Rotating Electric Machine

Abstract

To provide a rotary electric machine capable of appropriately assembling an armature core.SOLUTION: A rotary electric machine includes a rotor having a plurality of magnetic poles, a stator having a toothless structure and including multi-phase stator windings and a stator core, and a stator holder that is assembled on the opposite side of the stator winding among the radially inner and outer side of the stator core. The rotor and stator are provided so as to radially face each other. The stator core is formed in a cylindrical shape by a plurality of split cores 435 arranged in a circumferential direction. Each split core 435 is assembled to the stator holder 460 in a status in which a resin layer RS1 is interposed between the stator holder 460 and each split core 435.SELECTED DRAWING: Figure 57

Description

[Technical field]

[0001] The disclosure in this specification relates to rotating electrical machines. [Background technology]

[0002] Conventionally, a rotating electric machine is known that includes a field element including a magnet portion having a plurality of magnetic poles whose polarities alternate in the circumferential direction, and an armature having a multi-phase armature winding. The armature is provided, for example, as a stator, and includes a cylindrical stator core and a stator winding integrated with the stator core. Also, a technique is known in which the stator core is fitted and fixed to a cylindrical frame by shrink fitting or press fitting. However, when the stator core is fixed by shrink fitting or press fitting, a thermal load or mechanical load acts on the stator core, which may cause an overload. In response to this, a configuration is known in which the stator core is divided into a plurality of divided cores in the circumferential direction (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-25438 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in a configuration in which the stator core is divided into multiple split cores in the circumferential direction, unlike a configuration in which the stator core is fixed by shrink fitting or press fitting, no fixing force is generated in the radial direction. Therefore, a gap is generated between the stator core and the frame, which may cause rattling or reduce heat dissipation from the stator to the frame.

[0005] The present invention has been made in consideration of the above circumstances, and has an object to provide a rotating electric machine in which the armature core can be properly assembled. [Means for solving the problem]

[0006] The disclosed aspects in this specification adopt different technical means to achieve their respective objectives. The objectives, features, and advantages disclosed in this specification will become more apparent by referring to the following detailed description and the attached drawings.

[0007] Method 1 is: A field element having a plurality of magnetic poles; a toothless armature including a multi-phase armature winding and an armature core provided integrally with the armature winding on the radially inner side or the radially outer side; an armature holding member attached to one of the inner and outer radial sides of the armature core opposite to the armature winding; a rotating electric machine including: The armature core is formed into a cylindrical shape by a plurality of divided cores arranged in a circumferential direction, Each of the split cores is attached to the armature holding member with a resin layer interposed between the armature holding member and each of the split cores.

[0008] In the rotating electric machine having the above configuration, the armature core is formed into a cylindrical shape by a plurality of split cores arranged in the circumferential direction, and each of the split cores is assembled to the armature holding member. In this case, unlike a configuration in which the annular armature core and the armature holding member are fitted and fixed by shrink fitting or press fitting, there is a concern that a gap between the armature core and the armature holding member may cause rattle or a decrease in heat dissipation from the armature side to the armature holding member. In this regard, since each split core is assembled to the armature holding member with a resin layer interposed between the armature holding member and each split core, it is possible to suppress inconveniences caused by the gap between the armature core and the armature holding member. In particular, when an armature having a teethless structure is used, there is a concern that the armature winding may be displaced due to rattle of the armature core (each split core) because the armature winding is not engaged with the teeth of the armature core, but such inconveniences are also suppressed. As a result, the armature core can be properly assembled.

[0009] In a second aspect of the present invention, in accordance with the first aspect, the armature holding member and the divided core are provided at their radially opposing portions with engaging portions that are engageable with each other in the circumferential direction.

[0010] In the above configuration, since engaging portions that can engage in the circumferential direction are provided on the radially opposing portions of the armature holding member and the split cores, circumferential positional deviation of each split core relative to the armature holding member can be suppressed.

[0011] In a third aspect of the present invention, in the first or second aspect, the split core is formed by laminating a plurality of core sheets in the axial direction, and two or more types of core sheets are laminated together.

[0012] According to the above configuration, it is possible to realize a split core that requires different configurations in the axial direction (core sheet stacking direction). For example, in a split core having an engagement portion in a part in the axial direction that enables engagement with an armature holding member, different types of core sheets may be used in the part having the engagement portion and the part not having the engagement portion. Also, in a split core having a part that faces the coil end portion of the armature winding in the axial direction, different types of core sheets may be used in the part facing the coil end and the other part.

[0013] In a fourth aspect of the present invention, in any one of the first to third aspects, a fastener is attached to at least one location between each of the split cores aligned in the circumferential direction with a tip end portion of the fastener being inserted into the armature holding member.

[0014] According to the above configuration, the circumferential position of each split core is restricted by the fastener that is attached with its tip end inserted into the armature holding member, thereby making it possible to prevent the split core from being displaced in the circumferential direction.

[0015] In a fifth aspect of the present invention, the rotor is configured as any one of the first to third aspects, wherein a fastener is attached to a circumferential middle portion of at least one of the split cores arranged in the circumferential direction with a tip end of the split core being inserted into the armature holding member.

[0016] According to the above-mentioned configuration, the split cores are fixed to the armature holding member by the fasteners attached to the circumferential middle portions of the split cores, thereby making it possible to properly fix each of the split cores.

[0017] In Means 6, in any one of Means 1 to 5, the armature winding has a phase winding consisting of a plurality of partial windings for each phase, the partial windings have a pair of intermediate conductor portions arranged at a predetermined interval in the circumferential direction, and transition portions arranged at one and the other axial ends to connect the pair of intermediate conductor portions in a ring shape, the intermediate conductor portions of different partial windings are arranged adjacent to each other in the circumferential direction, and the circumferential dimension of the split core is the same as the circumferential width L of the partial windings, or is L×D when the circumferential dimension of the armature core is the width L×n, and D is a divisor of "n" other than 1 or n.

[0018] By making the circumferential dimension of the split core the same as the circumferential width L of the partial winding, it is possible to simplify the assembly of the partial winding to the split core. Alternatively, if the circumferential dimension of the split core is the width L×n, and D is a divisor of "n" other than 1 or n, then by making the circumferential dimension of the split core L×D, it is also possible to simplify the assembly of the partial winding to the split core.

[0019] In a seventh aspect of the present invention, in the sixth aspect, the plurality of partial windings include a partial winding provided so as to straddle a boundary between two of the divided cores adjacent in the circumferential direction.

[0020] By providing the partial winding across the boundary between two circumferentially adjacent split cores, misalignment of the split cores at the boundary between them is less likely to occur, which allows for optimal assembly of the split cores.

[0021] In the eighth aspect, in the sixth or seventh aspect, In the armature winding, one of the pair of intermediate conductor portions in the partial winding of another phase is disposed between the pair of intermediate conductor portions in the partial winding, and between the partial windings whose jumper portions overlap in the circumferential direction, the jumper portion of one partial winding is located on the radially inner side and the jumper portion of the other partial winding is located on the radially outer side, the plurality of partial windings include a first partial winding in which the transition portion is on the divided core side of either the inside or the outside in the radial direction, and a second partial winding in which the transition portion is on the opposite side of the divided core of either the inside or the outside in the radial direction, The first partial winding is arranged so that the boundary portions between the divided cores arranged in the circumferential direction correspond to the boundary portions between the first partial windings in the circumferential direction, and the second partial winding is arranged so as to straddle the boundary portions between the divided cores arranged in the circumferential direction.

[0022] By configuring the multiple partial windings to include a first partial winding whose transition portion is on the split core side of either the inside or outside of the radial direction, and a second partial winding whose transition portion is on the opposite side of the split core of either the inside or outside of the radial direction, the partial windings can be suitably arranged without interfering with each other. Furthermore, of the first and second partial windings, the first partial winding whose transition portion is on the split core side and which is assembled to the split core first has both circumferential ends corresponding to both circumferential ends of the split core, making it easy to assemble each partial winding to each split core (armature core).

