161 and 162 as "first insulating covers" on both axial sides, and the second partial winding 151B is fitted with insulating covers 163 and 164 as "second insulating covers" on both axial sides.

[0062] Next, the configuration of the coil modules 150A and 150B will be described in detail.

[0063] Here, first, the first coil module 150A of the coil modules 150A and 150B will be described. Fig. 19(a) is a perspective view showing the configuration of the first coil module 150A, and Fig. 19(b) is a perspective view showing the components of the first coil module 150A in an exploded view. Fig. 20 is a cross-sectional view taken along line 20-20 in Fig. 19(a).

[0064] 19(a) and 19(b), the first coil module 150A has a first partial winding 151A formed by multiple windings of a conductive wire CR, and insulating covers 161, 162 attached to one and the other axial ends of the first partial winding 151A. The insulating covers 161, 162 are made of an insulating material such as synthetic resin.

[0065] The first partial winding 151A has a pair of intermediate conductor portions 152 arranged parallel to each other and linearly, and a pair of transition portions 153A connecting the pair of intermediate conductor portions 152 at both axial ends, and is formed into an annular shape by the pair of intermediate conductor portions 152 and the pair of transition portions 153A. The pair of intermediate conductor portions 152 are arranged at a predetermined coil pitch apart, and an intermediate conductor portion 152 of the partial winding 151 of another phase can be arranged between the pair of intermediate conductor portions 152 in the circumferential direction. In this embodiment, the pair of intermediate conductor portions 152 are arranged at a distance of two coil pitches, and one intermediate conductor portion 152 of the partial winding 151 of the other two phases is arranged between the pair of intermediate conductor portions 152.

[0066] The pair of transition portions 153A have the same shape on both axial sides, and are provided as portions corresponding to the coil ends CE (see FIG. 11). Each transition portion 153A is provided so as to be bent in a direction perpendicular to the intermediate conductor portion 152, i.e., in a direction perpendicular to the axial direction.

[0067] 18, the first partial winding 151A has a crossover portion 153A on both axial sides, and the second partial winding 151B has a crossover portion 153B on both axial sides. The crossover portions 153A, 153B of the partial windings 151A, 151B have different shapes, and to clearly distinguish between them, the crossover portion 153A of the first partial winding 151A will also be referred to as the "first crossover portion 153A," and the crossover portion 153B of the second partial winding 151B will also be referred to as the "second crossover portion 153B."

[0068] In each of the partial windings 151A, 151B, the intermediate conductor portions 152 are provided as coil side conductor portions arranged one by one in the circumferential direction at the coil side CS. Also, each of the jumper portions 153A, 153B is provided as a coil end conductor portion at the coil end CE that connects intermediate conductor portions 152 of the same phase at two different positions in the circumferential direction.

[0069] As shown in FIG. 20, the first partial winding 151A is formed by winding the conductor wire CR in multiple layers so that the cross section of the conductor wire assembly portion is rectangular. FIG. 20 shows a cross section of the intermediate conductor portion 152, and the conductor wire CR is wound in multiple layers so as to be aligned in the circumferential direction and the radial direction in the intermediate conductor portion 152. That is, the first partial winding 151A is formed so that the conductor wire CR is arranged in multiple rows in the circumferential direction and multiple rows in the radial direction in the intermediate conductor portion 152, so that the cross section is substantially rectangular. Note that at the tip end portion of the first crossover portion 153A, the conductor wire CR is wound in multiple layers so as to be aligned in the axial direction and the radial direction by bending in the radial direction. In this embodiment, the first partial winding 151A is formed by winding the conductor wire CR by concentric winding. However, the winding method of the conductor wire CR is arbitrary, and the conductor wire CR may be wound in multiple layers by alpha winding instead of concentric winding.

[0070] In the first partial winding 151A, an end of the conductor wire CR is pulled out from one of the first crossover portions 153A on both axial sides (the upper first crossover portion 153A in Figure 19(b)), and these ends serve as winding ends 154, 155. The winding ends 154, 155 are the start and end of the winding of the conductor wire CR, respectively. One of the winding ends 154, 155 is connected to a current input / output terminal, and the other is connected to a neutral point.

[0071] In the first partial winding 151A, each intermediate conductor portion 152 is provided covered with a sheet-like insulating cover 157. Note that in Fig. 19(a), the first coil module 150A is shown in a state in which the intermediate conductor portion 152 is covered with the insulating cover 157 and the intermediate conductor portion 152 exists inside the insulating cover 157, but for convenience, the corresponding portion is referred to as the intermediate conductor portion 152 (the same applies to Fig. 22(a) described later).

[0072] Insulating cover 157 is provided by using a film material FM whose axial dimension is at least the length of the axial insulating coverage of intermediate conductor portion 152, and wrapping this film material FM around intermediate conductor portion 152. The film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film base and a foaming adhesive layer provided on one of the two surfaces of the film base. The film material FM is then wrapped around intermediate conductor portion 152 while adhered thereto by the adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.

[0073] As shown in Fig. 20, the intermediate conductor portion 152 has a generally rectangular cross section formed by arranging the conductor wire materials CR in the circumferential and radial directions, and the intermediate conductor portion 152 is covered with a film material FM with its circumferential ends overlapping each other to provide an insulating cover 157. The film material FM is a rectangular sheet whose vertical dimension is longer than the axial length of the intermediate conductor portion 152 and whose horizontal dimension is longer than the circumference of the intermediate conductor portion 152, and is wound around the intermediate conductor portion 152 with creases made to match the cross-sectional shape of the intermediate conductor portion 152. When the film material FM is wound around the intermediate conductor portion 152, the gap between the conductor wire materials CR of the intermediate conductor portion 152 and the film base material is filled by foaming in the adhesive layer. In the overlap portion OL of the film material FM, the circumferential ends of the film material FM are joined together by an adhesive layer.

[0074] The intermediate conductor portion 152 is provided with an insulating cover 157 so as to cover all of its two circumferential side surfaces and two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate conductor portion 152 is provided with an overlap portion OL where the film material FM overlaps a portion of the insulating cover 157 that faces the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., one of the two circumferential side surfaces of the intermediate conductor portion 152. In this embodiment, the overlap portion OL is provided on the same circumferential side of each of the pair of intermediate conductor portions 152.

[0075] In the first partial winding 151A, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portions of the first crossover portions 153A on both axial sides that are covered by the insulating covers 161, 162 (i.e., the portions inside the insulating covers 161, 162). In Fig. 17, in the first coil module 150A, the range AX1 is the portion not covered by the insulating covers 161, 162, and the insulating cover 157 is provided in a range extending above and below the range AX1.

[0076] Next, the configuration of the insulating covers 161 and 162 will be described.

[0077] The insulating cover 161 is attached to the first transition portion 153A on one axial side of the first partial winding 151A, and the insulating cover 162 is attached to the first transition portion 153A on the other axial side of the first partial winding 151A. The configuration of the insulating cover 161 is shown in Figures 21(a) and (b). Figures 21(a) and (b) are perspective views of the insulating cover 161 viewed from two different directions.

[0078] As shown in Figs. 21(a) and (b), the insulating cover 161 has a pair of side surface portions 171 that are circumferential side surfaces, an outer surface portion 172 on the axially outer side, an inner surface portion 173 on the axially inner side, and a front surface portion 174 on the radially inner side. Each of these portions 171 to 174 is formed in a plate shape, and is joined to each other in a three-dimensional shape such that only the radially outer side is open. Each of the pair of side surface portions 171 is provided in a direction that extends toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when a plurality of first coil modules 150A are arranged side by side in the circumferential direction, the side surface portions 171 of the insulating cover 161 of each of the adjacent first coil modules 150A face each other in abutment or close proximity. This allows each of the first coil modules 150A adjacent in the circumferential direction to be preferably arranged annularly while being insulated from each other.

[0079] In the insulating cover 161, an opening 175a is provided in the outer surface portion 172 for pulling out the winding end 154 of the first partial winding 151A, and an opening 175b is provided in the front surface portion 174 for pulling out the winding end 155 of the first partial winding 151A. In this case, one winding end 154 is pulled out in the axial direction from the outer surface portion 172, while the other winding end 155 is pulled out in the radial direction from the front surface portion 174.

[0080] Moreover, in the insulating cover 161, the pair of side portions 171 are provided with semicircular recesses 177 extending in the axial direction at positions which are both circumferential ends of the front portion 174, i.e., positions where each side portion 171 intersects with the front portion 174. Furthermore, the outer surface portion 172 is provided with a pair of protrusions 178 extending in the axial direction at positions which are symmetrical on both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

[0081] The recess 177 of the insulating cover 161 will be explained further. As shown in FIG. 20, the first crossover portion 153A of the first partial winding 151A is curved so as to be convex toward the radially inner side, i.e., toward the core assembly CA side. In this configuration, a gap is formed between the first crossover portions 153A adjacent in the circumferential direction, the gap becoming wider toward the tip side of the first crossover portion 153A. Therefore, in this embodiment, the gap between the first crossover portions 153A arranged in the circumferential direction is utilized to provide a recess 177 at a position on the side surface portion 171 of the insulating cover 161 that is outside the curved portion of the first crossover portion 153A.

[0082] A temperature detector (thermistor) may be provided in the first partial winding 151A, and in such a configuration, an opening for leading out a signal line from the temperature detector may be provided in the insulating cover 161. In this case, the temperature detector can be conveniently accommodated in the insulating cover 161.

[0083] Although detailed description using drawings will be omitted, the other insulating cover 162 in the axial direction has a configuration generally similar to that of the insulating cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side portions 171, an outer surface portion 172 on the axially outer side, an inner surface portion 173 on the axially inner side, and a front surface portion 174 on the radially inner side. In the insulating cover 162, semicircular recesses 177 are provided in the pair of side portions 171 at positions that are both circumferential ends of the front surface portion 174, and a pair of protrusions 178 are provided on the outer surface portion 172. A difference from the insulating cover 161 is that the insulating cover 162 does not have an opening for pulling out the winding ends 154, 155 of the first partial winding 151A.

[0084] The insulating covers 161 and 162 have different heights in the axial direction (i.e., widths in the axial direction at the pair of side portions 171 and the front portion 174). Specifically, as shown in FIG. 17, the axial height W11 of the insulating cover 161 and the axial height W12 of the insulating cover 162 are W11>W12. That is, when the conductor wire CR is wound in multiple layers, it is necessary to switch (change lanes) the winding stages of the conductor wire CR in a direction perpendicular to the winding direction (circumferential direction), and the winding width may increase due to the switching. To add, the insulating cover 161 of the insulating covers 161 and 162 is a portion that covers the first crossover portion 153A on the side including the winding start and winding end of the conductor wire CR. By including the winding start and winding end of the conductor wire CR, the winding allowance (overlap allowance) of the conductor wire CR becomes larger than other portions, which may result in an increase in the winding width. Taking this into consideration, the axial height dimension W11 of the insulating cover 161 is greater than the axial height dimension W12 of the insulating cover 162. This prevents the insulating covers 161, 162 from limiting the number of turns of the conductive wire CR, as opposed to a case in which the height dimensions W11, W12 of the insulating covers 161, 162 are the same.

[0085] Next, the second coil module 150B will be described.

[0086] Fig. 22(a) is a perspective view showing the configuration of the second coil module 150B, and Fig. 22(b) is a perspective view showing components of the second coil module 150B in an exploded manner. Also, Fig. 23 is a cross-sectional view taken along line 23-23 in Fig. 22(a).

[0087] 22(a) and 22(b), the second coil module 150B has a second partial winding 151B formed by multiple windings of conductive wire CR similar to the first partial winding 151A, and insulating covers 163, 164 attached to one and the other axial ends of the second partial winding 151B. The insulating covers 163, 164 are molded from an insulating material such as synthetic resin.

[0088] The second partial winding 151B has a pair of intermediate conductor parts 152 arranged parallel to each other and linearly, and a pair of second transition parts 153B connecting the pair of intermediate conductor parts 152 at both axial ends, and is formed into a ring shape by the pair of intermediate conductor parts 152 and the pair of second transition parts 153B. In the second partial winding 151B, the pair of intermediate conductor parts 152 has the same configuration as the intermediate conductor parts 152 of the first partial winding 151A. In contrast, the pair of second transition parts 153B has a different configuration from the first transition part 153A of the first partial winding 151A. The second transition part 153B of the second partial winding 151B is arranged to extend linearly in the axial direction from the intermediate conductor parts 152 without being bent in the radial direction. FIG. 18 clearly shows the difference between the partial windings 151A and 151B.

