Rotating Electric Machine

Abstract

To provide a rotary electric machine capable of reducing eddy current loss.SOLUTION: A rotary electric machine includes a stator 60 having a polyphase stator winding 61. The stator winding 61 is constituted by being wound by a conductor material CR and has an intermediate conductor unit 152 arranged at a predetermined interval in a circumferential direction at a position opposed to a magnet unit. The intermediate conductor portion 152 is formed by conductor material CR being arranged in one or a plurality of rows in a circumferential direction and arranged in one or a plurality of rows in a radial direction. Each of the conductor materials CR is covered with an insulating coating film 602 in a state in which a plurality of element wires 601a to 601d are laminated in the circumferential direction. Each of the conductor materials CR is constituted by each of the element wires 601a to 601d being connected in parallel. Each of the element wires 601a to 601d has a cross section of a long flat shape in the radial direction.SELECTED DRAWING: Figure 41

Description

[Technical field]

[0001] The present invention relates to a rotating electric machine. [Background technology]

[0002] Conventionally, as described in, for example, Patent Document 1, a rotating electric machine is known that includes a field element including a magnet portion having multiple magnetic poles with alternating polarities in the circumferential direction, and an armature having a multi-phase armature winding. This rotating electric machine employs a slotless structure to eliminate limitations due to magnetic saturation occurring in the teeth of the stator core, and employs polar anisotropic magnets to improve magnetic flux density. This makes it possible to appropriately improve output torque while eliminating limitations due to magnetic saturation. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-106864 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the above rotating electric machine, the larger the cross-sectional area of ​​the conductor is made in order to improve the space factor, which indicates the ratio of the conductor through which current flows to the space in which the armature winding is housed, the greater the eddy current loss increases when the magnetic flux from the magnet interlinks with the conductor. In particular, when a slotless structure is adopted and polar anisotropic magnets are used, the eddy current loss is likely to increase.

[0005] The present invention has been made in consideration of the above circumstances, and has as its main object to provide a rotating electric machine capable of reducing eddy current loss. [Means for solving the problem]

[0006] The various aspects disclosed in this specification employ 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 accompanying drawings.

[0007] A first means for solving the above problem is a rotating electric machine comprising a field element including a magnet section having a plurality of magnetic poles whose polarity alternates in the circumferential direction, and an armature having a multi-phase armature winding, in which either the field element or the armature is a rotor, the armature winding of each phase is formed by winding a conductor wire, and has conductor wire sections arranged at predetermined intervals in the circumferential direction at positions facing the magnet section, each conductor wire section is formed by arranging the conductor wire in one or more rows in the circumferential direction and in one or more rows in the radial direction, each conductor wire is formed by covering a plurality of strands with an insulating coating in a circumferentially stacked state, each conductor wire is formed by connecting the strands constituting the conductor wire in parallel, and each strand has a cross-section that is flat and elongated in the radial direction.

[0008] In the above configuration, each wire has a cross section that is long and flat in the radial direction, which makes it possible to suppress eddy currents. Also, by making the wires long and flat in the radial direction, it is possible to reduce radial gaps within the wire, i.e., gaps between conductors or between the insulating coating and the conductor, and improve the space factor of the conductor.

[0009] In addition, in the above configuration, the cross section of each wire is a flat shape that is long in the radial direction, which enhances the effect of reducing the circulating current. In other words, the amount of magnetic flux changes depending on the circumferential position of the magnet section. Therefore, as the rotor rotates, the amount of magnetic flux that links with each wire of each conductor changes, and a difference occurs in the electromotive voltage generated in each wire at a certain timing. Here, in Means 1, the cross section of each wire is a flat shape that is long in the radial direction. Therefore, in each conductor, the width dimension in the circumferential direction of the multiple wires arranged side by side can be reduced. As a result, the difference in electromotive voltage generated in each wire at a certain timing can be reduced in each conductor. This makes it possible to reduce the difference in electromotive voltage generated in the wires that make up the conductor, and reduce the circulating current.

[0010] The second means is the first means, wherein the wire has a cross section with a flat shape that is long in the radial direction, and comprises a conductor through which current flows and a fusion layer covering the surface of the conductor, the fusion layer being thinner than the insulating coating, and when multiple wires are stacked in the circumferential direction, the fusion layers come into contact with each other and are fused together.

[0011] The wires are insulated from each other by an insulating coating. On the other hand, the conductors of the wires are covered with a fusion layer, but since there is no insulating layer, the conductors may come into contact with each other and become conductive. However, the potential difference between the conductors is small, and even if the fusion layer is broken when bundling multiple wires or covering the insulating coating, the contact area between the conductors is very small and the contact resistance is very large. Therefore, even if the conductors are not completely insulated, it is possible to suppress the flow of eddy currents between the conductors.

[0012] Therefore, instead of providing an insulating layer on the surface of the conductor, a fusion layer is provided directly on the conductor and the fusion layers are fused together. This eliminates the need to provide an insulating layer. Furthermore, providing a fusion layer makes it easier to keep multiple strands bundled together and to cover them with an insulating coating. As a result, it becomes easier to manufacture the conductor and the rotating electric machine. Furthermore, since the insulating layer for the strands is omitted, the space factor of the conductor can be improved.