[0023] Means 9 is the same as any one of means 6 to 8, wherein the split core is provided with a fixing portion for fixing the partial winding.

[0024] The partial winding is fixed to the split core by a fixing portion provided on the split core, which allows the split core and the partial winding to be suitably assembled in an armature with a teethless structure.

[0025] In Means 10, in accordance with Means 9, an insulating member is attached to the transition portion of the partial winding to insulate the partial windings from each other, and the insulating member is provided with a fixed portion which is fixed to the fixed portion.

[0026] By providing the insulating member on the jumper parts of the partial windings, it is possible to preferably achieve mutual insulation even when the jumper parts of the partial windings are arranged so as to overlap each other in the circumferential direction. Also, by providing the insulating member with a fixed part that is fixed to the fixed part on the split core side, it is possible to impart to the insulating member an insulating function that insulates the partial windings from each other and a function of fixing the partial windings to the split core.

[0027] Means 11 is based on any one of means 6 to 10, wherein the armature holding member has an opposing portion that faces the crossover portion of the partial winding, and a fixing portion for fixing the partial winding is provided on the opposing portion.

[0028] In a configuration including an armature holding member, a teethless armature core, and an armature winding, the armature holding member is provided on one side of the armature core in the radial direction, and the armature winding is provided on the other side. The partial winding is fixed to a fixing portion provided on an opposing portion of the armature holding member that faces the jumper portion. In this case, the split core is interposed between the armature holding member and the armature winding, and is held in a sandwiched state between the two by fixing the two. This prevents the split core from shifting in position, and enables the split core to be properly assembled to the armature holding member.

[0029] In a twelfth aspect of the present invention, the split cores arranged in the circumferential direction have overlapping portions at their circumferential ends where they overlap with each other in the radial direction.

[0030] With this configuration, it is possible to suppress degradation of magnetic performance at the boundaries (joints) between the divided cores in the armature core.

[0031] In Means 13, in any of Means 1 to 12, the split core is formed by stacking a plurality of core sheets in the axial direction, and the core sheets are stacked with a circumferential offset, thereby forming steps on the circumferential end faces of the split core, and each of the split cores arranged in the circumferential direction is assembled to the armature holding member with the steps on their circumferential end faces engaged with each other.

[0032] In the above configuration, the split cores arranged in the circumferential direction are engaged with each other by the steps on the circumferential end faces of the split cores formed by the circumferential misalignment of the core sheets, thereby suppressing the deterioration of the magnetic resistance of the armature core.

[0033] Means 14 is the same as any one of Means 1 to 13, further comprising a second resin layer provided between each of the split cores and the armature winding.

[0034] In the above configuration, a resin layer is formed between the armature holding member and each of the split cores, and also between each of the split cores and the armature winding, which allows heat generated in the armature winding to be effectively transferred to the armature holding member via each of the split cores, thereby improving heat dissipation. [Brief description of the drawings]

[0035] [Figure 1] 1 is a perspective view showing an entire rotating electric machine according to a first embodiment; [Diagram 2] FIG. [Diagram 3] FIG. [Figure 4] FIG. [Diagram 5] FIG. [Figure 6] Cross-sectional view of the rotor. [Figure 7] FIG. 4 is a partial cross-sectional view showing the cross-sectional structure of a magnet unit. [Figure 8] FIG. 4 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. 13 is a graph showing the relationship between electrical angle and magnetic flux density for a magnet of a comparative example. [Figure 10] FIG. [Figure 11] FIG. [Figure 12] FIG. 4 is a perspective view of the core assembly as viewed from one axial side. [Figure 13]FIG. 4 is a perspective view of the core assembly as viewed from the other axial side. [Figure 14] FIG. [Figure 15] FIG. [Figure 16] FIG. 4 is a circuit diagram showing the connection state of partial windings in each of the three phase windings. [Figure 17] FIG. 4 is a side view showing the first coil module and the second coil module side by side for comparison. [Figure 18] FIG. 4 is a side view showing a first partial winding and a second partial winding arranged side by side for comparison; [Figure 19] FIG. 4 is a diagram showing the configuration of a first coil module. [Figure 20] Cross-sectional view taken along line 20-20 in Figure 19(a). [Figure 21] FIG. [Figure 22] FIG. 4 is a diagram showing the configuration of a second coil module. [Diagram 23] Cross-sectional view taken along line 23-23 in Figure 22(a). [Figure 24] FIG. [Diagram 25] FIG. 13 is a diagram showing overlap positions of film materials when each coil module is aligned in the circumferential direction. [Figure 26] FIG. 4 is a plan view showing a state in which the first coil module is assembled to the core assembly. [Figure 27] FIG. 4 is a plan view showing a state in which the first coil module and the second coil module are assembled to the core assembly. [Figure 28] FIG. 4 is a vertical cross-sectional view showing a fixed state by a fixing pin. [Figure 29] FIG. [Diagram 30] FIG. 2 is a cross-sectional view showing a portion of a vertical cross section of the bus bar module. [Diagram 31] FIG. 4 is a perspective view showing a state in which the bus bar module is assembled to the stator holder. [Diagram 32] FIG. 4 is a longitudinal cross-sectional view of a fixing portion for fixing the bus bar module. [Diagram 33] FIG. 4 is a vertical cross-sectional view showing a state in which the relay member is attached to the housing cover. [Diagram 34] FIG. [Diagram 35] FIG. 2 is an electric circuit diagram showing a control system for a rotating electric machine. [Diagram 36] FIG. 4 is a functional block diagram showing a current feedback control process performed by a control device. [Figure 37] FIG. 4 is a functional block diagram showing a torque feedback control process performed by the control device. [Figure 38] FIG. 11 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modified example. [Figure 39] FIG. 4 is a diagram showing the configuration of a stator unit having an inner rotor structure. [Diagram 40] FIG. 4 is a plan view showing the assembled state of the coil module to the core assembly. [Diagram 41] FIG. 11 is a perspective view showing an entire rotating electric machine according to a second embodiment. [Diagram 42] FIG. [Diagram 43] FIG. [Diagram 44] FIG. [Diagram 45] FIG. [Figure 46] FIG. [Figure 47] FIG. [Figure 48] FIG. [Figure 49] FIG. [Figure 50] FIG. [Figure 51] FIG. [Figure 52] FIG. 4 is an exploded perspective view showing an insulating cover in a partial winding. [Diagram 53] FIG. [Figure 54] FIG. 4 is an exploded perspective view showing an insulating cover in a partial winding. [Figure 55]FIG. 4 is a plan view showing partial windings arranged side by side in the circumferential direction. [Figure 56] FIG. [Figure 57] 4 is a cross-sectional view showing a state in which the split core and the partial windings are assembled to the stator holder. FIG. [Figure 58] FIG. 4 is a perspective view showing a state in which the partial winding and the divided core are integrated together. [Figure 59] FIG. 13 is a diagram showing a modified example of a split core. [Figure 60] FIG. 13 is a diagram showing a modified example of a split core. [Figure 61] FIG. 13 is a diagram showing a modified example of a split core. [Figure 62] FIG. 2 is an exploded cross-sectional view showing a rotating electric machine divided into a fixed portion and a rotating portion. [Figure 63] 4 is a cross-sectional view showing a state in which the split core and the partial windings are assembled to the stator holder. FIG. [Figure 64] 6A and 6B are diagrams showing a configuration for fixing split cores to a stator holder; [Figure 65] 13A and 13B are diagrams showing partial windings of a modified example and their assembled state. [Figure 66] 13A and 13B are diagrams showing partial windings of a modified example and their assembled state. [Figure 67] 4 is a cross-sectional view showing a state in which the split core and the partial windings are assembled to the stator holder. FIG. [Figure 68] FIG. 2 is a vertical cross-sectional view showing the configuration of a stator unit. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] 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 designated by the same reference numerals. For corresponding and / or associated parts, reference may be made to the description of other embodiments.