[0089] In the second partial winding 151B, an end of the conductor wire CR is pulled out from one of the second crossover portions 153B on both axial sides (the upper second crossover portion 153B in FIG. 22(b)), and this end serves as winding ends 154, 155. Similarly to the first partial winding 151A, in the second partial winding 151B, one of the winding ends 154, 155 is connected to a current input / output terminal, and the other is connected to a neutral point.

[0090] In the second partial winding 151B, similarly to the first partial winding 151A, each intermediate conductor portion 152 is covered with a sheet-like insulating covering 157. The insulating covering 157 is provided by using a film material FM having an axial dimension of at least the length of the axial insulating covering range of the intermediate conductor portion 152, and winding the film material FM around the intermediate conductor portion 152.

[0091] The configuration of the insulating covering 157 is also generally similar for each of the partial windings 151A, 151B. That is, as shown in Fig. 23, the intermediate conductor portion 152 is covered with a film material FM with its circumferential end portion overlapped. The intermediate conductor portion 152 is provided with the insulating covering 157 so as to cover all of its two circumferential side surfaces and two radial side surfaces. In this case, the insulating covering 157 surrounding the intermediate conductor portion 152 is provided with an overlapping portion OL where the film material FM overlaps a portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., one of the two circumferential side surfaces of the intermediate conductor portion 152. In this embodiment, the overlapping portion OL is provided on the same circumferential side of each of the pair of intermediate conductor portions 152.

[0092] In the second partial winding 151B, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portions of the second crossover portions 153B on both axial sides that are covered by the insulating covers 163, 164 (i.e., the portions inside the insulating covers 163, 164). In Fig. 17, in the second coil module 150B, the range AX2 is the portion not covered by the insulating covers 163, 164, and the insulating cover 157 is provided in a range extending above and below the range AX2.

[0093] In each of the partial windings 151A, 151B, the insulating covering 157 is provided in an area that includes a part of the transition portions 153A, 153B. That is, in each of the partial windings 151A, 151B, the insulating covering 157 is provided on the intermediate conductor portion 152 and on a portion of the transition portion 153A, 153B that extends linearly beyond the intermediate conductor portion 152. However, since the partial windings 151A, 151B have different axial lengths, the axial ranges of the insulating covering 157 are also different.

[0094] Next, the configuration of the insulating covers 163, 164 will be described.

[0095] The insulating cover 163 is attached to the second transition portion 153B on one axial side of the second partial winding 151B, and the insulating cover 164 is attached to the second transition portion 153B on the other axial side of the second partial winding 151B. The configuration of the insulating cover 163 is shown in Figures 24(a) and (b). Figures 24(a) and (b) are perspective views of the insulating cover 163 viewed from two different directions.

[0096] As shown in Figs. 24(a) and (b), the insulating cover 163 has a pair of side surface portions 181 which are circumferential side surfaces, an outer surface portion 182 on the axially outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side. Each of these portions 181 to 184 is formed in a plate shape, and is joined to each other in a three-dimensional shape so that only the axially inner side is open. Each of the pair of side surface portions 181 is provided in a direction extending toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when the multiple second coil modules 150B are arranged side by side in the circumferential direction, the side surface portions 181 of the insulating cover 163 of the adjacent second coil modules 150B face each other in abutment or close proximity. This allows the second coil modules 150B adjacent in the circumferential direction to be preferably arranged annularly while being insulated from each other.

[0097] In the insulating cover 163, the front surface portion 183 is provided with an opening 185a for pulling out the winding end 154 of the second partial winding 151B, and the outer surface portion 182 is provided with an opening 185b for pulling out the winding end 155 of the second partial winding 151B.

[0098] The front surface 183 of the insulating cover 163 is provided with a protruding portion 186 that protrudes radially inward. The protruding portion 186 is provided at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163 so as to protrude radially inward from the second crossover portion 153B. The protruding portion 186 has a tapered shape that tapers toward the radially inner side in a plan view, and a through hole 187 extending in the axial direction is provided at its tip. Note that the configuration of the protruding portion 186 is arbitrary as long as it protrudes radially inward from the second crossover portion 153B and has the through hole 187 at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163. However, assuming a state of overlap with the insulating cover 161 on the axially inner side, it is desirable to form the protruding portion 186 narrow in the circumferential direction to avoid interference with the winding ends 154, 155.

[0099] The protruding portion 186 has a stepped axial thickness at its radially inner tip, and the thinned lower step 186a is provided with a through hole 187. This lower step 186a corresponds to a portion where the height from the axial end face of the inner cylindrical member 81 is lower than the height of the second transition portion 153B when the second coil module 150B is assembled to the core assembly CA.

[0100] 23, a through hole 188 that penetrates in the axial direction is provided in the protruding portion 186. This makes it possible to fill the space between the insulating covers 161, 163 through the through hole 188 with adhesive when the insulating covers 161, 163 are overlapped in the axial direction.

[0101] Although detailed description using the drawings will be omitted, the other axial insulating cover 164 has a configuration generally similar to that of the insulating cover 163. Like the insulating cover 163, the insulating cover 164 has a pair of side portions 181, an outer surface portion 182 on the axially outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side, as well as a through hole 187 provided at the tip portion of the protruding portion 186. Also, the insulating cover 164 differs from the insulating cover 163 in that the insulating cover 164 does not have an opening for pulling out the winding ends 154, 155 of the second partial winding 151B.

[0102] The insulating covers 163 and 164 have different radial widths of the pair of side portions 181. Specifically, as shown in FIG. 17, the radial width W21 of the side portion 181 of the insulating cover 163 and the radial width W22 of the side portion 181 of the insulating cover 164 are such that W21>W22. In other words, the insulating cover 163 of the insulating covers 163 and 164 is a portion that covers the second crossover portion 153B on the side including the winding start and winding end of the conductor wire CR, and by including the winding start and winding end of the conductor wire CR, the winding allowance (overlap allowance) of the conductor wire CR is larger than other portions, and as a result, the winding width may become larger. Taking this into consideration, the radial width W21 of the insulating cover 163 is larger than the radial width W22 of the insulating cover 164. This prevents the number of turns of the conductive wire CR from being limited by the insulating covers 163, 164, which is a problem that occurs when the widths W21, W22 of the insulating covers 163, 164 are the same.

[0103] Fig. 25 is a diagram showing overlap positions of the film material FM when the coil modules 150A, 150B are arranged in the circumferential direction. As described above, in each of the coil modules 150A, 150B, the film material FM is placed around the intermediate conductor portion 152 so as to overlap the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., the circumferential side surface of the intermediate conductor portion 152 (see Figs. 20 and 23). Then, when the coil modules 150A, 150B are arranged in the circumferential direction, the overlap portions OL of the film material FM are arranged on the same side (the right side in the circumferential direction in the figure) of both sides in the circumferential direction. As a result, the overlap portions OL of the film material FM in the intermediate conductor portions 152 of the partial windings 151A, 151B of different phases adjacent to each other in the circumferential direction do not overlap each other in the circumferential direction. In this case, a maximum of three sheets of film material FM overlap between each of the intermediate conductor portions 152 aligned in the circumferential direction.

[0104] Next, a configuration for assembling the coil modules 150A, 150B to the core assembly CA will be described.

[0105] The coil modules 150A, 150B have different axial lengths and different shapes of the crossover portions 153A, 153B of the partial windings 151A, 151B, and are configured to be attached to the core assembly CA with the first crossover portion 153A of the first coil module 150A facing axially inward and the second crossover portion 153B of the second coil module 150B facing axially outward. With regard to the insulating covers 161-164, the insulating covers 161, 163 are axially overlapped at one axial end side of each of the coil modules 150A, 150B, and the insulating covers 162, 164 are axially overlapped at the other axial end side, and the insulating covers 161-164 are fixed to the core assembly CA.

[0106] Fig. 26 is a plan view showing a state in which a plurality of insulating covers 161 are lined up in the circumferential direction when the first coil module 150A is assembled to the core assembly CA, and Fig. 27 is a plan view showing a state in which a plurality of insulating covers 161, 163 are lined up in the circumferential direction when the first coil module 150A and the second coil module 150B are assembled to the core assembly CA. Fig. 28(a) is a vertical cross-sectional view showing a state before fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA, and Fig. 28(b) is a vertical cross-sectional view showing a state after fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA.

[0107] 26, in a state where a plurality of first coil modules 150A are assembled to a core assembly CA, a plurality of insulating covers 161 are arranged with their side surfaces 171 in contact or close to each other. Each insulating cover 161 is arranged such that a boundary line LB where the side surfaces 171 face each other coincides with a recess 105 on the axial end surface of the inner tube member 81. In this case, the side surfaces 171 of the insulating covers 161 adjacent in the circumferential direction come into contact or close to each other, so that a through hole portion extending in the axial direction is formed by each recess 177 of the insulating covers 161, and the positions of the through hole portion and the recess 105 coincide with each other.

[0108] 27, the second coil module 150B is further assembled to the integral body of the core assembly CA and the first coil module 150A. With this assembly, the multiple insulating covers 163 are arranged with their side portions 181 in contact with or close to each other. In this state, the transition portions 153A, 153B are arranged to intersect with each other on the circle on which the intermediate conductor portions 152 are arranged in the circumferential direction. Each insulating cover 163 is arranged such that the protruding portion 186 overlaps with the insulating cover 161 in the axial direction and the through hole 187 of the protruding portion 186 is connected in the axial direction to the through hole portion formed by each recess 177 of the insulating cover 161.

[0109] At this time, the protrusion 186 of the insulating cover 163 is guided to a predetermined position by a pair of protrusions 178 provided on the insulating cover 161, so that the position of the through hole 187 on the insulating cover 163 side coincides with the through hole portion on the insulating cover 161 side and the recess 105 of the inner tube member 81. In other words, in a state where the coil modules 150A, 150B are assembled to the core assembly CA, the recess 177 of the insulating cover 161 is located on the inner side of the insulating cover 163, so that it may be difficult to align the through hole 187 of the protrusion 186 with the recess 177 of the insulating cover 161. In this regard, the protrusion 186 of the insulating cover 163 is guided by the pair of protrusions 178 of the insulating cover 161, so that it becomes easy to align the insulating cover 163 with the insulating cover 161.

[0110] 28(a) and (b), the insulating cover 161 and the protruding portion 186 of the insulating cover 163 are engaged with each other at the overlapping portion thereof, and the fixing pin 191 is fixed as a fixing member. More specifically, the recess 105 of the inner cylindrical member 81, the recess 177 of the insulating cover 161, and the through hole 187 of the insulating cover 163 are aligned with each other, and the fixing pin 191 is inserted into the recess 105, 177 and the through hole 187. As a result, the insulating covers 161 and 163 are fixed integrally to the inner cylindrical member 81. According to this configuration, the coil modules 150A and 150B adjacent to each other in the circumferential direction are fixed to the core assembly CA at the coil end CE by the common fixing pin 191. The fixing pin 191 is preferably made of a material having good thermal conductivity, such as a metal pin.

[0111] 28(b), the fixing pin 191 is attached to the lower step 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end of the fixing pin 191 protrudes above the lower step 186a, but does not protrude above the upper surface (outer surface 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion between the insulating cover 161 and the protruding portion 186 (lower step 186a) of the insulating cover 163, and has a margin for protruding upward, which is considered to facilitate the work of inserting the fixing pin 191 into the recesses 105, 177 and the through hole 187 (i.e., the work of fixing the fixing pin 191). Furthermore, since the upper end of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, the inconvenience of the axial length of the stator 60 becoming longer due to the fixing pin 191 protruding can be suppressed.

[0112] After the insulating covers 161, 163 are fixed by the fixing pins 191, adhesive is filled through the through holes 188 provided in the insulating cover 163. This allows the insulating covers 161, 163, which overlap in the axial direction, to be firmly joined to each other. Note that, for the sake of convenience, the through holes 188 are shown in the range from the upper surface to the lower surface of the insulating cover 163 in Figures 28(a) and (b), but in reality, the through holes 188 are provided in a thin plate portion formed by hollowing out or the like.