[0013] A third aspect is the first or second aspect, wherein in each of the conductors, the wires are arranged in only one layer in the radial direction.

[0014] In each conductor, the strands are arranged in one layer in the radial direction. Therefore, unlike a configuration in which the strands of each conductor are layered in the radial direction, no difference in electromotive force occurs due to differences in the radial arrangement positions of the strands. This makes it possible to reduce the difference in electromotive force generated in the core strands that make up the conductor, and to reduce the circulating current flowing through the armature winding.

[0015] Furthermore, by using only one layer, gaps between the conductors in the radial direction within the insulating coating can be eliminated compared to the case where multiple layers are used, which means that the space factor of the conductors can be improved.

[0016] The fourth means is any one of the first to third means, wherein the magnet portion is oriented so that the axis of easy magnetization is parallel to the d-axis on the side of the d-axis which is the magnetic pole center compared to the side of the q-axis which is the magnetic pole boundary, and a magnetic flux path is formed along the axis of easy magnetization.

[0017] With the above configuration, the closer to the d-axis, the more likely the magnetic flux density is to be parallel to the radial direction. In other words, the closer to the d-axis, the more likely the radial component of the magnetic flux density is to be large, while the circumferential component is to be small. This makes it possible to more effectively suppress eddy current loss by reducing the thickness dimension in the circumferential direction.

[0018] The fifth means is any one of the first to third means, wherein the magnet portion has a first magnet portion arranged radially inside the conductor portion so as to face the conductor portion, and a second magnet portion arranged radially outside the conductor portion so as to face the conductor portion, and the magnetic poles of the first magnet portion and the magnetic poles of the second magnet portion radially opposite the magnetic poles of the first magnet portion are different on the d-axis which is the magnetic pole center.

[0019] With the above configuration, the magnetic flux density in the d-axis tends to be parallel to the radial direction. In other words, the radial component of the magnetic flux density tends to be large, while the circumferential component tends to be small. This makes it possible to more effectively suppress eddy current loss by reducing the thickness dimension in the circumferential direction. [Brief description of the drawings]

[0020] [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. [Figure 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 diagram showing a configuration of a first coil module according to a second modified example. [Diagram 42] FIG. 7 is a cross-sectional view of a conductive wire according to a second modified example. [Diagram 43] FIG. 11 is a side view of the conductive wire of the second modified example. [Diagram 44] FIG. 11 is a diagram showing a connection state of wires in Modification 2. [Diagram 45] 4 is a flowchart showing a manufacturing method of the stator winding. [Figure 46] FIG. 2 is a diagram showing an image of the manufacturing process of a stator winding. [Figure 47] FIG. 11 is a cross-sectional view of a magnet unit according to another embodiment. [Figure 48] FIG. 11 is a cross-sectional view of a stator and a magnet unit according to another embodiment. [Figure 49] 10 is a flowchart showing another example of a method for manufacturing a stator winding. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] A number of embodiments will be described with reference to the drawings. In a number of embodiments, functionally and / or structurally corresponding and / or associated parts may be given the same reference numerals or reference numerals with different digits in the hundredths or more. For corresponding and / or associated parts, reference may be made to the description of other embodiments.

[0022] 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, 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.

[0023] (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.

[0024] 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.

[0025] 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."

[0026] 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.

[0027] 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".

[0028] 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.

[0029] 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.

[0030] The radially inner peripheral surface of the magnet 32 ​​is the magnetic flux action surface 34 where magnetic flux is exchanged. In the magnet 32, the direction of the magnetization easy axis differs between the d-axis side (part closer to the d-axis) and the q-axis side (part closer to the q-axis), with the magnetization easy axis on the d-axis side being parallel to the d-axis and the magnetization easy axis on the q-axis side being 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 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 3, a resolver 41 serving as a rotation sensor is provided on one of both axial ends of the rotating shaft 11 opposite the joint with the rotor carrier 21 (the upper end in the figure). The resolver 41 includes a resolver rotor fixed to the rotating shaft 11, and a resolver stator disposed radially outside the resolver rotor to face it. The resolver rotor is in the shape of a disk ring, and is provided coaxially with the rotating shaft 11 with the rotating shaft 11 inserted therethrough. The resolver stator has a stator core and a stator coil, and is fixed to the housing cover 242.

[0040] 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.

[0041] 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".

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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).

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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).

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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."

[0066] 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.

[0067] Next, the configuration of the coil modules 150A and 150B will be described in detail.

[0068] 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).

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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."

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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).

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] Next, the configuration of the insulating covers 161 and 162 will be described.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] Next, the second coil module 150B will be described.

[0091] 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).

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] Next, the configuration of the insulating covers 163, 164 will be described.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] Next, a configuration for assembling the coil modules 150A, 150B to the core assembly CA will be described.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] Next, the bus bar module 200 will be described.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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, a protrusion 201a extending in an annular shape is provided.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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).

[0138] Next, the relay member 230 that electrically connects the input / output terminal 203 of the bus bar module 200 to an external device of the rotating electric machine 10 will be described.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] FIG. 36 is a block diagram showing a current feedback control process for controlling the currents of the U, V, and W phases.

[0151] 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.