[0037] 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.

[0038] (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.

[0039] 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.

[0040] 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."

[0041] 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.

[0042] 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".

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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 circular 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.

[0055] 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.

[0056] 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".

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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 as 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.

[0061] 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).

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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).

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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."

[0081] 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.

[0082] Next, the configuration of the coil modules 150A and 150B will be described in detail.

[0083] 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).

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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."

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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).

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] Next, the configuration of the insulating covers 161 and 162 will be described.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] Next, the second coil module 150B will be described.

[0106] 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).

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] Next, the configuration of the insulating covers 163, 164 will be described.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] Next, a configuration for assembling the coil modules 150A, 150B to the core assembly CA will be described.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] Next, the bus bar module 200 will be described.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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.

[0152] 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).

[0153] Next, the relay member 230 that electrically connects the input / output terminal 203 of the bus bar module 200 to an external device outside the rotating electric machine 10 will be described.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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.

[0165] FIG. 36 is a block diagram showing a current feedback control process for controlling the currents of the U, V, and W phases.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] FIG. 37 is a block diagram showing a torque feedback control process corresponding to the U, V, and W phases.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] (Modification) Below, a modification of the first embodiment will be described.

[0179] 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.

[0180] It is also possible to use a Halbach array magnet in the magnet unit 22.

[0181] 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.

[0182] 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.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] The rotating electric machine is not limited to one with star connection, and may be one with delta connection.

[0193] 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.

[0194] 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 of a vehicle. An outline of the rotating electric machine 400 is shown in Figs. 41 to 46. Fig. 41 is a perspective view showing the entire rotating electric machine 400, Fig. 42 is a plan view of the rotating electric machine 400, Fig. 43 is a vertical cross-sectional view of the rotating electric machine 400 (cross-sectional view taken along line 43-43 in Fig. 42), Fig. 44 is a horizontal cross-sectional view of the rotating electric machine 400 (cross-sectional view taken along line 44-44 in Fig. 43), Fig. 45 is a horizontal cross-sectional view of the rotating electric machine 400 (cross-sectional view taken along line 45-45 in Fig. 43), and Fig. 46 is an exploded cross-sectional view showing components of the rotating electric machine 400 in an exploded manner.

[0195] 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.

[0196] 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.

[0197] In rotating electric machine 400, the direction in which the axis of rotation extends (left and right direction in FIG. 43) 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.

[0198] 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.

[0199] As shown in FIG. 46, 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. 43).

[0200] 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.

[0201] The magnet unit 412, like the magnet unit 22 in Fig. 7, has multiple permanent magnets, each of which is polar anisotropic, and 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 oriented parallel to the d-axis on the d-axis side and perpendicular to the q-axis on the q-axis side. 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 more 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.

[0202] 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 at their outer peripheries by a fixing member such as yarn. Also, an annular end plate member may be attached to the axial end of each magnet.

[0203] Next, a configuration of the stator unit 420 will be described. Fig. 47 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.

[0204] Here, first, the stator 430 will be described. Figures 48 and 49 are exploded perspective views showing the stator winding 431 and the stator core 432 in the stator 430, while Figure 50 is an exploded cross-sectional view showing the stator 430, the stator holder 460, and the coil end cover 490 in the stator unit 420. Note that Figures 48 and 49 are exploded perspective views of the stator 430 as viewed from different axial directions.

[0205] The stator 430 is an armature with a teethless structure, and has a stator winding 431 and a stator core 432. In the stator 430, the stator winding 431 has three-phase windings, and each phase winding 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 the plurality of partial windings 441 are connected in parallel or in series for each phase. In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.

[0206] 50, 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 in a state in which both axial end portions thereof protrude axially outside the stator core 432 (i.e., toward the coil end CE).

[0207] 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. 48) bent, 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. 48) bent, 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 "partial winding 441A," and the partial winding 441 having a bent portion bent radially outward is also referred to as the "partial winding 441B."

[0208] The configuration of the partial windings 441A and 441B will be described in detail. Figures 51(a) and (b) are perspective views showing the configuration of the partial winding 441A, and Figure 52 is an exploded perspective view showing the insulating covers 451 and 452 attached to the transition portions 443 and 444 of the partial winding 441A. Figures 53(a) and (b) are perspective views showing the configuration of the partial winding 441B, and Figure 54 is an exploded perspective view showing the insulating covers 453 and 454 attached to the transition portions 443 and 444 of the partial winding 441B. Figures 51(a) and (b) are perspective views of the partial winding 441A as viewed from the radial inside and outside, respectively, and Figures 53(a) and (b) are similarly perspective views of the partial winding 441B as viewed from the radial inside and outside, respectively.

[0209] Each of the partial windings 441A, 441B is formed by winding a conductor material 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. In a state where the partial windings 441A, 441B are arranged side by side in the circumferential direction, the intermediate conductor portions 442 of the different partial windings 441A, 441B are arranged side by side in the circumferential direction in close proximity to each other.

[0210] 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.

[0211] Each of the crossover portions 443, 444 on both axial sides is provided as a portion corresponding to the coil end CE (see FIG. 50), and of each of the crossover portions 443, 444, one crossover portion 443 is formed to be bent in the radial direction, while the other crossover portion 444 is formed to be not bent in the radial direction. As a result, the partial windings 441A, 441B are substantially L-shaped when viewed from the side.

[0212] The partial windings 441A and 441B have different radial bending directions of the crossover portions 443, with the crossover portion 443 in the partial winding 441A being bent radially inward, and the crossover portion 443 in the 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 in plan view (radial plan shapes) of the crossover portions 443 in the partial windings 441A and 441B are different from each other, and it is preferable that the circumferential width of the crossover portion 443 of the partial winding 441A becomes narrower toward the tip side, and the circumferential width of the crossover portion 443 of the partial winding 441B becomes wider toward the tip side.

[0213] 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.

[0214] In partial winding 441A, 441B, similar to partial winding 151 described above, the conductor wire is wound in multiple layers so that the cross section of the conductor wire assembly portion is rectangular. In intermediate conductor portion 442, the conductor wire is arranged in multiple rows in the circumferential direction and multiple rows in the radial direction, so that the cross section is generally rectangular (see FIG. 20).

[0215] 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.

[0216] As shown in Figs. 51(a), (b) and 52, in the 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).

[0217] The insulating covers 451, 452 have engaging portions 451a, 452a that engage with the inside of curved portions at the tips of the crossover portions 443, 444 of the partial winding 441A, respectively. Parts of the brackets 455, 456 may be integrated with the engaging portions 451a, 452a as base materials. The brackets 455, 456 may be embedded in the insulating covers 451, 452, or may be fixed to the outer surfaces of the insulating covers 451, 452 by adhesive or the like.

[0218] As shown in Figs. 53(a), (b) and 54, in the partial winding 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).

[0219] The insulating covers 453, 454 have engaging portions 453a, 454a that engage with the inside of curved portions at the tips of the crossover portions 443, 444 of the partial winding 441B, respectively. Parts of the brackets 457, 458 may be integrated with the engaging portions 453a, 454a as base materials. 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 adhesive or the like.

[0220] Fig. 55 is a plan view showing a state in which the winding portions 441A and 441B are arranged side by side in the circumferential direction. Fig. 55 is a plan view of the stator winding 431 shown in Fig. 48 as viewed from one axial direction (from above in the figure).

[0221] 55, the crossover portion 443 of the partial winding 441A extends radially inward, and the crossover portion 443 of the partial winding 441B extends radially outward. Radially inward of the intermediate conductor portions 442 of the partial windings 441A, 441B, at one axial end side of the stator winding 431 (the far side of the paper in FIG. 55), a protrusion 455a of a bracket 455 provided on an insulating cover 451 of the partial winding 441A and a protrusion 458a of a bracket 458 provided on an insulating cover 454 of the partial winding 441B overlap in the axial direction, and the positions of the through holes 455b, 458b of the protrusions 455a, 458a match in a plan view.