[0113] As shown in FIG. 28(b), the fixing position of each insulating cover 161, 163 by the fixing pin 191 is the axial end face of the stator holder 70 radially inward (left side of the figure) of the stator core 62, and the fixing pin 191 is fixed to the stator holder 70. That is, the first transition portion 153A is fixed to the axial end face of the stator holder 70. In this case, since the stator holder 70 is provided with the refrigerant passage 85, the heat generated in the first partial winding 151A is directly transferred from the first transition portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. In addition, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, and the transfer of heat to the stator holder 70 side is promoted through the fixing pin 191. With this configuration, the cooling performance of the stator winding 61 is improved.

[0114] In this embodiment, 18 insulating covers 161, 163 are arranged in the coil end CE, stacked on the inside and outside in the axial direction, while 18 recesses 105 are provided on the axial end face of the stator holder 70 at the same number of locations as the insulating covers 161, 163. Fixation is performed by fixing pins 191 at the 18 recesses 105.

[0115] Although not shown, the same is true for the insulating covers 162, 164 on the opposite axial side. That is, when the first coil module 150A is assembled, the side portions 171 of the insulating covers 162 adjacent in the circumferential direction are brought into contact with or close to each other, so that the recesses 177 of the insulating covers 162 form through-holes extending in the axial direction, and the positions of the through-holes and the recesses 106 on the axial end surface of the outer tubular member 71 coincide with each other. Then, when the second coil module 150B is assembled, the position of the through-hole 187 on the insulating cover 164 side coincides with the through-hole portion on the insulating cover 163 side and the recesses 106 of the outer tubular member 71, and the fixing pin 191 is inserted into the recesses 106, 177 and the through-hole 187, so that the insulating covers 162, 164 are fixed integrally to the outer tubular member 71.

[0116] When assembling the coil modules 150A, 150B to the core assembly CA, it is preferable to first attach all of the first coil modules 150A to the outer periphery of the core assembly CA, and then assemble all of the second coil modules 150B and fix them with the fixing pins 191. Alternatively, it is also possible to first fix two first coil modules 150A and one second coil module 150B to the core assembly CA with one fixing pin 191, and then repeatedly assemble the first coil modules 150A, assemble the second coil modules 150B, and fix them with the fixing pins 191 in this order.

[0117] Next, the bus bar module 200 will be described.

[0118] The busbar module 200 is a winding connecting member that is electrically connected to the partial windings 151 of each coil module 150 in the stator winding 61, connects one end of the partial windings 151 of each phase in parallel for each phase, and connects the other ends of the partial windings 151 at a neutral point. Fig. 29 is a perspective view of the busbar module 200, and Fig. 30 is a cross-sectional view showing a part of a vertical cross section of the busbar module 200.

[0119] The busbar module 200 has an annular portion 201 having a circular ring shape, a plurality of connection terminals 202 extending from the annular portion 201, and three input / output terminals 203 provided for each phase winding. The annular portion 201 is formed in a circular ring shape from an insulating material such as resin.

[0120] As shown in FIG. 30, the annular portion 201 has laminated plates 204 that are substantially annular and laminated in multiple layers (five layers in this embodiment) in the axial direction, and four bus bars 211-214 are provided between the laminated plates 204. Each of the bus bars 211-214 has an annular shape and includes a U-phase bus bar 211, a V-phase bus bar 212, a W-phase bus bar 213, and a neutral bus bar 214. Each of the bus bars 211-214 is arranged in the annular portion 201 in the axial direction with the plate surfaces facing each other. Each of the laminated plates 204 and each of the bus bars 211-214 are bonded to each other with an adhesive. It is preferable to use an adhesive sheet as the adhesive. However, a liquid or semi-liquid adhesive may be applied. A connection terminal 202 is connected to each of the bus bars 211-214 so as to protrude radially outward from the annular portion 201.

[0121] On the upper surface of the annular portion 201, that is, on the upper surface of the laminated plate 204 on the outermost side of the five laminated plates 204 provided, a protrusion 201a extending in an annular shape is provided.

[0122] It should be noted that busbar module 200 may be one in which busbars 211-214 are provided in a state in which they are embedded in annular portion 201, and busbars 211-214 arranged at predetermined intervals may be integrally insert-molded. Furthermore, the arrangement of busbars 211-214 is not limited to a configuration in which all are lined up in the axial direction and all of their plate surfaces face the same direction, and may be a configuration in which busbars are lined up in the radial direction, a configuration in which they are lined up in two axial rows and two radial rows, a configuration including a configuration in which the plate surfaces extend in different directions, and the like.

[0123] 29, the connection terminals 202 are arranged in the circumferential direction of the annular portion 201 and are provided so as to extend in the axial direction on the radially outer side. The connection terminals 202 include a connection terminal connected to a U-phase busbar 211, a connection terminal connected to a V-phase busbar 212, a connection terminal connected to a W-phase busbar 213, and a connection terminal connected to a neutral busbar 214. The connection terminals 202 are provided in the same number as the winding ends 154, 155 of each partial winding 151 in the coil module 150, and the winding ends 154, 155 of each partial winding 151 are connected to each of these connection terminals 202. In this way, the busbar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151, respectively.

[0124] The input / output terminals 203 are made of, for example, a busbar material, and are provided so as to extend in the axial direction. The input / output terminals 203 include a U-phase input / output terminal 203U, a V-phase input / output terminal 203V, and a W-phase input / output terminal 203W. These input / output terminals 203 are connected to the busbars 211 to 213 for each phase within the annular portion 201. Through these input / output terminals 203, power is input / output from an inverter (not shown) to the phase winding of each phase of the stator winding 61.

[0125] Note that a current sensor for detecting a phase current of each phase may be integrally provided in the busbar module 200. In this case, a current detection terminal may be provided in the busbar module 200, and the detection result of the current sensor may be output to a control device (not shown) through the current detection terminal.

[0126] The annular portion 201 has a plurality of protruding portions 205 protruding toward the inner periphery as fixed portions to the stator holder 70, and the protruding portions 205 are each formed with a through hole 206 extending in the axial direction.

[0127] Fig. 31 is a perspective view showing a state in which the busbar module 200 is assembled to the stator holder 70, and Fig. 32 is a vertical cross-sectional view of a fixing portion that fixes the busbar module 200. Note that for the configuration of the stator holder 70 before the busbar module 200 is assembled, please refer to Fig. 12.

[0128] 31, the busbar module 200 is provided on the end plate portion 91 so as to surround the boss portion 92 of the inner cylinder member 81. The busbar module 200 is positioned by being assembled to the support portions 95 (see FIG. 12) of the inner cylinder member 81, and then fixed to the stator holder 70 (inner cylinder member 81) by fastening fasteners 217 such as bolts.

[0129] 32, an end plate portion 91 of the inner tube member 81 is provided with a support portion 95 extending in the axial direction. The busbar module 200 is fixed to the support portion 95 by a fastener 217 with the support portion 95 inserted into through holes 206 provided in a plurality of protrusions 205. In this embodiment, the busbar module 200 is fixed using a retainer plate 220 made of a metal material such as iron. The retainer plate 220 has a fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted, a pressing portion 223 that presses the upper surface of the annular portion 201 of the busbar module 200, and a bend portion 224 provided between the fastened portion 222 and the pressing portion 223.

[0130] In the attached state of the retainer plate 220, the fastener 217 is inserted into the insertion hole 221 of the retainer plate 220 and is screwed to the support portion 95 of the inner cylinder member 81. In addition, the pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200. In this case, as the fastener 217 is screwed into the support portion 95, the retainer plate 220 is pressed downward in the figure, and accordingly, the annular portion 201 is pressed downward by the pressing portion 223. The pressing force downward in the figure generated by the screwing of the fastener 217 is transmitted to the pressing portion 223 through the bent portion 224, so that the pressing by the pressing portion 223 is performed in a state accompanied by the elastic force of the bent portion 224.

[0131] As described above, an annular protrusion 201a is provided on the upper surface of the annular portion 201, and the tip of the retainer plate 220 on the pressing portion 223 side can abut against the protrusion 201a. This prevents the downward pressing force of the retainer plate 220 from escaping radially outward. In other words, the pressing force generated by the screwing of the fastener 217 is appropriately transmitted to the pressing portion 223 side.

[0132] 31, in a state in which the busbar module 200 is assembled to the stator holder 70, the input / output terminals 203 are provided at a position 180 degrees opposite in the circumferential direction to the inlet opening 86a and the outlet opening 87a that communicate with the refrigerant passage 85. However, the input / output terminals 203 and the openings 86a, 87a may be provided together at the same position (i.e., adjacent positions).

[0133] Next, the relay member 230 that electrically connects the input / output terminal 203 of the bus bar module 200 to an external device of the rotating electric machine 10 will be described.

[0134] 1, in the rotating electric machine 10, the input / output terminals 203 of the busbar module 200 are provided so as to protrude outward from the housing cover 242, and are connected to a relay member 230 on the outside of the housing cover 242. The relay member 230 is a member that relays the connection between the input / output terminals 203 for each phase extending from the busbar module 200 and a power line for each phase extending from an external device such as an inverter.

[0135] Fig. 33 is a vertical cross-sectional view showing a state in which relay member 230 is attached to housing cover 242, and Fig. 34 is a perspective view of relay member 230. As shown in Fig. 33, a through hole 242a is formed in housing cover 242, and input / output terminal 203 can be led out through through hole 242a.

[0136] The relay member 230 has a main body 231 fixed to the housing cover 242, and a terminal insertion portion 232 inserted into a through hole 242a of the housing cover 242. The terminal insertion portion 232 has three insertion holes 233 through which the input / output terminals 203 of each phase are inserted one by one. The three insertion holes 233 have an elongated cross-sectional opening, and are aligned with their longitudinal directions all oriented in substantially the same direction.

[0137] Three relay bus bars 234, one for each phase, are attached to the main body 231. The relay bus bars 234 are bent into a substantially L-shape, and are fixed to the main body 231 with fasteners 235 such as bolts, and are also fixed to the tips of the input / output terminals 203 inserted into the insertion holes 233 of the terminal insertion portions 232 with fasteners 236 such as bolts and nuts.

[0138] Although not shown in the figure, the relay member 230 can be connected to a power line for each phase extending from an external device, and power can be input and output to the input / output terminal 203 for each phase.

[0139] Next, a description will be given of the configuration of a control system that controls the rotating electric machine 10. Fig. 35 is an electric circuit diagram of the control system for the rotating electric machine 10, and Fig. 36 is a functional block diagram showing the control process by the control device 270.

[0140] As shown in FIG. 35, the stator winding 61 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 260 corresponding to a power converter is connected to the stator winding 61. The inverter 260 is configured as a full bridge circuit having upper and lower arms in the same number as the number of phases, and a series connection consisting of an upper arm switch 261 and a lower arm switch 262 is provided for each phase. Each of these switches 261, 262 is turned on and off by a driver 263, and the phase winding of each phase is energized by the on and off. Each of the switches 261, 262 is configured of a semiconductor switching element such as a MOSFET or an IGBT. In addition, a charge supply capacitor 264 for supplying a charge required at the time of switching to each of the switches 261, 262 is connected in parallel to the series connection of the switches 261, 262 to the upper and lower arms of each phase.

[0141] One end of the U-phase winding, the V-phase winding, and the W-phase winding are connected to the intermediate connection point between the upper and lower arm switches 261, 262. These phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at the neutral point.

[0142] The control device 270 includes a microcomputer including a CPU and various memories, and performs energization control by turning on and off the switches 261, 262 based on various detection information of the rotating electric machine 10 and requests for power running and power generation. The detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 20 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the energization current of each phase detected by a current sensor. The control device 270 performs on / off control of the switches 261, 262 by, for example, PWM control at a predetermined switching frequency (carrier frequency) or square wave control. The control device 270 may be an internal control device built into the rotating electric machine 10, or an external control device provided outside the rotating electric machine 10.

[0143] Incidentally, since the rotating electric machine 10 of this embodiment has a slotless structure (teethless structure), the inductance of the stator 60 is reduced and the electrical time constant is small, and under the circumstances where the electrical time constant is small, it is desirable to increase the switching frequency (carrier frequency) and the switching speed. In this regard, the charge supply capacitor 264 is connected in parallel to the series connection of the switches 261, 262 of each phase, thereby reducing the wiring inductance, and appropriate surge countermeasures are possible even in a configuration with a high switching speed.