[0152] 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.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] FIG. 37 is a block diagram showing a torque feedback control process corresponding to the U, V, and W phases.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] (Modification) Modifications to the above embodiment will be described below.

[0164] The configuration of the magnets in the magnet unit 22 may be changed as follows. In the magnet unit 22 shown in Fig. 38, the magnet easy axis of the magnet 32 ​​is oriented obliquely relative to the radial direction, and a linear magnet magnetic path is formed along the direction of the magnet easy axis. Even in this configuration, the magnet magnetic path length of the magnet 32 ​​can be made longer than the radial thickness dimension, making it possible to improve permeance.

[0165] It is also possible to use a Halbach array magnet in the magnet unit 22.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] The rotating electric machine is not limited to one with star connection, and may be one with delta connection.

[0178] 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.

[0179] (Variation 2) In the above embodiment or the above modified example, the configuration of the conductor wire CR as a conductor may be as follows. The configuration of the conductor wire CR in this modified example will be mainly described in detail below. Note that in this modified example, differences from the configurations described in the above embodiments and modified examples will be mainly described. Also, in this modified example, the basic configuration of the rotating electric machine 10 will be described using the first embodiment as an example.

[0180] In the above embodiment, the stator 60 has a slotless structure (see FIG. 4, etc.), and the magnet unit 22 has polar anisotropic magnets 32 that improve the magnetic flux density in the d-axis (see FIG. 7). For this reason, it is expected that the amount of magnetic flux linking each conductor CR will increase, and as a result, eddy current loss will increase. Therefore, in the second modification, the following configuration is adopted.

[0181] Fig. 41(a) shows a cross-sectional view of the intermediate conductor portion 152 of the first coil module 150A in Modification 2, and Fig. 41(b) shows an enlarged cross-sectional view of a portion of the intermediate conductor portion 152 in Fig. 41(a). Fig. 42 shows an enlarged cross-sectional view of the conductor wire material CR. Note that in Modification 2, the conductor wire material CR will be described using the first coil module 150A as an example, but the conductor wire material CR of the second coil module 150B is similar.

[0182] 41 and 42, in Modification 2, the cross section of the conductor wire CR is substantially rectangular. The conductor wire CR is wound so as to be stacked in the circumferential and radial directions to form an intermediate conductor portion 152 of the first coil module 150A.

[0183] Each conductor wire CR is configured by bundling a plurality of wires 601 and covering them with an insulating coating 602. This ensures insulation between the conductor wires CR overlapping each other in the circumferential or radial direction, and between the conductor wires CR and the stator core 62.

[0184] Stator winding 61 made of conductive wire CR has its insulation maintained by insulating coating 602, except for exposed portions for connection. The exposed portions are winding ends 154, 155, for example.

[0185] The wire 601 includes a conductor 603 through which a current flows, and a fusion layer 604 that covers the surface of the conductor 603. The conductor 603 is, for example, a conductive metal such as copper. The conductor 603 is a rectangular wire with a square cross section. In this second modification, the cross section of the conductor 603 is a flattened rectangle whose radial thickness is longer than its circumferential thickness. The fusion layer 604 is, for example, an epoxy adhesive resin. It has a heat resistance of about 150°C.

[0186] The fusion layer 604 is thinner than the insulating coating 602, and has a thickness of, for example, 10 μm or less. In the wire 601, only the fusion layer 604 is formed on the surface of the conductor 603, and no separate insulating layer is provided. The fusion layer 604 may be made of an insulating material. In other words, the idea is to combine the resin and insulation of the self-bonding wire. The insulating layer and the fusion layer are usually separate, but the epoxy adhesive resin that corresponds to the fusion layer 604 also functions as an insulating layer, and what is usually called an insulating layer is missing.

[0187] The fusion layer 604 also has the characteristics of melting at a lower temperature than the insulating coating 602, and having a high dielectric constant. The characteristic of melting at a low temperature has the effect of facilitating electrical continuity at the ends of the wires 601. Also, fusing is easy to perform. Another reason why a high dielectric constant is acceptable is that there is a prerequisite that the potential difference between the wires 601 is smaller than between the conductors CR. By setting it in this way, even if the fusion layer 604 melts, the eddy current loss can be effectively reduced by the contact resistance alone.

[0188] The fusion layer 604 covers the surface of the conductor 603 so that the thickness dimension is approximately uniform, and therefore the cross-sectional shape of the wire 601 is a flattened rectangle whose radial thickness dimension is longer than its circumferential thickness dimension, in accordance with the cross-sectional shape of the conductor 603.

[0189] When the plurality of wires 601 are bundled, as shown in Fig. 41(b) and Fig. 42, the wires 601 are stacked in the circumferential direction. Meanwhile, the wires 601 are arranged in only one layer in the radial direction. That is, the conductor wire material CR is composed of a plurality of wires 601a-601d (four in this second modification) arranged in one layer in the radial direction. In this modification, for convenience, the conductor wire material CR etc. are shown linearly developed in Fig. 42. In this manner, the wires 601a-601d are arranged side by side in the circumferential direction.

[0190] When the wires 601 are bundled, the fusion layers 604 are in contact with each other and fused. This fixes the adjacent wires 601 to each other, suppressing vibrations and noise caused by the wires 601 rubbing against each other. Furthermore, by bundling and assembling the wires 601 each having the fusion layers 604 and fusing the fusion layers 604 to each other, the shape is maintained. Furthermore, the layered state of the wires 601 is maintained.