[0222] Further, radially outward of the intermediate conductor portions 442 of the partial windings 441A, 441B, at the other axial end side of the stator winding 431 (the front side of the paper in FIG. 55), protrusions 456a of a bracket 456 provided on an insulating cover 452 of the partial winding 441A and protrusions 457a of a bracket 457 provided on an insulating cover 453 of the 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 at the same radial distance from the center of the plane of the stator 430 and are arranged at equal intervals in the circumferential direction.

[0223] As shown in Figures 48 and 49, the stator winding 431 is formed into an annular shape by arranging partial windings 441A, 441B in the circumferential direction, and the stator core 432 is arranged radially inside the stator winding 431. The stator core 432 is configured as a core sheet laminate in which core sheets made of magnetic steel plates are laminated in the axial direction, and has a cylindrical 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 irregularities. The stator core 432 functions as a back yoke.

[0224] In this embodiment, the stator core 432 is divided into a plurality of parts in the circumferential direction, and a cylindrical stator core 432 is formed by a plurality of divided cores 435 arranged in the circumferential direction. The divided cores 435 are provided to individually correspond to the partial winding 441A of the partial windings 441A, 441B, and the number of divided cores 435 is the same as that of the partial winding 441A, and the circumferential width dimension of the divided cores 435 is the same as that of the partial winding 441A. The axial width dimension of the divided cores 435 is the same as that of the magnet unit 412 (permanent magnet) of the rotor 410.

[0225] The split core 435 is a core sheet laminate in which a number of core sheets are laminated, and is formed by laminating the core sheets using, for example, a molding frame. However, it is also possible to laminate a number of core sheets punched into an annular plate shape in the axial direction to form a cylinder, and cut the cylinder into a number of pieces in the circumferential direction to form a number of split cores 435. It is also possible to laminate a long core sheet while winding it in an annular shape to form a cylinder with a helical core structure, and cut the cylinder into a number of pieces in the circumferential direction to form a number of split cores 435. Other detailed configurations of the split core 435 will be described later.

[0226] Next, the configuration of stator holder 460 will be described. Here, the configuration of stator holder 460 will be described with reference to Figures 50 and 56. Figure 56 is a cross-sectional view of stator holder 460 (a cross-sectional view at the same position as Figure 45).

[0227] 50 and 56, 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).

[0228] 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 .

[0229] One end of the inlet side passage 464 and one end of the outlet side passage 465 each open in the axial end face of the inner cylinder member 462. At the axial end face, an inlet piping port 467 is provided at the opening of the inlet side passage 464, and an outlet piping port 468 is provided at the opening of the outlet side passage 465 (see FIG. 42).

[0230] Although not shown, a circulation path for circulating the refrigerant is connected to the inlet piping port 467 and the outlet piping port 468. The circulation path is provided with, for example, an electric pump and a heat dissipation device such as a radiator, and the refrigerant circulates through the circulation path and the refrigerant passage 463 of the rotating electric machine 400 as the pump is driven.

[0231] 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.

[0232] 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. 50). The protrusions 473 function as reinforcing members for the inner tube member 462.

[0233] 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.

[0234] 56, an insertion hole 476 is provided in the end plate portion 471 of the inner tube member 462, penetrating in the axial direction, at a position radially outside the through hole 472 and at a position where at least one protrusion 473 is interposed between the end plate portion 471 and the opening portion 474 in the circumferential direction. The insertion hole 476 is a hole portion through which a resolver signal line 522, which will be described later, is inserted in the axial direction.

[0235] Here, the multiple split cores 435 constituting the stator core 432 will be described in detail while showing their relationship with the partial windings 441A, 441B and the stator holder 460. Fig. 57 is an enlarged cross-sectional view showing the state in which the split cores 435 and the partial windings 441A, 441B are assembled to the stator holder 460, and Fig. 58 is a perspective view showing the state in which the partial winding 441A and the split cores 435 are integrated together.

[0236] The split core 435 has a cross section formed in an arc shape to match the curved surface on the outer circumferential side of the stator holder 460, with the radially inner side being a concave curved surface and the radially outer side being a convex curved surface. The split core 435 is positioned relative to the stator holder 460 by engagement of the concave and convex surfaces of the opposing surfaces, and a convex portion 436 is provided on the radially inner surface of the split core 435, while a concave portion 477 is provided on the outer circumferential surface of the outer tubular member 461 of the stator holder 460. The convex portion 436 on the split core 435 side and the concave portion 477 on the stator holder 460 side are each provided to extend linearly in the axial direction, and the split core 435 is provided with the convex portion 436 in the range from one axial end to the other axial end. The convex portion 436 and the concave portion 477 each correspond to an "engagement portion."

[0237] Between the stator holder 460 and the split core 435, a resin layer RS1 made of synthetic resin is formed.

[0238] In addition, when the split core 435 is formed by laminating long plate-like core sheets, it is preferable to laminate a plurality of core sheets to form a rectangular parallelepiped laminated core, and then bend the laminated core with a predetermined curvature. According to this manufacturing method, it is possible to easily accommodate stator holders 460 having different outer diameter dimensions of the cylindrical part by using a common laminated core. In addition, it is possible to easily accommodate not only outer rotor type rotating electric machines, but also inner rotor type rotating electric machines.

[0239] Partial windings 441A and 441B are attached to the split core 435 on the opposite side of the stator holder 460, i.e., on the radially outer side of the split core 435. The circumferential dimension of the split core 435 is the same as the circumferential width of the partial windings 441A and 441B. In this case, the split cores 435 are provided in one-to-one correspondence with the partial windings 441A, and a pair of intermediate conductor parts 442 of each partial winding 441A are fixed to each split core 435. The partial winding 441B is provided so as to straddle the boundary between two split cores 435 adjacent to each other in the circumferential direction. A resin layer RS2 made of synthetic resin is formed between the intermediate conductor parts 442 of each partial winding 441A and the split core 435.

[0240] In each of the partial windings 441A, 441B, the crossover portion of one partial winding 441A is on the radially inner side, and the crossover portion of the other partial winding 441B is on the radially outer side, so that the crossover portions overlap in the circumferential direction. In this case, the crossover portion of the partial winding 441A is on the split core 435 side of the radial inner or outer side, and the crossover portion of the partial winding 441B is on the opposite side of the split core 435 of the radial inner or outer side (see FIG. 50).

[0241] Generally, the stator core 432 is assembled to the stator holder 460 by fitting and fixing with a predetermined tightening margin, such as shrink fitting or press fitting. In contrast, in this embodiment, the stator core 432 is assembled by fixing each of the divided cores 435 to the stator holder 460. In this case, since it is difficult to generate a radial assembly force, a gap is generated between the stator holder 460 and the stator core 432, which may cause rattling or a decrease in heat dissipation. However, the resin layer RS1 is formed between the stator holder 460 and the divided cores 435, which suppresses rattling and a decrease in heat dissipation. In a rotating electric machine with an outer rotor structure, it is necessary to heat the stator core 432 on the radial outer side of the stator holder 460 and the stator core 432 to perform shrink fitting, and there is a possibility that characteristics may change due to heating, but the configuration using the divided cores 435 eliminates such concerns.

[0242] With a configuration in which resin layer RS1 is interposed between stator holder 460 and split core 435, and resin layer RS2 is interposed between partial windings 441A, 441B and split core 435, heat generated by partial windings 441A, 441B can be suitably released toward stator holder 460 having refrigerant passages 463 as a cooling section, improving heat dissipation. Note that resin layers RS1, RS2 are preferably formed from a material with high thermal conductivity (for example, a resin with a thermal conductivity of 0.3 W / mK or more).