[0144] A high potential side terminal of the inverter 260 is connected to a positive terminal of a DC power supply 265, and a low potential side terminal is connected to a negative terminal (ground) of the DC power supply 265. The DC power supply 265 is configured, for example, by a battery pack in which a plurality of single cells are connected in series. In addition, a smoothing capacitor 266 is connected in parallel to the DC power supply 265 to the high potential side terminal and the low potential side terminal of the inverter 260.

[0145] FIG. 36 is a block diagram showing a current feedback control process for controlling the currents of the U, V, and W phases.

[0146] 36, a current command value setting unit 271 uses a torque-dq map to set a d-axis current command value and a q-axis current command value based on a powering torque command value or a power generation torque command value for the rotating electric machine 10, and an electrical angular velocity ω obtained by time-differentiating the electrical angle θ. Note that the power generation torque command value is a regenerative torque command value when the rotating electric machine 10 is used as a power source for a vehicle, for example.

[0147] The dq conversion unit 272 converts the current detection values ​​(three phase currents) detected by the current sensors provided for each phase into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system in which the field direction (direction of an axis of a magnetic field, or field direction) is the d-axis.

[0148] The d-axis current feedback control unit 273 calculates a d-axis command voltage as a manipulated variable for feedback-controlling the d-axis current to the d-axis current command value. The q-axis current feedback control unit 274 calculates a q-axis command voltage as a manipulated variable for feedback-controlling the q-axis current to the q-axis current command value. Each of these feedback control units 273, 274 calculates a command voltage using a PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.

[0149] The three-phase conversion unit 275 converts the d-axis and q-axis command voltages into U-phase, V-phase, and W-phase command voltages. The above units 271 to 275 are feedback control units that perform feedback control of the fundamental wave current based on the dq conversion theory, and the U-phase, V-phase, and W-phase command voltages are feedback control values.

[0150] The operation signal generating unit 276 generates an operation signal for the inverter 260 based on the three-phase command voltages using a well-known triangular wave carrier comparison method. Specifically, the operation signal generating unit 276 generates switch operation signals (duty signals) for the upper and lower arms in each phase by PWM control based on a magnitude comparison between a signal obtained by normalizing the three-phase command voltages with the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signals generated by the operation signal generating unit 276 are output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

[0151] Next, the torque feedback control process will be described. This process is mainly used for the purpose of increasing the output of the rotating electric machine 10 and reducing losses under operating conditions where the output voltage of the inverter 260 is large, such as in a high rotation range and a high output range. The control device 270 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotating electric machine 10.

[0152] FIG. 37 is a block diagram showing a torque feedback control process corresponding to the U, V, and W phases.

[0153] The voltage amplitude calculation unit 281 calculates a voltage amplitude command, which is a command value for the magnitude of a voltage vector, based on a powering torque command value or a power generation torque command value for the rotating electric machine 10 and an electrical angular velocity ω obtained by time-differentiating the electrical angle θ.

[0154] Similar to dq converter 272, dq converter 282 converts current detection values ​​by current sensors provided for each phase into d-axis current and q-axis current. Torque estimator 283 calculates torque estimation values ​​corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. Torque estimator 283 may calculate a voltage amplitude command based on map information in which the d-axis current, the q-axis current, and a voltage amplitude command are associated with each other.

[0155] The torque feedback control unit 284 calculates a voltage phase command, which is a command value for the phase of a voltage vector, as a manipulated variable for feedback control of the torque estimate value to the power running torque command value or the power generation torque command value. The torque feedback control unit 284 calculates the voltage phase command using a PI feedback method based on the deviation of the torque estimate value from the power running torque command value or the power generation torque command value.

[0156] The operation signal generating unit 285 generates an operation signal for the inverter 260 based on a voltage amplitude command, a voltage phase command, and an electrical angle θ. Specifically, the operation signal generating unit 285 calculates three-phase command voltages based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates switch operation signals for the upper and lower arms in each phase by PWM control based on a comparison of the magnitude between a signal obtained by normalizing the calculated three-phase command voltages by the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signals generated by the operation signal generating unit 285 are output to a driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

[0157] Incidentally, the operation signal generating unit 285 may generate the switch operation signal based on pulse pattern information, which is map information in which the voltage amplitude command, the voltage phase command, the electrical angle θ, and the switch operation signal are associated with each other, the voltage amplitude command, the voltage phase command, and the electrical angle θ.

[0158] (Modification) Below, a modification of the first embodiment will be described.

[0159] The configuration of the magnet 32 ​​in the magnet unit 22 may be changed as follows. In the magnet unit 22 shown in FIG. 38, the magnetization easy axis of the magnet 32 ​​is inclined to the radial direction, and a linear magnetic flux path is formed along the direction of the magnetization easy axis. In other words, the magnet 32 ​​is configured such that the direction of the magnetization easy axis is inclined to the d-axis between the magnetic flux action surface 34a on the stator 60 side (radially inner side) and the magnetic flux action surface 34b on the opposite stator side (radially outer side), and is linearly oriented so as to approach the d-axis on the stator 60 side in the circumferential direction and move away from the d-axis on the opposite stator side. Even in this configuration, the magnetic flux path length of the magnet 32 ​​can be made longer than the radial thickness dimension, making it possible to improve permeance.

[0160] It is also possible to use a Halbach array magnet in the magnet unit 22.

[0161] In each partial winding 151, the bending direction of the transition portion 153 may be either radially inward or outward, and in terms of its relationship with the core assembly CA, the first transition portion 153A may be bent toward the core assembly CA, or the first transition portion 153A may be bent toward the opposite side of the core assembly CA. The second transition portion 153B may be bent either radially inward or outward, as long as it is located axially outward of the first transition portion 153A and spans a portion of the first transition portion 153A in the circumferential direction.

[0162] The partial winding 151 may not have two types of partial windings 151 (the first partial winding 151A and the second partial winding 151B), but may have one type of partial winding 151. Specifically, the partial winding 151 may be formed to have a substantially L-shape or a substantially Z-shape in side view. When the partial winding 151 is formed to have a substantially L-shape in side view, the transition portion 153 is bent radially inward or outward at one axial end side, and is not bent radially at the other axial end side. When the partial winding 151 is formed to have a substantially Z-shape in side view, the transition portion 153 is bent radially in opposite directions at one axial end side and the other axial end side. In either case, the coil module 150 may be fixed to the core assembly CA by an insulating cover that covers the transition portion 153 as described above.

[0163] In the above-described configuration, all the partial windings 151 for each phase winding in the stator winding 61 are connected in parallel, but this may be changed. For example, all the partial windings 151 for each phase winding may be divided into a plurality of parallel connection groups, and the plurality of parallel connection groups may be connected in series. That is, all n partial windings 151 in each phase winding may be divided into two parallel connection groups of n / 2 partial windings each or three parallel connection groups of n / 3 partial windings each, and these may be connected in series. Alternatively, all the partial windings 151 for each phase winding in the stator winding 61 may be connected in series.

[0164] The stator winding 61 in the rotating electric machine 10 may be configured to have two-phase windings (a U-phase winding and a V-phase winding). In this case, for example, in the partial winding 151, a pair of intermediate conductor portions 152 may be provided spaced apart by one coil pitch, and one intermediate conductor portion 152 in the partial winding 151 of the other phase may be disposed between the pair of intermediate conductor portions 152.

[0165] The rotating electric machine 10 may be embodied as an inner rotor type surface magnet type rotating electric machine instead of an outer rotor type surface magnet type rotating electric machine. Figs. 39(a) and 39(b) are diagrams showing the configuration of the stator unit 300 in the case of an inner rotor structure. Fig. 39(a) is a perspective view showing the state in which the coil modules 310A and 310B are assembled to the core assembly CA, and Fig. 39(b) is a perspective view showing the partial windings 311A ​​and 311B included in each coil module 310A and 310B. In this example, the core assembly CA is configured by assembling the stator holder 70 to the radial outside of the stator core 62. Also, a configuration is adopted in which a plurality of coil modules 310A and 310B are assembled to the radial inside of the stator core 62.

[0166] The partial winding 311A ​​has a configuration generally similar to that of the first partial winding 151A described above, and includes a pair of intermediate conductor portions 312 and a transition portion 313A formed by bending the transition portion 313A toward the core assembly CA side (radially outward) on both axial sides. The partial winding 311B has a configuration generally similar to that of the second partial winding 151B described above, and includes a pair of intermediate conductor portions 312 and a transition portion 313B provided on both axial sides so as to straddle the transition portion 313A in the circumferential direction on the axially outer side. An insulating cover 315 is attached to the transition portion 313A of the partial winding 311A, and an insulating cover 316 is attached to the transition portion 313B of the partial winding 311B.

[0167] Insulating cover 315 is provided with semicircular recesses 317 extending in the axial direction on both circumferential side surfaces. Insulating cover 316 is provided with protruding portions 318 protruding radially outward beyond transition portion 313B, and a through hole 319 extending in the axial direction is provided at the tip of protruding portion 318.

[0168] Fig. 40 is a plan view showing a state in which the coil modules 310A, 310B are assembled to the core assembly CA. In Fig. 40, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of the stator holder 70. The stator holder 70 has a cooling structure using a liquid refrigerant or air, and may have a plurality of heat dissipation fins formed on the outer circumferential surface as an air-cooling structure, for example.

[0169] 40, insulating covers 315, 316 are arranged so as to overlap in the axial direction. A recess 317 provided on a side surface of insulating cover 315 and a through hole 319 provided in a protruding portion 318 of insulating cover 316 at a central position between one circumferential end and the other end of insulating cover 316 are connected in the axial direction, and are fixed at each portion by a fixing pin 321.

[0170] 40, the fixing positions of the insulating covers 315, 316 with the fixing pins 321 are the axial end faces of the stator holder 70 radially outward of the stator core 62, and the fixing pins 321 are fixed to the stator holder 70. In this case, since the stator holder 70 is provided with a cooling structure, heat generated in the partial windings 311A, 311B is easily transferred to the stator holder 70. This allows the cooling performance of the stator winding 61 to be improved.

[0171] The stator 60 used in the rotating electric machine 10 may have protrusions (e.g., teeth) extending from the back yoke. In this case, too, it is sufficient that the coil module 150 and the like are attached to the stator core by the back yoke.

[0172] The rotating electric machine is not limited to one with star connection, and may be one with delta connection.

[0173] As the rotating electric machine 10, instead of a rotating field type rotating electric machine in which the field element is the rotor and the armature is the stator, it is also possible to adopt a rotating armature type rotating electric machine in which the armature is the rotor and the field element is the stator.

[0174] Second embodiment Next, a rotating electric machine 400 according to a second embodiment will be described. The rotating electric machine 400 according to this embodiment is used as an in-wheel motor for a vehicle. An overview of the rotating electric machine 400 is shown in Figs. 41 to 44. Fig. 41 is a vertical cross-sectional view of the rotating electric machine 400, Fig. 42 is a horizontal cross-sectional view of the rotating electric machine 400 (cross-sectional view taken along line 44-44 in Fig. 41), Fig. 43 is a horizontal cross-sectional view of the rotating electric machine 400 (cross-sectional view taken along line 45-45 in Fig. 41), and Fig. 44 is an exploded cross-sectional view showing components of the rotating electric machine 400 in an exploded manner.

[0175] The rotating electric machine 400 is an outer rotor type surface magnet type rotating electric machine. The rotating electric machine 400 is provided with a rotating electric machine main body having a rotor 410 and a stator unit 420 including a stator 430, and is configured such that a spindle 401 fixed to a vehicle body (not shown) and a hub 402 fixed to a wheel (not shown) are integrated with the rotating electric machine main body. The spindle 401 and the hub 402 are required to have high strength and are made of, for example, a steel material.