[0191] The insulating coating 602 is made of resin, for example, modified PI enamel resin with heat resistance of 220°C to 240°C. The use of modified PI provides oil resistance. It is protected from hydrolysis and sulfur attack by ATF and the like. In this case, the linear expansion coefficient of the epoxy adhesive resin is larger than that of the modified PI enamel resin.

[0192] This insulating coating 602 is formed in a wide tape shape, and is wound in a spiral shape around the outer circumference of the bundled wires 601. As shown in Fig. 43, the insulating coating 602 is wound in a spiral shape, shifted slightly in the extension direction of the wires 601 (left and right direction in Fig. 43) so that the insulating coatings 602 overlap each other. Specifically, the insulating coatings 602 are wound so as to overlap by about half the width of the insulating coating 602. In this way, the insulating coating 602 is configured to be double-layered everywhere except the end parts. It is not necessarily required to have double layers, and it may be triple or more layers. Also, it may be single-layered as long as no gaps are created.

[0193] This insulating coating 602 has higher insulating performance than the fusion layer 604 of the wire 601, and is configured to provide insulation between phases. For example, if the thickness of the fusion layer 604 of the wire 601 is about 1 μm, it is desirable to set the total thickness of the insulating coating 602 to about 9 μm to 50 μm so that insulation between phases can be suitably achieved. Specifically, if the insulating coating 602 is doubled, the thickness of each layer may be about 5 μm.

[0194] 44 shows an electrical connection state of a plurality of strands 601a-601d constituting the conductor wire material CR. The stator winding 61 is formed by winding the conductor wire material CR, and is connected to another stator winding 61 or a neutral point at winding ends 154, 155 of the conductor wire material CR. Therefore, the plurality of strands 601a-601d constituting the conductor wire material CR are connected in parallel with each other.

[0195] Next, a method for manufacturing the rotating electric machine 10, more specifically, the stator winding 61, will be described with reference to Fig. 45. Fig. 45 is a flow chart showing the flow of the manufacturing method, and Fig. 46 is an image diagram of the manufacturing line.

[0196] From a plurality of cylindrical bobbins 701 (reels) around which linear conductors 603 are wound, the conductors 603 are pulled out and coated with adhesive layer 604 on their surfaces (step S101). Alternatively, the wire 601 on which the conductors 603 are coated with adhesive layer 604 may be wound around the bobbin 701 in advance and stored, and the wire 601 may be pulled out from the bobbin 701.

[0197] Then, the wires 601 are bundled and assembled (step S102). At this time, the fusion layers are brought into contact with each other and fused. In step S102, tension is applied to each wire 601 to make it straight. Note that the wires may be straightened before being assembled (before step S102). This step S102 is the assembly process.

[0198] On the other hand, the wide tape-like insulating coating 602 is rolled to make it thinner (step S103). The rolling process hardens the insulating coating 602, and the tensile strength of the insulating coating 602 is improved compared to before the rolling. This step S103 is the rolling process.

[0199] Thereafter (after steps S102 and S103), a rolled tape-shaped insulating coating 602 is wound spirally around the outer periphery of the bundled wires 601 to cover the outer periphery (step S104). Step S104 is the covering step. Then, with the wires 601 covered with the insulating coating 602, a crushing step is performed (step S105) so that the cross section has a predetermined shape (e.g., rectangular). In this way, the conductor wire CR is formed. The crushing step may be performed after the gathering step of bundling the wires 601.

[0200] Then, as explained in the first embodiment, the conductor wire CR is wound to form the stator winding 61 (step S106). For example, the conductor wire CR is wound around the stator winding bobbin 702 to form the stator winding 61. Step S106 is the winding process. Note that the straightness of the wire 601 is maintained from when the wire 601 is made straight until it is wound to form the stator winding 61 (steps S102 to S106). In other words, the production line is configured so that the wire CR is not wound again around a cylindrical bobbin after it is formed.

[0201] The configuration in the above-described modified example 2 has the following advantages.

[0202] The magnet unit 22 is oriented such that the axis of easy magnetization is parallel to the d-axis on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary. This makes it easier for the magnetic flux density to be parallel to the radial direction as it approaches the d-axis. In other words, the radial component of the magnetic flux density tends to increase while the circumferential component tends to decrease as it approaches the d-axis. Therefore, by reducing the circumferential thickness dimension of the wire 601, eddy current loss can be effectively suppressed.

[0203] Further, the cross section of each of the wires 601a to 601d has a flat shape elongated in the radial direction, which enhances the effect of reducing the circulating current. That is, the amount of magnetic flux changes according to the circumferential position of the magnet unit 22. Therefore, as the rotor 20 rotates, the amount of magnetic flux linking each of the wires 601a to 601d of each of the conductor wires CR changes, and a difference occurs in the electromotive voltage generated in each of the wires 601a to 601d at a certain timing. Here, in the above-mentioned modified example 2, the cross section of each of the wires 601a to 601d has a flat shape elongated in the radial direction. Therefore, in each of the conductor wires CR, the width dimension in the circumferential direction of the plurality of wires 601a to 601d arranged side by side can be reduced. As a result, in each of the conductor wires CR, the difference in the electromotive voltage generated in each of the wires 601a to 601d at a certain timing can be reduced. This makes it possible to reduce the difference in the electromotive voltage generated in the wires 601a to 601d constituting the conductor wire CR, and to reduce the circulating current.