[0243] The resin layers RS1 and RS2 are preferably formed from the same resin material. However, the resin layers RS1 and RS2 may be made from different resin materials, and the resin material of the resin layer RS2 on the partial windings 441A and 441B side may have a higher adhesive strength than the resin material of the resin layer RS1 on the stator holder 460 side. In this case, the split core 435 on the stator holder 460 side is fixed by a concave-convex engagement, whereas the split core 435 and the partial windings 441A and 441B are fixed not by engagement but by enhanced adhesive strength to improve reliability.

[0244] Alternatively, the resin material of the resin layer RS2 on the partial windings 441A, 441B side may have a higher thermal conductivity than the resin material of the resin layer RS1 on the stator holder 460 side. In this case, the heat dissipation can be improved by increasing the heat transfer coefficient of the resin layer RS2 on the coil side, which is the heat source. Also, since it is considered that gaps are more likely to occur between the partial windings 441A, 441B side and the split core 435 than on the stator holder 460 side, the heat dissipation can also be improved by increasing the heat transfer coefficient of the resin layer RS2.

[0245] As described above, by providing the recess 477 on the stator holder 460 side and the protrusion 436 on the split core 435 side (in other words, by providing no recess on the split core 435 side), it is possible to achieve the desired positioning effect while suppressing the generation of cogging torque.

[0246] When the stator 430 is assembled to the stator holder 460, the split core 435 and the partial winding 441A are integrated as shown in FIG. 58, and the integrated body is assembled to the cylindrical portion of the stator holder 460, i.e., the outer cylinder member 461. At this time, the position of each split core 435 is performed by the recess 477 on the stator holder 460 side and the protrusion 436 on the split core 435 side, and the split core 435 is assembled with the resin layer RS1 interposed between the stator holder 460 and the split core 435. The split core 435 can be assembled from the radial direction. Therefore, unlike assembly from the axial direction, the resin material applied to at least either the stator holder 460 side or the split core 435 side is less likely to be scraped off.

[0247] Then, the partial winding 441B is assembled after the split core 435 and the partial winding 441A are assembled to the stator holder 460. In the state where the partial windings 441A, 441B are assembled, the partial winding 441A is arranged so that the boundary between the split cores 435 aligned in the circumferential direction corresponds to the boundary between the partial windings 441A in the circumferential direction. Moreover, the partial winding 441B is arranged so as to straddle the boundary between the split cores 435 aligned in the circumferential direction.

[0248] The stator 430 may be attached to the stator holder 460 by first attaching each divided core 435 to the stator holder 460, and then attaching the partial winding 441A to each divided core 435, and then attaching the partial winding 441B.

[0249] As a configuration for the concave-convex engagement between the stator holder 460 and the divided core 435, the following configuration can also be used.

[0250] Fig. 59(a) is a front view of split core 435 as viewed from the radial inside (stator holder 460 side), and Fig. 59(b) is a cross-sectional view taken along line BB in Fig. 59(a). In the configuration shown in Figs. 59(a) and (b), split core 435 has convex portion 436 provided in a range that is a part of the area between one axial end and the other axial end. Although not shown, concave portion 477 is also provided in the same range in the axial direction on the stator holder 460 side. In this case, it is possible to position split core 435 and stator holder 460 by engagement of concave and convex portions not only in the circumferential direction but also in the axial direction.

[0251] In the split core 435 shown in Figures 59(a) and (b), different types (shapes) of core sheets are used for the portion A1 having a convex portion 436 in the axial direction and the portion A2 not having the convex portion 436. Specifically, a core sheet having a notch and a core sheet having no notch are used in each of the portions A1 and A2. The split core 435 is preferably manufactured by forming each of the portions A1 and A2 by laminating long plate-shaped core sheets, joining them together, and then bending them with a predetermined curvature.

[0252] As shown in Figs. 59(c) and (d), the split cores 435 arranged in the circumferential direction may have their circumferential ends overlap each other in the radial direction. In the configuration of Fig. 59(c), the end faces of the circumferential ends of the split cores 435 extend obliquely to the radial direction, and the split cores 435 are arranged in the circumferential direction with the circumferential end faces closely facing each other. In the configuration of Fig. 59(d), a step is formed on the end face of the circumferential end of the split cores 435, and the step causes the circumferential ends of the split cores 435 adjacent in the circumferential direction to overlap each other in the radial direction. OL in the figure corresponds to the overlapping portion where the split cores 435 overlap each other in the radial direction. According to each of these configurations, it is possible to suppress the deterioration of the magnetic performance at the boundary (seam) between the split cores 435 in the stator core 432.

[0253] 59(d), the thickness of the overlapping portions of the circumferential ends of the split cores 435 differs between the stator holder 460 side (lower side of the figure) and the stator winding 431 side (upper side of the figure), with the stator winding 431 side being thicker. This makes it possible to suitably suppress deterioration in magnetic resistance in a configuration in which the circumferential ends of the split cores 435 are stepped.

[0254] 59(e), the engagement portion between the stator holder 460 and the split core 435 may be configured such that a convex portion is provided on the stator holder 460 side and a concave portion is provided on the split core 435 side. In this case, taking into consideration that the stator holder 460 is provided with an annular refrigerant passage 463, the formation of a convex portion rather than a concave portion on the stator holder 460 side makes it less likely to affect the formation of the refrigerant passage 463.

[0255] In the split core 435 shown in Fig. 60, the core sheets are stacked with a circumferential offset, and the offset forms a step on the circumferential end face of the split core 435. Similarly, the protrusions 436 of the split core 435 are also offset in the axial direction. It is preferable that the core sheets are stacked with a circumferential offset for each of the multiple core sheets. However, each core sheet may be offset in the circumferential direction for each sheet in the stacking direction.

[0256] When each split core 435 is assembled to the stator holder 460, the steps (concave and convex) formed on the circumferential end faces of each split core 435 engage with each other. In other words, the split cores 435 arranged in the circumferential direction are configured to engage with each other due to the steps on the circumferential end faces of the split cores 435 formed by the circumferential misalignment of the core sheets. This makes it possible to suppress deterioration of the magnetic resistance in the stator core 432.

[0257] 61(a), split core 435 may be provided with convex portions 436 extending in a direction oblique to the axial direction. Concave portions may be provided instead of convex portions 436. This makes it possible to suppress the generation of cogging torque caused by providing split core 435 with convex portions or concave portions.

[0258] As shown in FIG. 61(b), both circumferential end faces of a split core 435 may be inclined in the same direction relative to the axial direction, so that the split core 435 has a substantially parallelogram shape when viewed from the front.

[0259] As shown in FIG. 61(c), the circumferential end faces of the split core 435 may be inclined in opposite directions relative to the axial direction, so that the split core 435 has a substantially trapezoidal shape (isosceles trapezoidal shape) when viewed from the front.

[0260] Next, the coil end cover 490 will be described.

[0261] 47 and 50, coil end cover 490 has an annular shape and is attached to end plate portion 471 of stator holder 460. In other words, coil end cover 490 is provided on a 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 positions partial windings 441A, 441B on the one axial end side.

[0262] Coil end cover 490 is provided with a plurality of mounting holes 492 aligned in the circumferential direction, and coil end cover 490 is attached to stator holder 460 by fasteners such as fixing pins and screws in each mounting hole 492. Note that stator holder 460 and coil end cover 490 together correspond to the "armature holding member."

[0263] In the present embodiment, in the stator unit 420, partial windings 441A, 441B are fixed to the respective split cores 435 of the stator core 432 and the coil end cover 490 by mechanical coupling, and a specific configuration thereof will be described below.

[0264] As explained in Figure 55, in each partial winding 441A, 441B, radially inward of the intermediate conductor portion 442, the protrusion 455a of the bracket 455 provided on the insulating cover 451 of the partial winding 441A and the protrusion 458a of the bracket 458 provided on the insulating cover 454 of the partial winding 441B overlap in the axial direction, and the positions of the through holes 455b, 458b of each protrusion 455a, 458a coincide when viewed in a planar view.