[0176] The spindle 401 has a flange portion 403 extending in a direction perpendicular to the axial direction, and a fixed shaft portion 404 having a cylindrical shape, extending toward the center of the rotating electric machine from the flange portion 403, and inserted into a hollow portion of the stator unit 420. The fixed shaft portion 404 may have a large diameter portion and a small diameter portion as shown in the figure. The hub 402 has an insertion hole 406 through which the fixed shaft portion 404 is inserted. The hub 402 is rotatably supported by a pair of bearings 407, 408 with the fixed shaft portion 404 inserted into the insertion hole 406 of the hub 402. The hub 402 is rotatably supported by the bearings 407, 408 at two positions in the axial direction. The bearings 407, 408 are, for example, radial ball bearings, and each has an outer ring, an inner ring, and a plurality of balls arranged between the outer ring and the inner ring. The bearings 407 and 408 may be roller bearings (needle roller bearings, tapered roller bearings) that use rollers instead of balls as rolling elements.

[0177] In rotating electric machine 400, the direction in which the axis of rotation extends (left and right direction in FIG. 41) is the axial direction, and rotating electric machine 400 is attached to a vehicle so that the axial direction is horizontal or approximately horizontal. If the wheels have a camber angle, it is preferable that the axial direction of rotating electric machine 400 is approximately horizontal with a tilt of the camber angle applied.

[0178] In the rotating electric machine 400, a rotor 410 and a stator 430 are disposed facing each other in the radial direction with an air gap therebetween. A stator unit 420 is fixed to a spindle 401, and the rotor 410 is fixed to a hub 402. Therefore, the hub 402 and the rotor 410 are rotatable relative to the spindle 401 and the stator unit 420.

[0179] As shown in FIG. 44, the rotor 410 has a substantially cylindrical rotor carrier 411 and an annular magnet unit 412 fixed to the rotor carrier 411. The rotor carrier 411 has a cylindrical tubular portion 413 and an end plate portion 414 provided on one axial end side of the tubular portion 413, and the magnet unit 412 is fixed in an annular shape to the radial inside of the tubular portion 413. The other axial end side of the rotor carrier 411 is open. The rotor carrier 411 functions as a magnet holding member. A through hole 414a is formed in the center of the end plate portion 414, and the hub 402 is fixed to the end plate portion 414 by a fastener such as a bolt while being inserted into the through hole 414a (see FIG. 41).

[0180] The magnet unit 412 is composed of multiple permanent magnets arranged so that the polarity alternates along the circumferential direction of the rotor 410. The magnet unit 412 corresponds to a "magnet section." As a result, the magnet unit 412 has multiple magnetic poles in the circumferential direction. The magnet unit 412 has the configuration described as the magnet unit 22 in Figs. 6 and 7 of the first embodiment, for example, and is composed of sintered neodymium magnets as permanent magnets, with an intrinsic coercive force of 400 kA / m or more and a residual magnetic flux density Br of 1.0 T or more.

[0181] The magnet unit 412 has a plurality of permanent magnets, each of which is polar anisotropic, similar to the magnet unit 22 in FIG. 7. The orientation of the magnetization easy axis of each magnet differs between the d-axis side (part closer to the d-axis) and the q-axis side (part closer to the q-axis), with the magnetization easy axis on the d-axis side being parallel or nearly parallel to the d-axis, and the magnetization easy axis on the q-axis side being perpendicular or nearly perpendicular to the q-axis. In this case, an arc-shaped magnetic flux path is formed along the direction of the magnetization easy axis. In short, each magnet is configured so that the magnetization easy axis is oriented closer to parallel to the d-axis on the d-axis side, which is the magnetic pole center, than on the q-axis side, which is the magnetic pole boundary.

[0182] The magnets of the magnet unit 412 may be fixed to each other in the circumferential direction by adhesive or the like, and may be integrated by attaching a fixing member such as yarn to the outer periphery. Also, an annular end plate member may be attached to the axial end of each magnet.

[0183] Next, a configuration of the stator unit 420 will be described. Fig. 45 is an exploded perspective view of the stator unit 420. The stator unit 420 has a circular cylindrical stator 430, a stator holder 460 that holds the stator 430, a wiring module 480 attached to one axial end side, and a coil end cover 490 attached to the other axial end side of the stator 430.

[0184] First, a description will be given of stator 430. Figures 46 and 47 are exploded perspective views of stator 430, and Figure 48 is an exploded cross-sectional view of stator unit 420. Figures 46 and 47 are exploded perspective views of stator 430 as viewed from different axial directions.

[0185] The stator 430 has a stator winding 431 as an armature winding and a stator core 432 as a winding support member. In the stator 430, the stator winding 431 has three-phase windings 431U, 431V, and 431W, and each of the phase windings 431U, 431V, and 431W is composed of a plurality of partial windings 441. The partial windings 441 are provided according to the number of poles of the rotating electric machine 400, and a plurality of partial windings 441 are connected in parallel or in series for each phase (described in detail later). In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.

[0186] 48, the stator 430 has, in the axial direction, a portion corresponding to the coil side CS radially facing the stator core 432, and a portion corresponding to the coil end CE that is axially outside the coil side CS. The coil side CS is also a portion radially facing the magnet unit 412 of the rotor 410. The partial winding 441 is assembled to the radial outside of the stator core 432. In this case, the partial winding 441 is assembled with both axial end portions thereof protruding axially outward beyond the stator core 432 (i.e., toward the coil end CE).

[0187] Each of the partial windings 441 is provided such that one of both axial ends is bent in the radial direction and the other is not bent in the radial direction. Half of all the partial windings 441 have one axial end (lower side in FIG. 46) as the bent side, and are bent radially inward at that bent side. The remaining half of the partial windings 441 have the other axial end (upper side in FIG. 46) as the bent side, and are bent radially outward at that bent side. In the following description, the partial winding 441 having a bent portion bent radially inward among the partial windings 441 is also referred to as the "first partial winding 441A," and the partial winding 441 having a bent portion bent radially outward is also referred to as the "second partial winding 441B."

[0188] The configuration of the partial windings 441A and 441B will be described in detail. Fig. 49(a) and (b) are perspective views showing the configuration of the first partial winding 441A, and Fig. 50 is an exploded perspective view showing the insulating covers 451 and 452 attached to the transition portions 443 and 444 in the first partial winding 441A. Fig. 51(a) and (b) are perspective views showing the configuration of the second partial winding 441B, and Fig. 52 is an exploded perspective view showing the insulating covers 453 and 454 attached to the transition portions 443 and 444 in the second partial winding 441B. Fig. 49(a) and (b) are perspective views of the first partial winding 441A as viewed from the radial inside and outside, respectively, and Fig. 51(a) and (b) are similarly perspective views of the second partial winding 441B as viewed from the radial inside and outside, respectively.

[0189] Each of the partial windings 441A, 441B is formed by winding a conductor CR in multiple layers, and includes a pair of intermediate conductor parts 442 that are parallel to each other and arranged linearly, and a pair of transition parts 443, 444 that connect the pair of intermediate conductor parts 442 at both axial ends. The pair of intermediate conductor parts 442 and the pair of transition parts 443, 444 form an annular shape. The pair of intermediate conductor parts 442 are spaced apart by a predetermined coil pitch, and an intermediate conductor part 442 of the partial winding 441 of another phase can be arranged between the pair of intermediate conductor parts 442 in the circumferential direction. In this embodiment, the pair of intermediate conductor parts 442 are spaced apart by two coil pitches, and one intermediate conductor part 442 of the partial winding 441 of the other two phases is arranged between the pair of intermediate conductor parts 442.

[0190] In the winding portions 441A and 441B, each intermediate conductor portion 442 is provided covered with a sheet-like insulating covering 445. The configuration of the insulating covering 445 is similar to that of the insulating covering 157 of the winding portion 151 in the above-described first embodiment. That is, the insulating covering 445 is provided by using a film material having an axial dimension of at least the length of the axial insulating covering range of the intermediate conductor portion 442, and winding the film material around the intermediate conductor portion 442. The insulating covering 445 is provided around the intermediate conductor portion 442 with the circumferential ends of the film material overlapping.

[0191] The crossover portions 443, 444 on both axial sides are provided as portions corresponding to the coil ends CE (see FIG. 48), and of the crossover portions 443, 444, one crossover portion 443 is bent in the radial direction, while the other crossover portion 444 is not bent in the radial direction. This causes the partial windings 441A, 441B to have a substantially L-shape when viewed from the side.

[0192] The partial windings 441A and 441B have different radial bending directions of the crossover portions 443, with the crossover portion 443 of the first partial winding 441A being bent radially inward, and the crossover portion 443 of the second partial winding 441B being bent radially outward. In this case, assuming that the partial windings 441A and 441B are arranged side by side in the circumferential direction, it is preferable that the shapes of the crossover portions 443 in plan view (radial plan shapes) of the partial windings 441A and 441B are different from each other. It is preferable that the crossover portion 443 of the first partial winding 441A has a narrower circumferential width toward the tip side, and the crossover portion 443 of the second partial winding 441B has a wider circumferential width toward the tip side.

[0193] In each partial winding 441A, 441B, the intermediate conductor portions 442 are provided as coil side conductor portions arranged one by one in the circumferential direction at the coil side CS. Also, each of the jumper portions 443, 444 is provided as a coil end conductor portion at the coil end CE that connects the intermediate conductor portions 442 of the same phase at two different positions in the circumferential direction.

[0194] In the partial windings 441A and 441B, similar to the partial winding 151 described above, the conductor wire CR is wound in multiple layers so that the cross section of the conductor wire assembly portion is rectangular. In the intermediate conductor portion 442, the conductor wire CR is arranged in multiple rows in the circumferential direction and in multiple rows in the radial direction, so that the cross section is generally rectangular (see FIG. 20).

[0195] Next, a description will be given of the insulating covers 451-454 attached to the respective winding portions 441A, 441B. The insulating covers 451-454 are insulating members provided to insulate the winding portions 441 from each other at the respective transition portions 443, 444. The insulating covers 451-454 are formed from an insulating material such as synthetic resin.

[0196] As shown in Figs. 49(a), (b) and 50, in the first partial winding 441A, an insulating cover 451 is attached to the transition portion 443 at one axial end, and an insulating cover 452 is attached to the transition portion 444 at the other axial end. A bracket 455 made of, for example, a metal plate is embedded in the insulating cover 451. The bracket 455 has a protruding portion 455a protruding radially outward from the tip of the transition portion 443, and the protruding portion 455a is provided with a through hole 455b penetrating in the axial direction (the up-down direction in the figure). A bracket 456 made of, for example, a metal plate is embedded in the insulating cover 452. The bracket 456 has a protruding portion 456a protruding radially outward from the tip of the transition portion 444, and the protruding portion 456a is provided with a through hole 456b penetrating in the axial direction (the up-down direction in the figure).

[0197] The insulating covers 451 and 452 have engaging portions 451a and 452a that engage with the inside of the curved portions at the tips of the transition portions 443 and 444, respectively. Parts of the brackets 455 and 456 may be integrated with the engaging portions 451a and 452a as base materials. The brackets 455 and 456 may be embedded in the insulating covers 451 and 452, or may be fixed to the outer surfaces of the insulating covers 451 and 452 by adhesive or the like.

[0198] 51(a), (b) and 52, in the second winding portion 441B, an insulating cover 453 is attached to the transition portion 443 at one axial end, and an insulating cover 454 is attached to the transition portion 444 at the other axial end. A bracket 457 made of, for example, a metal plate is embedded in the insulating cover 453. The bracket 457 has a protruding portion 457a protruding radially inward from the tip of the transition portion 443, and the protruding portion 457a is provided with a through hole 457b penetrating in the axial direction (the up-down direction in the figure). A bracket 458 made of, for example, a metal plate is embedded in the insulating cover 454. The bracket 458 has a protruding portion 458a protruding radially inward from the tip of the transition portion 444, and the protruding portion 458a is provided with a through hole 458b penetrating in the axial direction (the up-down direction in the figure).

[0199] The insulating covers 453, 454 have engaging portions 453a, 454a that engage with the inside of the curved portion at the tip of the transition portion 443, 444, respectively. Parts of the brackets 457, 458 may be integrated with these engaging portions 453a, 454a as a base material. The brackets 457, 458 may be embedded in the insulating covers 453, 454, or may be fixed to the outer surfaces of the insulating covers 453, 454 by adhesion or the like.

[0200] Fig. 53 is a plan view showing a state in which the winding sections 441A and 441B are arranged side by side in the circumferential direction. Fig. 53 is a plan view of the stator winding 431 shown in Fig. 46 as viewed from one axial direction (from above in the figure).