[0204] In addition, by making it flat and elongated in the radial direction, the radial gaps within the conductive wire CR, i.e., the gaps between the conductors 603 or between the insulating coating 602 and the conductor 603, can be reduced, thereby improving the space factor of the conductor 603.

[0205] The conductive wires CR are insulated from each other by an insulating coating 602. On the other hand, the conductors 603 of the strands 601a to 601d are covered with a fusion layer 604, but since no insulating layer is provided, the conductors 603 may come into contact with each other and become conductive. However, the potential difference between the conductors 603 is small, and even if the fusion layer 604 is broken when bundling the strands 601a to 601d or covering the insulating coating 602, the contact area between the conductors 603 is very small and the contact resistance is very large. Therefore, even if the conductors 603 are not completely insulated, it is possible to suppress the flow of eddy current between the conductors 603.

[0206] Therefore, instead of providing an insulating layer on the surface of the conductor 603, a fusion layer 604 is provided directly on the conductor 603, and the fusion layers 604 are fused together. This eliminates the need to provide an insulating layer. Furthermore, by providing the fusion layer 604, the wires 601a-601d can be easily kept bundled together and can be easily covered with the insulating coating 602. As a result, the conductor wire CR and the rotating electric machine 10 can be easily manufactured. Furthermore, since the insulating layer of the wires 601a-601d is omitted, the space factor of the conductor 603 can be improved.

[0207] In each conductor CR, the wires 601a-601d are arranged in one layer in the radial direction. Therefore, unlike a configuration in which the wires 601a-601d of each conductor CR are layered in the radial direction, no difference in electromotive voltage occurs due to differences in the radial arrangement positions of the wires 601a-601d. This makes it possible to reduce the difference in electromotive voltage generated in the wires 601a-601d constituting the conductor CR, and to reduce the circulating current flowing through the conductor CR.

[0208] Moreover, by using only one layer, gaps between the conductors 603 in the radial direction can be eliminated in the insulating coating 602, compared to the case of using multiple layers. That is, the space factor of the conductor 603 can be improved. Also, the wires 601 of the conductor material CR are arranged in one layer in the radial direction. Therefore, unlike a configuration in which the wires 601 of the conductor material CR are laminated in multiple layers in the radial direction, no difference in electromotive voltage occurs due to differences in the arrangement positions of the wires 601 in the radial direction. That is, although the amount of magnetic flux generally differs depending on the radial position, in the above configuration, no difference in electromotive voltage occurs due to differences in the arrangement positions of the wires 601 in the radial direction. This makes it possible to reduce differences in electromotive voltages generated in the wires 601a to 601d, and to reduce circulating currents.

[0209] Insulating coating 602 is formed in a tape shape and is wound in a spiral shape around the outer circumference of the bundled wires 601. Since tape-shaped insulating coating 602 is wound around the wires 601 to form the conductor wire material CR, it is possible to make insulating coating 602 thinner than when the wires 601 are resin-molded. In addition, since wires 601 are fused by fusion layer 604, the shape of the bundled wires can be maintained, and tape-shaped insulating coating 602 can be easily wound.

[0210] Unlike the conventional process of applying a coating by extrusion, the insulating coating 602 is rolled, and therefore can be thinned and work-hardened. Therefore, when the conductor wire CR is wound to form the stator winding 61, the insulating coating 602 will not break. In other words, when the divided strands 601 are bent, they move irregularly and tend to break the insulating coating 602. This force, which is specific to a divided wire, can be borne by the insulating coating 602, which is a strengthened tape. Note that when the coating is applied by extrusion, there is a risk of it cracking. In addition, since the insulating coating 602 can be thinned, the space factor of the conductor 603 relative to the space in which the stator winding 61 is accommodated can be improved.

[0211] In the covering process of step S104, when the insulating coating 602 is wound around the outer periphery of the bundled wires 601, the insulating coating 602 is wound in a spiral shape so that the insulating coating 602 overlaps. This makes it possible to prevent foreign matter such as dust and water from reaching the wires 601 from the outside through gaps between the insulating coatings 602. In addition, since the insulating coatings 602 are overlapped, gaps are unlikely to be formed even when the stator winding 61 is formed by winding the conductive wire material CR. Also, electrodeposition or enamel coating cannot be performed well in the gaps between the wires 601, which results in the formation of air bubbles, but this problem can be solved by using the tape-shaped insulating coating 602.

[0212] When the conductor wire CR wound around a bobbin is used after it is formed (after the covering process), the conductor wire CR drawn out from the bobbin bends and a slight deviation in straightness occurs, which hinders the improvement of the space factor. In other words, when the conductor wire CR is wound around a bobbin, there is a problem specific to a split wire in that the wire inside the bobbin and the wire outside the bobbin have different elongations. Specifically, only the wire outside the bobbin is in an elongated state. Then, when the conductor wire CR that has only been stretched on the outside is drawn out from the bobbin to form the stator winding 61, the conductor wire CR becomes wavy because a portion of it is in a shrunk state. When it is wound to form the stator winding 61, gaps are generated between the conductor wires CR, which hinders the increase in the space factor and increases copper loss.