[0265] On the other hand, as shown in FIG. 49, a recess 437 is formed in the end face at one axial end of each split core 435, and when a cylindrical stator core 432 is formed by a plurality of split cores 435, a plurality of recesses 437 are arranged at predetermined intervals in the circumferential direction.

[0266] Each split core 435 is assembled radially inward of each partial winding 441A, 441B. In this case, the through holes 455b, 458b of the brackets 455, 458 of the insulating covers 451, 454 are aligned with the recesses 437 in the axial end surface of the stator core 432 radially inward of the intermediate conductor portions 442 of each partial winding 441A, 441B. Then, a coupling member, for example a metal fixing pin, is assembled to the through holes 455b, 458b and the recesses 437, whereby the partial windings 441A, 441B are fixed to the split cores 435.

[0267] Further, 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 in an insulating cover 452 of the partial winding 441A and a through hole 457b of a bracket 457 in an insulating cover 453 of the partial winding 441B. The coil end cover 490 corresponds to an opposing portion that faces the crossover portion of the partial windings 441A and 441B. In this case, with the coil end cover 490 attached to one axial end side of the stator 430, the through holes 491 on the coil end cover 490 side are aligned with the through holes 456b and 457b on the insulating covers 452 and 453 sides, and further 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.

[0268] Assuming the state in which the coil end cover 490 is attached to the stator winding 431, the multiple through holes 491 lined up in the circumferential direction are positioned radially outward of a transition portion 444 (in other words, the position of the intermediate conductor portion 442) in the stator winding 431 that is not bent radially and extends axially, and the multiple mounting holes 492 lined up in the circumferential direction are positioned radially inward of the transition portion 444 of the stator winding 431.

[0269] In short, the structure of fixing the partial windings 441A, 441B to each split core 435 and the coil end cover 490 can be summarized as follows: At one axial end of each of the partial windings 441A, 441B, the crossover portion 443 of the partial winding 441A is bent radially inward, and the crossover portions 443, 444 of each of the partial windings 441A, 441B are fixed to the split core 435. On the other hand, at the other axial end of each of the partial windings 441A, 441B, the crossover portion 443 of the partial winding 441B is bent radially outward, and the crossover portions 443, 444 of each of the partial windings 441A, 441B are fixed to the coil end cover 490.

[0270] With regard to the fixing of the split core 435 and each partial winding 441A, 441B, the recess 437 of the split core 435 corresponds to the "fixing portion", and the through holes 455b, 458b of the brackets 455, 458 of the insulating covers 451, 454 correspond to the "fixed portion". Also, with regard to the fixing of the coil end cover 490 and each partial winding 441A, 441B, the through hole 491 of the coil end cover 490 corresponds to the "fixing portion", and the through holes 456b, 457b of the brackets 456, 457 of the insulating covers 452, 453 correspond to the "fixed portion".

[0271] 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 in series for each phase by this wiring module 480, and the phase windings of each phase are connected at a neutral point. As shown in Fig. 43, 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 (opposite the coil end cover 490).

[0272] More specifically, the stator winding 431 has a partial winding 441A bent radially inward at one axial end and a partial winding 441B bent radially outward at the other axial end, and these partial windings 441A, 441B are arranged side by side with some overlapping in the circumferential direction, with the bent side of the partial winding 441A and the non-bent side of the partial winding 441B facing the end plate portion 414 of the rotor carrier 411. A wiring module 480 is provided on one of both axial ends of the stator winding 431, facing the end plate portion 414 of the rotor carrier 411.

[0273] 47, the wiring module 480 has an annular portion 481 having an annular 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 an annular shape from an insulating member such as resin. Wiring for each phase and a neutral point wiring (both not shown) are embedded in the annular portion 481, and a connection terminal 482 is electrically connected to each of the wiring. The connection terminals 482 are provided for each partial winding 441, and are fixed so as to extend in the axial direction.

[0274] 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.

[0275] In the stator winding 431, at the end on the lower side of FIG. 47, 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. In other words, the ring 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 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.

[0276] To each bus bar 483 of the wiring module 480, a power line 485 is connected to supply power to the stator winding 431 for each phase. The power lines 485 are arranged in a line in the circumferential direction and extend in the axial direction. The power lines 485 may be a conductor wire itself that is a rigid body such as a metal bus bar, or the conductor wire 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 lines 485 may be made of a flexible harness. Each power line 485 is connected to a terminal block 475 provided on an end plate portion 471 of the inner cylinder member 462.

[0277] 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. 43 and Fig. 62. Fig. 62 is an exploded cross-sectional view of rotating electric machine 400 showing a state 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.

[0278] 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.

[0279] 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. 62, the integral 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 integral body of the hub 402 and the rotor 410 has an annular space S2 formed around the hub 402. The integral body of the spindle 401 and the stator unit 420 and the integral 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.

[0280] 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.

[0281] 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.

[0282] 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.

[0283] 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. 56). The resolver 520 (resolver stator) is attached to an axial end surface of the protruding portion 473 of the inner cylindrical member 462.

[0284] As shown in Fig. 44, resolver 520 has terminal portion 521 at a part in the circumferential direction, and resolver signal line 522 is connected to terminal portion 521. Also, as shown in Figs. 42 and 43, resolver signal line 522 is guided to the outside of the rotating electric machine (axial end portion of rotating electric machine 400) through insertion hole 476 provided in end plate portion 471 of inner cylinder member 462. Note that insertion hole 476 may be sealed with a sealing member such as a grommet. Also, a signal line terminal portion connected to resolver signal line 522 may be provided on an axial end surface of inner cylinder member 462.

[0285] According to the present embodiment described above in detail, the following excellent effects can be obtained.

[0286] In the rotating electric machine 400, the stator core 432 is formed into a cylindrical shape by a plurality of split cores 435 arranged in the circumferential direction, and each of the split cores 435 is assembled to the stator holder 460. In this case, unlike a configuration in which the annular stator core 432 and the stator holder 460 are fitted and fixed by shrink fitting or press fitting, there is a concern that a gap between the stator core 432 and the stator holder 460 may cause rattling or a decrease in heat dissipation from the stator 430 side to the stator holder 460. In this regard, since each split core 435 is assembled to the stator holder 460 with a resin layer RS1 interposed between the stator holder 460 and each split core 435, inconveniences caused by the gap between the stator core 432 and the stator holder 460 can be suppressed. In particular, when using a stator 430 with a teethless structure, since the stator windings 431 are not engaged with the teeth of the stator core 432, there is concern that the stator core 432 (each divided core 435) may wobble, causing problems such as misalignment of the stator windings 431, but this prevents such problems from occurring. As a result, the stator core 432 can be properly assembled.

[0287] Since engagement portions (convex portion 436 and concave portion 477) that can engage in the circumferential direction are provided at the radially opposing portions of the stator holder 460 and the split cores 435, circumferential positional deviation of each split core 435 relative to the stator holder 460 can be suppressed.

[0288] Since the circumferential dimension of the split core 435 is set to be the same as the circumferential width of the partial windings 441A, 441B, assembly of the partial windings 441A, 441B to the split core 435 can be simplified.

[0289] By providing partial winding 441B across the boundaries between split cores 435 arranged in the circumferential direction, misalignment of each split core 435 at the boundaries between split cores 435 is less likely to occur. This allows each split core 435 to be appropriately assembled.

[0290] By configuring the partial windings 441 to include a partial winding 441A (first partial winding) whose transition portion is on the split core 435 side of the radial inside or outside, and a partial winding 441B (second partial winding) whose transition portion is on the opposite side of the split core 435 of the radial inside or outside, it is possible to suitably arrange each partial winding 441 without interfering with each other in the transition portions of the partial windings 441. Furthermore, of the partial windings 441A, 441B, the partial winding 441A whose transition portion is on the split core 435 side and which is assembled to the split core 435 first has both circumferential ends corresponding to both circumferential ends of the split core 435, which makes it easy to assemble each partial winding 441 to each split core 435 (stator core 432).