[0201] 53, the crossover portion 443 of the first partial winding 441A extends radially inward, and the crossover portion 443 of the second partial winding 441B extends radially outward. Radially inward of the intermediate conductor portions 442 of the partial windings 441A and 441B, at one axial end side of the stator winding 431 (the back side of the paper in FIG. 53), a protrusion 455a of a bracket 455 provided on an insulating cover 451 of the first partial winding 441A and a protrusion 458a of a bracket 458 provided on an insulating cover 454 of the second partial winding 441B overlap in the axial direction, and the positions of the through holes 455b and 458b of the protrusions 455a and 458a match in a plan view.

[0202] Further, radially outward of the intermediate conductor portions 442 of the partial windings 441A, 441B, on the other axial end side of the stator winding 431 (the front side of the paper in FIG. 53), protrusions 456a of a bracket 456 provided on an insulating cover 452 of the first partial winding 441A and protrusions 457a of a bracket 457 provided on an insulating cover 453 of the second partial winding 441B are arranged alternately and at equal intervals in the circumferential direction. In this case, the through holes 456b, 457b of the protrusions 456a, 457a are arranged at the same radial distance from the center of the plane of the stator 430 and at equal intervals in the circumferential direction.

[0203] As shown in Figs. 46 and 47, the stator winding 431 is formed in an annular shape by partial windings 441A and 441B, and the stator core 432 is assembled to the radially inner side thereof. The stator core 432 is configured as a core sheet laminate in which core sheets made of magnetic steel sheets are laminated in the axial direction, and is cylindrical in shape with a predetermined thickness in the radial direction. The inner and outer circumferential surfaces of the stator core 432 are curved surfaces without any unevenness. The stator core 432 functions as a back yoke. The stator core 432 is configured by, for example, laminating a plurality of core sheets, which are punched into an annular plate shape, in the axial direction. However, the stator core 432 may have a helical core structure.

[0204] The stator winding 431 may be attached to the stator core 432 by individually assembling the partial windings 441A and 441B to the stator core 432. Alternatively, the stator winding 431 may be attached to the stator core 432 by forming the annular stator winding 431 with the partial windings 441A and 441B.

[0205] 47, a plurality of recesses 433 are formed at a predetermined interval in the circumferential direction on an end face on one axial end side of the stator core 432. When the stator winding 431 and the stator core 432 are integrated, the through holes 455b, 458b of the brackets 455, 458 of the insulating covers 451, 454 are aligned with the recesses 433 on the axial end face of the stator core 432 on the radial inner side of the intermediate conductor portions 442 of the partial windings 441A, 441B. Then, a coupling member, for example a metal fixing pin, is attached to the through holes 455b, 458b and the recesses 433, whereby the partial windings 441A, 441B are fixed to the stator core 432.

[0206] Next, the configuration of stator holder 460 will be described. Here, the configuration of stator holder 460 will be described with reference to Figures 48 and 54. Figure 54 is a cross-sectional view of stator holder 460 (a cross-sectional view at the same position as Figure 43).

[0207] 48 and 54, the stator holder 460 has an outer cylinder member 461 and an inner cylinder member 462 each having a cylindrical shape, and is configured by assembling them together with the outer cylinder member 461 on the radial outside and the inner cylinder member 462 on the radial inside. Each of these members 461, 462 is configured from a metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

[0208] The inner diameter of the cylinder of the outer cylinder member 461 is larger than the outer diameter of the cylinder of the inner cylinder member 462. Therefore, when the inner cylinder member 462 is assembled to the radial inside of the outer cylinder member 461, an annular gap is formed between these members 461, 462, and the gap space serves as a refrigerant passage 463 through which a refrigerant such as cooling water flows. The refrigerant passage 463 is provided in an annular shape in the circumferential direction of the stator holder 460. The inner cylinder member 462 is provided with an inlet-side passage 464 serving as an inlet for the refrigerant and an outlet-side passage 465 serving as an outlet for the refrigerant, and a partition portion 466 is provided between the inlet-side passage 464 and the outlet-side passage 465 in the refrigerant passage 463. The inlet-side passage 464 and the outlet-side passage 465 are connected to the refrigerant passage 463 on both sides of the partition portion 466, and are provided to extend in the axial direction. The refrigerant flowing in from the inlet side passage 464 flows in the circumferential direction through the refrigerant passage 463 and then flows out from the outlet side passage 465 .

[0209] One end of the inlet side passage 464 and one end of the outlet side passage 465 each open to the axial end surface of the inner cylinder member 462. Although not shown, an inlet piping port is provided at the opening of the inlet side passage 464, and an outlet piping is provided at the opening of the outlet side passage 465 on the axial end surface. A circulation path for circulating the refrigerant is connected to the inlet piping port and the outlet piping port. For example, an electric pump and a heat dissipation device such as a radiator are provided in the circulation path, and the refrigerant circulates through the circulation path and the refrigerant passage 463 of the rotating electric machine 400 as the pump is driven.

[0210] The stator core 432 is attached to the radial outside of the stator holder 460, more specifically, to the radial outside of the outer tubular member 461. The stator core 432 is attached to the stator holder 460 (outer tubular member 461) by, for example, adhesion. Alternatively, the stator core 432 may be fitted and fixed to the stator holder 460 with a predetermined interference by shrink fitting or press fitting.

[0211] The inner cylinder member 462 is cylindrical, and has an end plate portion 471 at one axial end thereof. A through hole 472 is provided in the center of the end plate portion 471, penetrating in the axial direction, and the fixed shaft portion 404 of the spindle 401 can be inserted into the through hole 472.

[0212] Furthermore, a plurality of protrusions 473 are provided at predetermined intervals in the circumferential direction on the inner peripheral side of the inner tube member 462. Each of these protrusions 473 is provided so as to protrude radially inward in the hollow portion of the inner tube member 462, and is provided in the axial range from the end plate portion 471 to the axial middle position (see FIG. 48). The protrusions 473 function as reinforcing members for the inner tube member 462.

[0213] An opening 474 penetrating in the axial direction is provided in the end plate portion 471 of the inner cylindrical member 462 at a position radially outside the through hole 472. This opening 474 is an insertion hole portion through which power lines 485 of each phase, which will be described later, are inserted in the axial direction. A terminal block 475 is provided in the opening 474 (see FIG. 41), and external wiring (not shown) is connected to the terminal block 475.

[0214] Next, the wiring module 480 will be described. The wiring module 480 is a winding connection member electrically connected to each partial winding 441A, 441B in the stator winding 431, and the partial windings 441 of each phase are connected in parallel or series for each phase by this wiring module 480, and the phase windings 431U, 431V, 431W of each phase are connected at a neutral point. As shown in Fig. 41, the wiring module 480 is provided on one end side of both axial ends of the stator 430, specifically, on the side of the end plate portion 414 of the rotor carrier 411.

[0215] More specifically, the stator winding 431 has a first partial winding 441A whose one axial end is bent radially inward, and a second partial winding 441B whose other axial end is bent radially outward. The bent side of the first partial winding 441A and the non-bent side of the second partial winding 441B are arranged side by side with some overlapping in the circumferential direction, with the bent side of the first partial winding 441A and the non-bent side of the second partial winding 441B facing the end plate portion 414 of the rotor carrier 411. A wiring module 480 is provided on one of the axial ends of the stator winding 431, facing the end plate portion 414 of the rotor carrier 411.

[0216] 45, the wiring module 480 has an annular portion 481 having a circular shape, and a plurality of connection terminals 482 arranged in a circumferential direction along the annular portion 481. The annular portion 481 is formed in a circular shape from an insulating member such as resin. Wires for each phase and a neutral point wire (described in detail later) are embedded in the annular portion 481, and a connection terminal 482 is electrically connected to each of the wires. The connection terminals 482 are provided for each partial winding 441, and are fixed so as to extend in the axial direction.

[0217] In the wiring module 480, a bus bar 483 is connected for each phase to the wiring for each phase embedded in the annular portion 481. Each bus bar 483 is a part of the power wiring for U-phase power, V-phase power, and W-phase power, respectively, and is provided so as to protrude radially inward.

[0218] In the stator winding 431, at the end on the lower side of FIG. 45, transition parts 444 that are not bent in the radial direction are arranged in a ring shape, and the wiring module 480 is provided on the radial inside of the transition parts 444. That is, the ring-shaped part 481 of the wiring module 480 is formed to have a smaller diameter than the annular part formed by the transition parts 444 arranged in the circumferential direction. The ring-shaped part 481 is provided with an attachment member 484 for attaching the wiring module 480 to the stator holder 460. The attachment member 484 is made of, for example, a metal plate, and has a plurality of attachment parts at predetermined intervals in the circumferential direction.

[0219] A power line 485 that supplies power to the stator winding 431 for each phase is connected to each bus bar 483 of the wiring module 480. The power lines 485 are arranged in a line in the circumferential direction and extend in the axial direction. The power line 485 may be a conductor itself that is a rigid body such as a metal bus bar, or the conductor may be inserted into a tube that is a rigid body such as a synthetic resin. This makes it possible to reduce the influence of vibration even if vibration occurs in the rotating electric machine 400. The power line 485 may also be made of a flexible harness. In this case, disconnection can be suppressed by absorbing vibration in the rotating electric machine 400.

[0220] Furthermore, it is preferable that the power line 485 has a shielding layer on the outer periphery. This makes it possible to suppress the generation of a magnetic field to the outside. It is also preferable that the outer coating of the power line 485 is a fluorine coating. In this case, it is possible to improve the heat resistance in anticipation of a rise in the temperature of the power line 485.

[0221] Next, the coil end cover 490 will be described.

[0222] 47, coil end cover 490 has an annular shape and is provided on the coil end portion on one axial end side of stator 430, i.e., on the coil end portion on the side where crossover portion 443 is bent radially outward among the coil end portions on both axial ends of stator 430. Coil end cover 490 axially covers the coil end portion of stator winding 431 and also positions partial windings 441A, 441B on the one axial end side.

[0223] The coil end cover 490 is provided with a plurality of through holes 491 at equal intervals in the circumferential direction, and every other one of the plurality of through holes 491 corresponds to a through hole 456b of a bracket 456 of the insulating cover 452 of the first partial winding 441A and a through hole 457b of a bracket 457 of the insulating cover 453 of the second partial winding 441B. In this case, with the coil end cover 490 attached to one axial end side of the stator 430, each through hole 491 on the coil end cover 490 side is aligned with the through holes 456b, 457b on the insulating covers 452, 453 sides. Then, a coupling member, for example a metal fixing pin, is assembled in each through hole 491, thereby fixing the coil end cover 490 to the stator 430. In this state, one axial end side of each of the partial windings 441A, 441B is fixed by the coil end cover 490.

[0224] Furthermore, coil end cover 490 is provided with a plurality of mounting holes 492 for mounting coil end cover 490 to stator holder 460. Assuming a state in which coil end cover 490 is mounted to stator winding 431, a plurality of through holes 491 lined up in the circumferential direction are arranged radially outward of transition portion 444 (in other words, the position of intermediate conductor portion 442) in stator winding 431 that is not bent in the radial direction and extends in the axial direction, and a plurality of mounting holes 492 lined up in the circumferential direction are arranged radially inward of transition portion 444 of stator winding 431.

[0225] In the stator unit 420, a stator winding 431 consisting of a plurality of partial windings 441A, 441B is integrated with a stator core 432. At this time, the partial windings 441A, 441B are fixed to the stator core 432 at one axial end side (the lower end side in FIG. 45) using brackets 455, 458 of insulating covers 451, 454. Also, a stator holder 460 is assembled to a stator 430 consisting of the stator winding 431 and the stator core 432 from one axial end side, and a coil end cover 490 is attached to the stator holder 460. At this time, a fixing tool such as a fixing pin or a screw is inserted into an attachment hole 492 of the coil end cover 490, and the coil end cover 490 is fixed to the stator holder 460. Furthermore, fasteners such as fixing pins or screws are inserted into through holes 491 of coil end cover 490, and coil end cover 490 is fixed to stator winding 431 (each of partial windings 441A, 441B).

[0226] Moreover, on the axially opposite side of the coil end cover 490, the wiring module 480 is attached to the stator holder 460 by an attachment member 484. In this state, in the hollow portion of the stator holder 460 (the inner cylinder member 462), power lines 485 of each phase are provided so as to extend from one axial end side to the other axial end side of the stator unit 420. Then, each of these power lines 485 is connected to external wiring.