[0213] Therefore, in the gathering step of step S101, pressure is applied to the multiple strands 601 in a bundled state to straighten them, and each strand 601 is maintained in a straight state from the gathering step until the conductor wire material CR is wound in the winding step of step S106 to form the stator winding 61. This improves the straightness of the conductor wire material CR compared to the case where the conductor wire material CR is wound again around a cylindrical bobbin. That is, when the conductor wire material CR is wound around the bobbin, the straightness of the conductor wire material CR is less likely to deviate and the conductor wire material CR is less likely to become wavy due to the difference in curvature between the outer peripheral side and the inner peripheral side. Therefore, when the conductor wire material CR is wound to form the stator winding 61, gaps are less likely to be formed between the conductor wire material CR, and the space factor can be improved.

[0214] The first coil module 150A has a shape in which the partial winding 151 is bent radially inward at the coil end CE, i.e., toward the stator core 62. However, as described above, the insulating coating 602 is rolled to improve its tensile strength, making it less likely to break and allowing for proper insulation. In addition, by bending the coil end CE in the radial direction, the axial length of the stator winding 61 can be reduced.

[0215] The thickness of the insulating coating 602 is made thicker than that of the fusion layer 604. This ensures the necessary intra-phase and inter-phase withstand voltages and prevents eddy current loss without increasing copper loss. Copper loss occurs when the area of ​​copper decreases due to an increase in the coating.

[0216] When the magnet unit 22 is configured as described above, the orientation of the magnets 32 makes it easier for the magnetic flux to escape straight in the radial direction, reducing the amount of magnetic flux in the lateral direction. In other words, since less magnetic flux escapes in the circumferential direction, it is no longer necessary to make the wire 601 thinner in the circumferential direction than necessary. The wire 601 is covered with a thin fusion layer 604, which increases the occupancy rate of the conductor 603.

[0217] (Another example of Modification 2) The configuration in the above-mentioned modified example 2 may be modified as described below. In this other example, differences from the configurations described in the above-mentioned embodiments and modified examples will be mainly described. In addition, in this modified example, the basic configuration will be described using the modified example 2 as an example.

[0218] In the magnet 32 ​​of the above-mentioned modified example 2, as shown in FIG. 47, a plurality of arc-shaped magnetization easy axes may be oriented with the center of orientation C10 set on the q-axis as the center, and a magnetic flux path may be formed along the magnetization easy axes. Among these plurality of arc-shaped magnetization easy axes, there is included a magnetic flux easy axis on an arc OA that is centered on the center of orientation C10 set on the q-axis and passes through a first intersection P1 between the d-axis side end and the stator side peripheral surface (magnetic flux action surface 34). The shape of the magnetic flux path may be an arc shape that is a part of a perfect circle, or an arc shape that is a part of an ellipse. In addition, the center of orientation C10 is set on the q-axis, but it does not have to be on the q-axis. However, it is preferable that the center of orientation C10 is closer to the q-axis than the d-axis. In addition, in FIG. 47, the center of orientation C10 is set between the magnet 32 ​​and the stator winding 61, but it may be provided on the opposite side of the stator (the magnet holder 31 side) from the stator side peripheral surface (magnetic flux action surface 34).

[0219] The tangent Tn1 at the first intersection point P1 may be set to be parallel to the d-axis, or the tangent at the first intersection point P1 on the arc OA may be set to have a predetermined orientation inclination angle θ10 with respect to the d-axis as shown in Fig. 47. To explain in more detail, the axis of easy magnetization of the magnet 32 ​​may be aligned to have an inclination angle within a predetermined angle range (for example, 15° to 45° [deg]) with respect to the d-axis at least at the d-axis side end and the first intersection point P1 on the stator side peripheral surface.

[0220] In addition, it has been found that by tilting multiple easy magnetization axes to a certain extent, compared to when the easy magnetization axes are parallel to the d-axis, the vectors of the magnetic flux flowing out from the stator side peripheral surface (magnetic flux action surface 34) are concentrated on the d-axis, improving the magnetic flux density on the d-axis.

[0221] However, if the axis of easy magnetization is tilted too far beyond a certain point, the radial vector component of the magnetic flux flowing out from the stator side peripheral surface (magnetic flux action surface 34) becomes too small, and the magnetic flux density on the d axis decreases. For this reason, it is desirable to set the orientation tilt angle within a predetermined angle range, taking into consideration the shape of magnet 32, the size of the air gap, etc., so that the magnetic flux density on the d axis is at least larger than when it is parallel to the d axis.