[0291] Partial windings 441A, 441B are fixed to split core 435 by recesses 437 (fixing portions) provided in split core 435. This allows split core 435 and partial windings 441A, 441B to be suitably assembled in stator 430 having a teethless structure.

[0292] By providing the insulating covers 451-454 on the transition portions of the partial windings 441A, 441B, mutual insulation can be suitably achieved even when the transition portions of the partial windings 441A, 441B are arranged to overlap each other in the circumferential direction. Also, by making the through holes 455b, 458b of the brackets 455, 458 in the insulating covers 451, 454 fixed portions that are fixed to the fixed portion on the split core 435 side, the insulating covers 451-454 can be provided with an insulating function of insulating the partial windings from each other and a function of fixing the partial windings 441A, 441B to the split core 435.

[0293] In the stator unit 420, an outer tube member 461 (cylindrical portion) of a stator holder 460 is provided on one side of a stator core 432 in the radial direction, and a stator winding 431 is provided on the other side. The partial windings 441A and 441B are fixed to through holes 491 of a coil end cover 490 integrated with the stator holder 460. In this case, the split core 435 is interposed between the outer tube member 461 of the stator holder 460 and each of the partial windings 441A and 441B, and is held in a sandwiched state between the two by fixing the two. This restricts the positional deviation of the split core 435, and allows the split core 435 to be properly assembled to the stator holder 460.

[0294] A resin layer RS1 is formed between the stator holder 460 and each divided core 435, and a resin layer RS2 is also formed between each divided core 435 and the partial windings 441A, 441B (stator winding 431). This allows heat generated in the stator winding 431 to be suitably transferred to the stator holder 460 side via each divided core 435, improving heat dissipation.

[0295] (Modification of the second embodiment) As shown in Fig. 63, one split core 435 may be provided for two partial windings 441A. Alternatively, one split core 435 may be provided for three or more partial windings 441A. However, the number of split cores 435 in the stator core 432 is two or more and is half or less than the number of partial windings 441A. With the above configuration, the partial windings 441 can be easily attached to the split cores 435.

[0296] Here, if the circumferential width of partial windings 441A, 441B is L, the circumferential dimension of stator core 432 is L×n (n is a natural number), and a divisor of "n" other than 1 and n is D, then the circumferential dimension of split core 435 is L×D. In this embodiment, the circumferential dimension of stator core 432 is L×18, and divisors D of "18" other than 1 and 18 are 2, 3, 6, and 9. In this case, in the configuration of FIG. 63, the circumferential dimension of split core 435 is "L×2".

[0297] The following configuration may be used as a method of fixing the split core 435 to the stator holder 460. Note that in the stator holder 460 and the split core 435 shown in Figures 64(a) to (c), the configuration related to the recessed and protruding engagement between them is omitted.

[0298] As shown in FIG. 64(a), a configuration may be adopted in which a fixing device 531 is attached between each of the split cores 435 adjacent in the circumferential direction with its tip portion inserted into the stator holder 460. The fixing device 531 is a member having a sharp tip and a wedge shape, and has a length dimension longer than the radial thickness dimension of the split cores 435. The fixing device 531 may be a needle-shaped member or a long plate-shaped member extending in the axial direction. The fixing device 531 is preferably made of a magnetic material, but may also be made of a non-magnetic material. According to this configuration, the circumferential position of each of the split cores 435 is regulated by the fixing device 531. This makes it possible to suppress the circumferential positional deviation of each of the split cores 435.

[0299] Alternatively, a pilot hole may be formed in advance in stator holder 460, and fastener 531 may be inserted into the pilot hole. It is sufficient that fastener 531 is used to fasten split cores 435 arranged in the circumferential direction at least at one location in the circumferential direction.

[0300] 64(b), the fixing device 531 may have an engagement portion that engages with a radial end face, more specifically, a circumferential end face on the opposite side to the holder, of each split core 435. This makes it possible to prevent the split cores 435 from being displaced radially.

[0301] As shown in Fig. 64(c), the fixing device 531 may be inserted into the circumferential middle portion of each split core 435. The fixing device 531 only needs to be provided on at least one of the split cores 435 lined up in the circumferential direction. This allows each split core 435 to be properly fixed. Note that it is also possible to omit the engaging portion of the fixing device 531 that engages with the radial end face of the split core 435 (more specifically, the circumferential end face on the opposite side to the holder).

[0302] As shown in Fig. 65(a), the split core 435 may have portions with different radial thicknesses. Specifically, the split core 435 has a protruding portion 438 with a large radial thickness at one axial end, and is assembled to the stator holder 460 with the protruding portion 438 extending to the opposite side of the stator holder 460. In this case, the axial length of the split core 435 is longer than the coil side portion, and the protruding portion 438 is arranged axially outward of the bridge portions of the partial windings 441A, 441B.

[0303] As described above, one axial end of split core 435 is provided with recess 437, and protruding portion 438 at the other axial end is provided with recess 439. These recesses 437, 439 correspond to fixing portions for fixing partial windings 441A, 441B, respectively.

[0304] As shown in FIG. 65(b), at one axial end of the split core 435, the bridge portions of the partial windings 441A, 441B are fixed using recesses 437, and at the other axial end of the split core 435, the bridge portions of the partial windings 441A, 441B are fixed using recesses 439 of the protrusions 438.

[0305] In the split core 435 shown in FIG. 65, the overhanging portion 438 and the other portions are formed by stacking different types of core sheets. That is, the split core 435 has the overhanging portion 438 as a portion facing the coil end portion of the partial windings 441A, 441B (stator winding 431) in the axial direction, and different types of core sheets are used for the overhanging portion 438 (coil end facing portion) and the other portions in the axial direction. In addition, the core sheets for the overhanging portion 438 and the other portions may be made of different materials. For example, the permeability and strength may be different from each other. In this case, the overhanging portion 438 may be a non-magnetic material. Alternatively, in the split core 435, the overhanging portion 438 may be stronger than the other portions. According to the above configuration, the split core 435 that is required to have a different shape in the axial direction (core sheet stacking direction) can be suitably realized.

[0306] The partial windings 441A and 441B of the stator winding 431 may have the following configuration.

[0307] 66(a) and (b), one of the partial windings 441A and 441B has a substantially C-shape in side view, and the other partial winding 441B has a substantially I-shape in side view. Of the partial windings 441A and 441B, the partial winding 441A whose transition portion is on the split core 435 side is pre-attached to the split core 435, and the partial winding 441B whose transition portion is on the opposite side of the split core 435 is post-attached to the split core 435. The partial winding 441A is a first partial winding whose transition portion is on the split core 435 side (radially inner side) of the radial inside and outside, and the partial winding 441B is a second partial winding whose transition portion is on the opposite side of the split core 435 (radially outer side) of the radial inside and outside.

[0308] 66(b), the transition portions of the partial windings 441A, 441B are fixed by fixing pins inserted into recesses 437 of the split core 435. In this configuration, recesses 437 are provided on both axial end faces of the split core 435, so that the transition portions at both axial ends of the partial windings 441A, 441B are fixed to the split core 435.

[0309] Alternatively, the crossover portions at both axial ends of the partial windings 441A, 441B may be fixed to the stator holder 460, that is, not directly fixed to the split core 435.

[0310] The partial windings 441A, 441B may be assembled to the respective divided cores 435 arranged in a cylindrical shape as shown in Fig. 67. In Fig. 67, the partial winding 441A is provided so as to straddle the boundary between the divided cores 435 arranged in the circumferential direction. The partial winding 441B is provided so that the boundary between the divided cores 435 arranged in the circumferential direction corresponds to the boundary between the partial windings 441B in the circumferential direction.