[0227] Each power line 485 may be clamped to the inner cylinder member 462 (stator holder 460). Specifically, as shown in FIG. 48, a clamping material 495 made of anti-vibration rubber is provided in an opening 474 of the inner cylinder member 462, and the power line 485 provided to pass through the opening 474 is clamped by the clamping material 495. In this case, by clamping each power line 485 to the inner cylinder member 462, the earthquake resistance of each power line 485 can be improved. In particular, by using anti-vibration rubber as the clamping material 495, the earthquake resistance can be further improved. Note that the clamping position of the power line 485 in the inner cylinder member 462 may be a place other than the opening 474.

[0228] Fig. 55 is a perspective view of the stator unit 420 as viewed from the wiring module 480 side (i.e., the side opposite the coil end cover 490). For convenience, Fig. 55 omits specific illustration of each partial winding 441 in the stator winding 431, and illustrates the stator winding 431 as an integrated cylindrical body.

[0229] 55, at one coil end portion of the stator 430, the wiring module 480 is disposed radially inside the stator winding 431 (specifically, radially inside each of the transition portions 444 aligned in the circumferential direction). In this case, the upper side of FIG. 55 is the hub 402 side, i.e., the wheel side, in the axial direction of the rotating electric machine 400, and the wiring module 480 is disposed on the hub 402 side, i.e., the wheel side, in the axial direction. In this configuration, the wiring module 480 is disposed radially inside the stator winding 431 at the coil end portion (radially inside each of the transition portions 444), so that the wiring module 480 does not protrude radially outward, and the stator unit 420 can be made smaller.

[0230] In the stator winding 431 of this embodiment, the transition portion 443 is bent radially inward at the coil end on the hub 402 side, and the transition portion 443 is bent radially outward at the coil end on the anti-hub side, and the wiring module 480 is disposed on the hub 402 side (the side on which the transition portion 443 is bent radially inward). In this case, assuming a configuration in which the wiring module 480 is disposed on the anti-hub side, the wiring module 480 and the coil end cover 490 are provided to protrude radially outward from the transition portion 444, which raises concerns about the resulting large radial outward protrusion, but the configuration of this embodiment suppresses this inconvenience.

[0231] Further, a terminal block 531 is provided on an axial end surface of the stator holder 460 (specifically, an axial end surface of the outer cylinder member 461), and the bus bar 483 and the power line 485 of the wiring module 480 are connected via the terminal block 531. Specifically, the terminal portion of the bus bar 483 and the terminal portion of the power line 485 are overlapped with each other, and in this overlapped state, the bus bar 483 and the power line 485 are fixed to the terminal block 531 by a fastener such as a screw. In this case, each power line 485 can be firmly fixed. That is, if the bus bar 483 and the power line 485 are simply connected to each other, there is a concern that the connection part may be broken due to vibrations generated in the rotating electric machine 400. Therefore, since the bus bar 483 and the power line 485 are configured to be connected to each other via the terminal block 531 of the stator holder 460 (the inner cylinder member 462), it is possible to suppress the breakage of the connection part due to vibrations.

[0232] A rotation prevention mechanism for suppressing relative rotation between bus bar 483 and power line 485 may be provided at the connection portion between bus bar 483 and power line 485. This suppresses unintended positional deviation of power line 485 from bus bar 483, thereby improving the ease of assembly and insulation of power line 485.

[0233] In addition, bus bar 483 has a bent structure, and its middle portion is bent into a crank shape, so that vibrations in terminal block 531 and annular portion 481 can be absorbed suitably.

[0234] In addition, when assembling the stator 430 and the stator holder 460, the stator holder 460 and the stator core 432 may be assembled first, and then the stator winding 431 (i.e., the partial windings 441A, 441B) may be assembled to the integrated body of the stator holder 460 and the stator core 432.

[0235] Next, the overall configuration of rotating electric machine 400 including rotor 410 and stator unit 420 described above will be described with reference to Fig. 41 and Fig. 56. Fig. 56 is an exploded cross-sectional view of rotating electric machine 400 in which spindle 401 and stator unit 420 are integrated as a fixed object, and hub 402 and rotor 410 are integrated as a rotating object.

[0236] The spindle 401 is assembled to the stator unit 420 in a state where it is inserted into a through-hole 472 of the stator holder 460. More specifically, the fixed shaft portion 404 of the spindle 401 is inserted into the through-hole 472 of the stator holder 460, and in this state, the spindle 401 is fixed to an end plate portion 471 of the inner cylinder member 462 by a fastener such as a bolt. On the other hand, a hub 402 is fixed to the rotor 410. More specifically, the hub 402 is inserted into a through-hole 414a of the rotor carrier 411, and in this state, the hub 402 is fixed to the end plate portion 414 by a fastener such as a bolt.

[0237] With the fixed shaft portion 404 of the spindle 401 inserted into the insertion hole 406 of the hub 402, the stator unit 420 and the rotor 410 are disposed at positions that are radially inward and outward from each other. As shown in FIG. 56, the integrated body of the spindle 401 and the stator unit 420 has an annular space S1 formed around the fixed shaft portion 404 of the spindle 401. The integrated body of the hub 402 and the rotor 410 has an annular space S2 formed around the hub 402. The integrated body of the spindle 401 and the stator unit 420 and the integrated body of the hub 402 and the rotor 410 are assembled to each other such that the hub 402 enters the annular space S1 and the stator unit 420 enters the annular space S2.

[0238] Bearings 407, 408 are assembled between the fixed shaft portion 404 of the spindle 401 and the hub 402, and the hub 402 is rotatably supported by the bearings 407, 408. In other words, the hub 402 and the rotor 410 are rotatably supported by the bearings 407, 408 relative to the spindle 401 and the stator unit 420. In the bearings 407, 408, the inner ring is assembled to the fixed shaft portion 404 side, and the outer ring is assembled to the hub 402 side.

[0239] In a state where the integrated body of the spindle 401 and the stator unit 420 and the integrated body of the hub 402 and the rotor 410 are assembled together, a rotor cover 511 is fixed to the open end side of the rotor 410, i.e., the opposite side of the hub 402 in the axial direction (the opposite side of the end plate portion 414 of the rotor carrier 411). The rotor cover 511 is in the shape of an annular plate, and is fixed to the rotor carrier 411 by a fastener such as a bolt, with a bearing 512 interposed between the rotor cover 511 and the inner cylinder member 462.

[0240] When the integrated body of the spindle 401 and the stator unit 420 and the integrated body of the hub 402 and the rotor 410 are assembled together, an annular closed space SA that is closed in the axial and radial directions is formed on the inner circumferential side of the stator unit 420. A resolver 520 is provided in the closed space SA as a rotation sensor. The resolver 520 has an annular shape and includes a resolver stator fixed to the inner cylindrical member 462 of the stator unit 420, which is the fixed body side, and a resolver rotor fixed to the hub 402, which is the rotating body side. The resolver rotor is disposed facing the radially inner side of the resolver stator.

[0241] In this embodiment, as described above, a plurality of protruding portions 473 are provided at predetermined intervals in the circumferential direction on the inner peripheral side of the inner cylindrical member 462 in the stator holder 460 (see FIG. 54). The resolver 520 (resolver stator) is attached to an axial end surface of the protruding portion 473 of the inner cylindrical member 462.

[0242] Next, the connection mode of the partial windings 441A, 441B in the stator winding 431 will be described with reference to FIG. 57. As described above, the phase windings 431U, 431V, 431W of each phase (in this embodiment, three phases: U-phase, V-phase, and W-phase) constituting the stator winding 431 are formed by connecting a plurality of partial windings 441. At this time, as shown in FIG. 57, the first partial winding 441A and the second partial winding 441B are connected in series to form a series-connected body 600, and the plurality of series-connected bodies 600 are further connected in parallel to form the respective phase windings 431U, 431V, 431W. The respective phase windings 431U, 431V, 431W are star-connected at the neutral point to form the stator winding 431.

[0243] Here, how the partial windings 441 are connected in the wiring module 480 will be described with reference to FIG. 58. FIG. 58 is a development view in which the circumferential direction of the stator winding 431 and the wiring module 480 is developed in the left-right direction. In FIG. 58, the partial windings 441 are illustrated in two stages, upper and lower, with the partial winding 441 in the upper stage corresponding to the first partial winding 441A bent radially inward, and the partial winding 441 in the lower stage corresponding to the second partial winding 441B bent radially outward. Also, in FIG. 58, the partial windings 441 constituting the U-phase winding 431U are indicated as the first partial winding 441AU and the second partial winding 441BU, respectively. Similarly, the partial windings 441 constituting the V-phase winding 431V are respectively indicated as a first partial winding 441AV and a second partial winding 441BV, and the partial windings 441 constituting the W-phase winding 431W are respectively indicated as a first partial winding 441AW and a second partial winding 441BW.

[0244] 58, the second partial winding 441B is arranged at a position spaced apart by approximately two coil pitches from the first partial winding 441A of the same phase. Note that, since each phase is configured in the same way, only the U-phase winding 431U will be described below.

[0245] 58, one end of the U-phase first partial winding 441AU is connected to a U-phase wiring 483U embedded in the wiring module 480. More specifically, in FIG. 58, the left side of the U-phase first partial winding 441AU (a portion corresponding to the intermediate conductor portion 442 arranged on one circumferential side) is connected to the U-phase wiring 483U via a connection terminal 482.

[0246] The other end of the U-phase first partial winding 441AU is connected to one end of a connection wiring 601U embedded in the wiring module 480. More specifically, in FIG. 58, a right side of the U-phase first partial winding 441AU (a portion corresponding to the intermediate conductor portion 442 arranged on the other circumferential side) is connected via a connection terminal 482 to the left end of the connection wiring 601U.

[0247] One end of the U-phase second partial winding 441BU arranged at a position two coil pitches away from the first partial winding 441AU is connected to the other end of the connection wiring 601U. More specifically, in FIG. 58, the left side of the U-phase second partial winding 441BU (a portion corresponding to the intermediate conductor portion 442 arranged on one circumferential side) is connected to the right end of the connection wiring 601U via a connection terminal 482. In this way, the connection wiring 601U is configured to have a length of about two coil pitches in the circumferential direction to connect between the first partial winding 441AU and the second partial winding 441BU arranged at a position about two coil pitches away from the first partial winding 441AU.

[0248] 58, the other end of the U-phase second partial winding 441BU is connected to the neutral point wiring 602 embedded in the wiring module 480. More specifically, in FIG. 58, the right side of the U-phase second partial winding 441BU (the portion corresponding to the intermediate conductor portion 442 arranged on the other circumferential side) is connected to the neutral point wiring 602 via the connection terminal 482.

[0249] The respective phase wirings 483U, 483V, 483W, the connection wirings 601U, 601V, 601W, and the neutral point wiring 602 are each formed in a circular or arc shape and are made of a thin plate-like conductive material. The partial windings 441 constituting the stator windings 431 of the other phases (V phase, W phase) are also connected in the same manner. For this reason, the connection wirings 601U, 601V, 601W connecting the first partial winding 441A and the second partial winding 441B each have a length of about two coil pitches and are configured not to overlap each other in the circumferential direction. Therefore, as shown in FIG. 61, the connection wirings 601U, 601V, 601W are embedded in the wiring module 480 in a state where they are arranged side by side in the circumferential direction so that their axial positions are the same. This suppresses the height dimension of the wiring module 480 in the axial direction.

[0250] The effect of connecting the partial windings 441 in this manner will be described. As described above, the first partial winding 441A and the second partial winding 441B have different shapes. In particular, since the partial windings 441A, 441B are arranged side by side in the circumferential direction, the circumferential width of the crossover portion 443 of the first partial winding 441A becomes narrower toward the tip, and the circumferential width of the crossover portion 443 of the second partial winding 441B becomes wider toward the tip. For this reason, it is highly likely that the coil resistance of the first partial winding 441A and the second partial winding 441B will be different.

[0251] For this reason, when configuring the phase windings 431U, 431V, 431W of each phase by connecting all the partial windings 441 in parallel as in the comparative example of Fig. 59, the following problem occurs. That is, there is a risk of a circulating current (indicated by the arrow) flowing due to the difference in coil resistance between the first partial winding 441A and the second partial winding 441B. In particular, when a stator 430 having a teethless, slotless structure is used as in the above embodiment, the magnetic flux from the magnet unit 412 passes directly through the stator winding 431, and the magnetic flux passing through the stator winding 431 increases, which may increase the circulating current.