[0222] In the second modification, in order to increase the linear force of the magnetic flux density of the magnet 32, the magnet 32 ​​may be used in a dual rotor type rotating electric machine in which the stator winding 61 is sandwiched between the magnets 32. Specifically, as shown in FIG. 48, in a dual rotor type rotating electric machine 10, the magnet unit 22 has a first magnet portion 501 arranged on the radial inside of the intermediate conductor portion 152 so as to face the intermediate conductor portion 152, and a second magnet portion 502 arranged on the radial outside of the intermediate conductor portion 152 so as to face the intermediate conductor portion 152. Both the first magnet portion 501 and the second magnet portion 502 are configured in an annular shape, and the first magnet portion 501 is configured to have a smaller diameter than the second magnet portion 502. Both the first magnet portion 501 and the second magnet portion 502 have multiple magnetic poles whose polarities alternate in the circumferential direction. The first magnet portion 501 and the second magnet portion 502 are arranged to sandwich the intermediate conductor portion 152 in the radial direction. At this time, a predetermined air gap is formed between the first magnet portion 501 and the intermediate conductor portion 152, and between the second magnet portion 502 and the intermediate conductor portion 152.

[0223] The magnetic poles of the first magnet portion 501 and the magnetic poles of the second magnet portion 502 that face the magnetic poles of the first magnet portion 501 in the radial direction are set to be different on the d-axis. That is, the N pole of the first magnet portion 501 and the S pole of the second magnet portion 502 are arranged to face each other in the radial direction, and the S pole of the first magnet portion 501 and the N pole of the second magnet portion 502 are arranged to face each other in the radial direction.

[0224] With this configuration, the magnetic flux density in the d-axis tends to be parallel to the radial direction. In other words, the radial component of the magnetic flux density tends to be large, while the circumferential component tends to be small. As a result, as shown in FIG. 48(b), the eddy current loss can be more effectively suppressed by reducing the circumferential thickness of the conductor 603.

[0225] In the above-mentioned modification 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 604 may be different from that of the insulating coating 602. That is, as described above, the potential difference between the conductors 603 is small, and even if the fusion layer 604 is broken when bundling the multiple strands 601 or covering the insulating coating 602, the contact area between the conductors 603 is very small and the contact resistance is very large. Therefore, even if the conductors 603 are not completely insulated, it is possible to suppress the flow of eddy current between the conductors 603. It can also be said that there is no problem even if the fusion layer 604 is broken and the conductors 603 come into contact with each other after manufacturing. Therefore, any material having a linear expansion coefficient different from that of the insulating coating 602 can be selected as the fusion layer 604, which makes it easy to design. For example, the linear expansion coefficient of the fusion layer 604 may be larger than that of the insulating coating 602.

[0226] Naturally, the linear expansion coefficient of the bonding layer 604 may be made smaller than that of the insulating coating 602. If the linear expansion coefficient is made smaller, the bonding layer 604 becomes less likely to break, the number of contact points between the conductors 603 does not increase, and an increase in eddy current loss can be suppressed.

[0227] In the above-described second modification, the linear expansion coefficient (linear expansion rate) of the bonding layer 604 may be set to be the same as the linear expansion coefficient of the insulating coating 602. This makes it possible to prevent the bonding layer 604 and the insulating coating 602 from cracking at the same time.

[0228] In the above-described modification 2, the linear expansion coefficient (linear expansion rate) of the fusion layer 604 may be different from that of the conductor 603. When the linear expansion coefficient (linear expansion rate) of the fusion layer 604 is between the linear expansion coefficient of the conductor 603 and the linear expansion coefficient of the insulating coating 602, the fusion layer 604 acts as a cushion and can prevent the insulating coating 602 from cracking.

[0229] PA, PI, PAI, PEEK, etc. may be used as the insulating coating 602 of the above-mentioned modified example 2. Also, fluorine, polycarbonate, silicon, epoxy, polyethylene naphthalate, LCP may be used as the adhesive layer 604.

[0230] In the above-mentioned modification 2, the cross-sectional shape of the conductor 603 does not have to be rectangular as long as it is a flat shape long in the radial direction, and may be, for example, an elliptical shape or a polygonal shape. The cross-sectional shape of the conductive wire material CR may also be any of hexagonal, pentagonal, quadrangular, triangular, and round.

[0231] In the above-mentioned modification 2, the crushing step is provided, but if the conductor 603 has a flat rectangular shape and can be bundled without gaps, the crushing step may be omitted. If the conductor 603 is a round wire, it is preferable to provide the crushing step. The crushing step may be performed after bundling the wires 601, but it may also be performed before bundling the wires 601 so that the cross-sectional shape of each wire 601 has a predetermined shape.

[0232] In the above-mentioned modification 2, a gap may be provided between the insulating coating 602 and the wire 601, or between the wires. Also, the shapes of the conductors 603 and the fusion layers 604 do not all need to be the same, and some or all of the conductors 603 or the fusion layers 604 may have different shapes due to a crushing process or the like. Naturally, it does not matter if the shapes of some or all of the conductors 603 or the fusion layers 604 become somewhat irregular as a result of the crushing process.

[0233] In the above-mentioned second modification, the conductor 603 of the strand 601 may be configured as a composite of thin fibrous conductive members bundled together. For example, the conductor may be a composite of CNT (carbon nanotube) fibers. As the CNT fibers, fibers including boron-containing fine fibers in which at least a portion of carbon is replaced with boron may be used. As the carbon-based fine fibers, vapor grown carbon fibers (VGCF) and the like may be used in addition to CNT fibers, but it is preferable to use CNT fibers.