[0311] In the above embodiment, the stator winding 431 is configured to use a plurality of partial windings 441A, 441B, and the divided core 435 is provided corresponding to the partial winding 441A, but this may be changed. For example, the stator winding 431 may be wave-wound. In this case, it is preferable to arrange the plurality of divided cores 435 side by side in the cylindrical portion of the stator holder 460, and then assemble a wave-wound coil to the outer circumferential side of the divided cores 435.

[0312] In the above configuration, as shown in Fig. 47, the stator holder 460 and the coil end cover 490 are provided separately in the stator unit 420, and the coil end cover 490 is fixed to the stator holder 460 by fasteners such as fixing pins and screws, but this configuration may be modified. Specifically, as shown in Fig. 68, the coil end cover 497 is provided in a state of being integrated with the end plate portion 471 of the stator holder 460. In this case, the stator holder 460 is formed with a flange-shaped coil end cover 497 extending radially outward, and the coil end portions (transfer portions 443) of the partial windings 441A, 441B are fixed by the coil end cover 497.

[0313] In the second embodiment, the rotating electric machine 400 has an outer rotor structure, but this may be changed to an inner rotor structure. In an inner rotor structure rotating electric machine, the stator is provided on the radial outside and the rotor is provided on the radial inside. Even in this structure, the above-mentioned structure in which the stator core is formed by a plurality of split cores and the associated structure may be used as appropriate.

[0314] The rotating electric machine 400 may be used for purposes other than a motor for driving a vehicle, and may be a rotating electric machine used in a wide range of moving objects including aircraft, or a rotating electric machine used in industrial or household electrical equipment.

[0315] 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. [Explanation of symbols]

[0316] 400... rotating electric machine, 410... rotor, 430... stator, 431... stator winding, 432... stator core, 435... split core, 460... stator holder, RS1... resin layer.

Claims

1. A field element (410) having a plurality of magnetic poles; A toothless armature (430) including a polyphase armature winding (431) and an armature core (432) integrally provided on the radially inner side or the radially outer side of the armature winding; an armature holding member (460) attached to the radially inner or outer side of the armature core on the opposite side to the armature winding; A rotating electric machine (400) comprising: the field element and the armature are provided so as to face each other in a radial direction, The armature core is formed in a cylindrical shape by a plurality of divided cores (435) arranged in a circumferential direction, each of the split cores is assembled to the armature holding member with a resin layer (RS1) interposed between the armature holding member and each of the split cores; A rotating electric machine in which a fixing device (531) is attached to at least one location between each of the divided cores arranged in the circumferential direction with its tip end inserted into the armature holding member.

2. A field element (410) having a plurality of magnetic poles; A toothless armature (430) including a polyphase armature winding (431) and an armature core (432) integrally provided on the radially inner side or the radially outer side of the armature winding; an armature holding member (460) attached to the radially inner or outer side of the armature core on the opposite side to the armature winding; A rotating electric machine (400) comprising: the field element and the armature are provided so as to face each other in a radial direction, The armature core is formed in a cylindrical shape by a plurality of divided cores (435) arranged in a circumferential direction, each of the split cores is assembled to the armature holding member with a resin layer (RS1) interposed between the armature holding member and each of the split cores; A rotating electric machine in which a fixing device (531) is attached to a circumferential middle portion of at least one of the split cores arranged in the circumferential direction with its tip portion inserted into the armature holding member.

3. The armature winding has a phase winding consisting of a plurality of partial windings (441) for each phase, The partial windings each have a pair of intermediate conductor portions (442) spaced a predetermined distance apart in the circumferential direction, and transition portions (443, 444) that are provided at one and the other axial ends and connect the pair of intermediate conductor portions in an annular manner, and the intermediate conductor portions of different partial windings are arranged adjacent to each other in the circumferential direction, 3. The rotating electric machine according to claim 1, wherein the circumferential dimension of the split core is the same as the circumferential width L of the partial winding, or the circumferential dimension of the armature core is the circumferential width L x n, where D is a divisor of "n" other than 1 or n, and is L x D.

4. A field element (410) having a plurality of magnetic poles; A toothless armature (430) including a polyphase armature winding (431) and an armature core (432) integrally provided on the radially inner side or the radially outer side of the armature winding; an armature holding member (460) attached to the radially inner or outer side of the armature core on the opposite side to the armature winding; A rotating electric machine (400) comprising: the field element and the armature are provided so as to face each other in a radial direction, The armature core is formed in a cylindrical shape by a plurality of divided cores (435) arranged in a circumferential direction, each of the split cores is assembled to the armature holding member with a resin layer (RS1) interposed between the armature holding member and each of the split cores; The armature winding has a phase winding consisting of a plurality of partial windings (441) for each phase, The partial windings each have a pair of intermediate conductor portions (442) spaced a predetermined distance apart in the circumferential direction, and transition portions (443, 444) that are provided at one and the other axial ends and connect the pair of intermediate conductor portions in an annular manner, and the intermediate conductor portions of different partial windings are arranged adjacent to each other in the circumferential direction, A rotating electric machine in which the circumferential dimension of the split core is the same as the circumferential width L of the partial winding, or the circumferential dimension of the armature core is the circumferential width L x n, where D is a divisor of "n" other than 1 or n, and is L x D.

5. 5. The rotating electric machine according to claim 3, wherein the plurality of partial windings include a partial winding that is provided so as to straddle a boundary between two of the divided cores that are adjacent in the circumferential direction.

6. In the armature winding, one of the pair of intermediate conductor portions in the partial winding of another phase is disposed between the pair of intermediate conductor portions in the partial winding, and between the partial windings whose jumper portions overlap in the circumferential direction, the jumper portion of one partial winding is located on the radially inner side and the jumper portion of the other partial winding is located on the radially outer side, The plurality of partial windings include a first partial winding (441A) in which the transition portion is on the divided core side of the radial inside or outside, and a second partial winding (441B) in which the transition portion is on the opposite side of the divided core of the radial inside or outside, A rotating electric machine as described in any one of claims 3 to 5, wherein the first partial winding is arranged so that the boundary portions between the divided cores arranged in the circumferential direction correspond to the boundary portions between the first partial windings in the circumferential direction, and the second partial winding is arranged so as to straddle the boundary portions between the divided cores arranged in the circumferential direction.

7. The rotating electric machine according to any one of claims 3 to 6, wherein the split core is provided with fixing portions (437, 439) for fixing the partial windings.

8. Insulating members (451, 454) for insulating the partial windings from each other are attached to the transition portions of the partial windings, 8. The rotating electric machine according to claim 7, wherein the insulating member is provided with a fixed portion (455b, 458b) fixed to the fixed portion.

9. The rotating electric machine according to any one of claims 3 to 8, wherein the armature holding member has an opposing portion (490, 497) that faces the jumper portion of the partial winding, and a fixing portion (491) that fixes the partial winding is provided on the opposing portion.

10. The rotating electric machine according to any one of claims 1 to 9, wherein the armature holding member and the divided core are provided at their radially opposing portions with engaging portions (436, 477) that are engageable in the circumferential direction.

11. The rotating electric machine according to any one of claims 1 to 10, wherein the split core is formed by stacking a plurality of core sheets in the axial direction, and two or more types of the core sheets are stacked together.

12. The rotating electric machine according to any one of claims 1 to 11, wherein each of the split cores arranged in the circumferential direction has an overlapping portion (OL) at a circumferential end portion where the split cores overlap each other in the radial direction.

13. The split core is formed by stacking a plurality of core sheets in the axial direction, The core sheets are laminated in a state including a circumferential misalignment, so that a step is formed on the circumferential end surface of the split core, 13. The rotating electric machine according to claim 1, wherein each of the split cores arranged in the circumferential direction is assembled to the armature holding member in a state in which steps on the circumferential end faces of the split cores are engaged with each other.

14. The rotating electric machine according to any one of claims 1 to 13, further comprising a second resin layer (RS2) provided between each of the split cores and the armature winding.

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