[0252] Therefore, as shown in Fig. 57, the phase windings 431U, 431V, 431W of each phase are configured by connecting in parallel series-connected bodies 600 in which a first partial winding 441A and a second partial winding 441B that are different in shape, i.e., may have different coil resistances, are connected in series. This equalizes the coil resistance of all the series-connected bodies 600 connected in parallel, and as a result, the circulating current between the series-connected bodies 600 connected in parallel is suppressed.

[0253] According to the present embodiment described above in detail, the following excellent effects can be obtained.

[0254] As shown in FIG. 57, the first partial winding 441A and the second partial winding 441B, which have different coil resistances, are connected in series to form a series-connected body 600, and the phase windings 431U, 431V, and 431W of each phase are formed by connecting the series-connected bodies 600 in parallel. This makes it possible to level the coil resistances between the series-connected bodies 600 connected in parallel, and to suppress circulating currents between the series-connected bodies 600. Furthermore, by connecting the series, the number of turns of the series-connected body 600 can be made larger than that of the stator winding 431 of the comparative example shown in FIG. 59, and therefore field-weakening control can be effectively performed. Furthermore, since the phase windings 431U, 431V, and 431W of each phase are not formed by connecting all the partial windings 441 in series, eddy current loss can be suppressed.

[0255] The first partial winding 441A and the second partial winding 441B have different shapes. Accordingly, the length of the conductive wire material CR serving as the wire constituting the partial windings is made different. This allows the partial winding 441 to be shaped in accordance with the arrangement of the partial winding 441, the arrangement space, and the like, making it possible to increase output while reducing the size.

[0256] The intermediate conductor portions 442 of the partial windings 441 are arranged side by side in the circumferential direction. The first partial winding 441A is formed by bending the transition portion 443 at one axial end side radially inward, and the second partial winding 441B is formed by bending the transition portion 443 at the other axial end side radially outward. This makes it possible to assemble the partial windings 441 to form the stator winding 431, and then move it along the axial direction to assemble cylindrical members to the radially inner and outer sides of the intermediate conductor portions 442.

[0257] For example, as shown in FIG. 46, after assembling the stator winding 431, by moving the stator core 432 in the axial direction from above the stator winding 431 (the side of the non-bent portion of the first partial winding 441A) in FIG. 46, it is possible to position the stator core 432 so that it abuts against the radially inner side of the intermediate conductor portion 442 without interfering with the bent portion of the first partial winding 441A.

[0258] Similarly, as shown in FIG. 45, after assembling the stator 430, by moving the stator holder 460 in the axial direction from above the stator 430 (the side of the non-bent portion of the first partial winding 441A) in FIG. 45, it is possible to position the stator holder 460 so that it abuts against the radially inner side of the stator 430 without interfering with the bent portion of the first partial winding 441A.

[0259] 44, after assembling the stator 430, by moving the rotor carrier 411 in the axial direction from above the stator 430 (the side of the non-bent portion of the second partial winding 441B) in Fig. 44, it is possible to arrange the rotor carrier 411 on the radially inner side of the stator 430 without interfering with the bent portion of the second partial winding 441B. At that time, by arranging the bent portion of the second partial winding 441B on the outer side of the rotor carrier 411 as shown in Fig. 43, it is possible to minimize the gap between the magnet unit 412 and the intermediate conductor portion 442.

[0260] As a result, the degree of freedom in the assembly order during manufacture can be increased, making assembly easier. Also, the rotating electrical machine 10 can be made smaller.

[0261] The connection wirings 601U, 601V, and 601W connect the first partial winding 441A and the second partial winding 441B that is arranged at a position two coil pitches away and that constitutes the same phase. Therefore, the connection wirings 601U, 601V, and 601W only need to have a length of about two coil pitches, and can be prevented from overlapping each other in the circumferential direction. Therefore, by embedding the connection wirings 601U, 601V, and 601W in the wiring module 480 in a state in which they are arranged side by side in the circumferential direction at the same position in the axial direction, the axial dimension of the connection wirings 601U, 601V, and 601W can be suppressed, and the rotating electric machine 10 can be made compact.

[0262] Each winding portion 441 is formed by winding a conductive wire CR a number of times, as shown in Fig. 20. Therefore, eddy current loss can be suppressed.

[0263] (Modification of the second embodiment) In the second embodiment, the shape and size of the cross-sectional area, the shape, material, thickness, length, etc. of the conductor CR may be different between the first partial winding 441A and the second partial winding 441B. Also, the number of turns of the conductor CR may be changed between the first partial winding 441A and the second partial winding 441B. The shape of the coil module may be the same as long as the coil resistance is different.

[0264] In the second embodiment, the configuration of the first partial winding 441A may be changed as desired. For example, the partial windings 441 may be connected in series or in parallel to form the first partial winding 441A. Similarly, the configuration of the second partial winding 441B may be changed as desired. For example, the partial windings 441 may be connected in series or in parallel to form the second partial winding 441B.

[0265] In the second embodiment, the configuration of each of the partial windings 441A, 441B of the stator winding 431 may be changed as follows.

[0266] Figures 60(a) and (b) are front views showing the assembled state of each partial winding 441A, 441B to the stator core 432, of which Figure 60(a) shows each partial winding 441A, 441B in a separated state, and Figure 60(b) shows each partial winding 441A, 441B in an assembled state.

[0267] The partial windings 441A and 441B have different axial lengths and different end shapes (transfer portion shapes) on both axial sides. The first partial winding 441A is substantially C-shaped in side view, and the second partial winding 441B is substantially I-shaped in side view. In Figs. 60(a) and (b), dotted portions indicate conductor portions at the ends of the transition portions of the partial windings 441A and 441B. When the partial windings 441A and 441B are assembled, the intermediate conductor portions 442 are aligned in the circumferential direction, and the transition portions 443 and 444 overlap each other in the axial direction.

[0268] The first partial winding 441A and the second partial winding 441B are assembled to the stator core 432 in a different order, with the first partial winding 441A, which has bent portions at both axial ends, being assembled to the stator core 432 first, and then the second partial winding 441B, which does not have bent portions at both axial ends, being assembled from the radial outside.

[0269] By assembling the first partial winding 441A and the second partial winding 441B in an annular shape in this manner, the stator winding 431 is configured in an annular shape as shown in Fig. 61(a). Fig. 61(b) is a perspective view showing the state in which the first partial winding 441A and the second partial winding 441B are assembled.

[0270] As shown in Figures 62(a) and (b), the second partial winding 441B, which does not have bent portions at both axial ends, may be first assembled to the stator core 432, and then the first partial winding 441A, which has bent portions at both axial ends, may be assembled from the radially outside.

[0271] 63(a) and (b), the first partial winding 441A and the second partial winding 441B are both substantially C-shaped in side view, and have different lengths (axial lengths) in the axial direction. That is, the partial windings 441A and 441B have crossover portions 443 and 444 on both axial sides thereof bent radially toward the stator core 432 (the opposite side of the magnet unit 412). The axial length of the second partial winding 441B is longer than the axial length of the first partial winding 441A. Therefore, at one and the other axial ends, the crossover portions 443 and 444 of the first partial winding 441A are on the axial inner side, and the crossover portions 443 and 444 of the second partial winding 441B are on the axial outer side. In addition, with the first partial winding 441A being attached to the stator core 432 in advance, the second partial winding 441B is assembled from the outside in the radial direction.

[0272] In the configuration shown in Figures 64(a) and (b), the first partial winding 441A and the second partial winding 441B are both substantially Z-shaped in side view. That is, in each of these partial windings 441A, 441B, the crossover portions 443, 444 on both axial sides are bent in opposite directions in the radial direction. The partial windings 441A, 441B have the same shape in side view, and are assembled to the stator core 432 with their axial assembly positions shifted from each other. The second partial winding 441B is assembled from the radial outside with the first partial winding 441A attached to the stator core 432 in advance.

[0273] By assembling the first partial winding 441A and the second partial winding 441B in an annular shape in this manner, the stator winding 431 is configured in an annular shape as shown in Fig. 65(a). Fig. 65(b) is a perspective view showing the state in which the first partial winding 441A and the second partial winding 441B are assembled.

[0274] In the configuration shown in Fig. 66(a) and (b), the first partial winding 441A and the second partial winding 441B are both substantially C-shaped in side view, and are assembled in the radial direction in opposite directions. That is, in the first partial winding 441A, the crossover portions 443, 444 on both sides in the axial direction are bent toward the stator core 432, and in the second partial winding 441B, the crossover portions 443, 444 on both sides in the axial direction are bent toward the opposite side of the stator core 432. Then, in a state in which the first partial winding 441A is attached to the stator core 432 in advance, the second partial winding 441B is assembled from the radial outside. Note that in the configuration of Fig. 66, the crossover portions 443, 444 of the first partial winding 441A and the crossover portions 443, 444 of the second partial winding 441B overlap each other in the radial direction.

[0275] 60 to 66, it is preferable that the partial winding 441 is connected in the same manner as in the second embodiment. That is, the first partial winding 441A and the second partial winding 441B are connected in series to form a series-connected body 600, and a plurality of series-connected bodies 600 are connected in parallel to form the phase windings 431U, 431V, and 431W of the respective phases. This makes it possible to suppress circulating currents.

[0276] In the configuration of FIGS. 64 to 66 described above, in addition to assembling the second partial winding 441B from the radial direction, the second partial winding 44B can be assembled from the axial direction.

[0277] The disclosure in this specification is not limited to the exemplified embodiments. The disclosure includes the exemplified embodiments and modifications based thereon by those skilled in the art. For example, the disclosure is not limited to the combination of parts and / or elements shown in the embodiments. The disclosure can be implemented by various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes the omission of parts and / or elements of the embodiments. The disclosure includes the substitution or combination of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.

[0278] Although the present disclosure has been described based on the embodiment, it is understood that the present disclosure is not limited to the embodiment or structure. The present disclosure also encompasses various modifications and modifications within the equivalent range. In addition, various combinations and forms, and other combinations and forms including only one element, more than one element, or less than one element, are also within the scope and concept of the present disclosure.

Claims

1. A field element (410) having a plurality of magnetic poles; a toothless armature (430) including an armature winding (431) including a plurality of partial windings (441) and a winding support member (432) provided on one of the radially inner side and the radially outer side of the armature winding opposite to the field element and supporting the plurality of partial windings; A rotating electric machine (400) comprising: the armature winding is composed of a multi-phase phase winding (431U, 431V, 431W), the phase winding of each phase includes a plurality of series-connected partial windings (600) and the series-connected partial windings are connected in parallel, The partial winding includes a first partial winding (441A) and a second partial winding (441B) having different coil resistances, Each of the series-connected bodies is configured by connecting the first partial winding and the second partial winding in series, The partial winding has a pair of intermediate conductor portions (442) and crossover portions (443, 444) at both axial ends of the pair of intermediate conductor portions, and is formed into an annular shape by the intermediate conductor portions and the crossover portions, The intermediate conductor portions of the partial windings are arranged side by side in the circumferential direction, the first partial winding is configured such that the jumper portion at one axial end of the armature winding is bent radially inward, the second winding portion has the jumper portion at the other axial end bent radially outward, a ring-shaped wiring module (480) to which the first partial winding and the second partial winding are connected; a rotating electric machine in which, of the jumper portions at both axial ends of the second partial winding, the jumper portions that are not bent radially outward are arranged side by side in the circumferential direction, and the wiring module is arranged radially inward of these jumper portions.

2. 2. The rotating electric machine according to claim 1, wherein the first partial winding and the second partial winding are different from each other in at least one of the shape, the number of turns, and the length of the wires constituting the partial winding.

3. In each of the partial windings, a pair of the intermediate conductor parts are provided at a distance of two coil pitches, and two of the intermediate conductor parts in the partial winding of another phase are disposed between the pair of intermediate conductor parts, The first partial winding is connected in series to the second partial winding of the same phase that is arranged at a position two coil pitches away from the first partial winding via connection wiring (602U, 602V, 602W), 3. The rotating electric machine according to claim 1, wherein the connection wires are arranged side by side in the circumferential direction at the same position in the axial direction.

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