[0234] In the above embodiment and modification 2, the stator winding 61 is covered and sealed with sealing members such as the insulating covers 161-164 and the insulating coating 157, but each wound conductive wire CR may be sealed by resin molding so as to cover the periphery thereof. In this case, it is preferable that the sealing member formed by resin molding is provided in a range including the coil end CE of the stator winding 61. In other words, it is preferable that substantially the entire stator winding 61 is sealed with resin except for the winding ends 154, 155, i.e., the connection portions.

[0235] In addition, when the rotating electric machine 10 is used as a vehicle power source, it is preferable that the above-mentioned sealing member is made of a highly heat-resistant fluororesin, epoxy resin, PPS resin, PEEK resin, LCP resin, silicon resin, PAI resin, PI resin, or the like. In addition, in terms of the linear expansion coefficient from the viewpoint of suppressing cracks due to the expansion difference, it is preferable that the sealing member and the insulating coating 602 are made of the same material. That is, silicon resin, whose linear expansion coefficient is generally more than twice that of other resins, is preferably excluded. In addition, in electrical products that do not have an engine that utilizes combustion, such as electric vehicles, PPO resin, phenol resin, and FRP resin, which have a heat resistance of about 180°C, are also candidates. In fields where the ambient temperature of the rotating electric machine is considered to be less than 100°C, this is not the case.

[0236] Furthermore, when a sealing member is provided, the linear expansion coefficient of the sealing member may be made different from that of the insulating coating 602. For example, the linear expansion coefficient of the insulating coating 602 may be made smaller than that of the sealing member and also smaller than that of the bonding layer 604. This makes it possible to prevent both from cracking together. In other words, expansion due to external temperature changes can be prevented once by the insulating coating 602, which has a smaller linear expansion coefficient. The reverse is also true.

[0237] The linear expansion coefficient of the insulating coating 602 may be a value between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604. For example, the linear expansion coefficient of the sealing member may be greater than that of the insulating coating 602, and the linear expansion coefficient of the insulating coating 602 may be greater than that of the fusion layer 604. That is, the linear expansion coefficient may be higher toward the outside. The linear expansion coefficient of the sealing member may be smaller than that of the insulating coating 602, and the linear expansion coefficient of the insulating coating 602 may be smaller than that of the fusion layer 604. That is, the linear expansion coefficient may be higher toward the inside. As a result, even if there is a difference between the linear expansion coefficient of the sealing member and the linear expansion coefficient of the fusion layer 604, by interposing the insulating coating 602 having an intermediate linear expansion coefficient, the insulating coating 602 becomes a cushion. Therefore, it is possible to prevent the sealing member and the fusion layer 604 from cracking at the same time due to a temperature change outside the stator winding 61 or heat generation from the conductor 603.

[0238] In the above-mentioned modification 2, the adhesive strength between the conductor 603 and the adhesive layer 604, the adhesive strength between the adhesive layer 604 and the insulating coating 602, and the adhesive strength between the sealing member and the insulating coating 602 may be different. For example, the adhesive strength may be configured to be weaker toward the outside. The magnitude of the adhesive strength can be understood, for example, from the tensile strength required to peel off the two layers of coating. By setting the adhesive strength as described above, even if a temperature difference occurs between the inside and outside due to heating or cooling, it is possible to prevent cracks from occurring on both the inner layer side and the outer layer side (common cracks).

[0239] In the above-mentioned modified example 2, after the conductor wire CR is formed, it may be temporarily wound around a cylindrical bobbin and housed therein. That is, as shown in Fig. 49, after step S105, the conductor wire CR may be formed, and then temporarily wound around a cylindrical bobbin and housed therein (step S105a). Then, the conductor wire CR may be pulled out from the bobbin (step S105b), and the stator winding 61 may be formed by winding the conductor wire CR as described in the first embodiment (step S106).

[0240] In this case, when the conductor wire CR is wound around the bobbin, the straightness of the conductor wire CR is deviated due to the difference in curvature between the outer circumferential side and the inner circumferential side, and the conductor wire CR is shaped into a wave-like shape. Therefore, when the conductor wire CR is wound to form the stator winding 61, gaps are likely to be formed between the conductor wire CR. Therefore, a filler such as varnish is filled into the minute gaps between the wires (step S107). This makes it possible to reduce vibration. In addition, since the conductor wire CR is once wound around a cylindrical bobbin after it is formed, it is not necessary to maintain the straightness of the wire 601 from when the wire 601 is made straight until it is wound to form the stator winding 61 (steps S102 to S106). In other words, it is not necessary to realize these steps on one manufacturing line, and the flexibility of the manufacturing line can be improved.

[0241] Even if the rotating electric machine is provided with teeth or a structure equivalent to teeth, the circulating current can be reduced by applying the structure of the modified example 2.

[0242] 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]

[0243] 20...rotor, 22...magnet unit, 60...stator, 61...stator winding, 152...intermediate conductor portion, 601...strand, 602...insulating coating, CR...conductor material.

Claims

1. A rotating electric machine (10) comprising a field element (20) including a magnet portion (22) having a plurality of magnetic poles whose polarities alternate in the circumferential direction, and an armature (60) having a multi-phase armature winding (61), wherein either the field element or the armature is a rotor, The armature winding of each phase is formed by winding a conductor (CR), and has conductor portions (152) arranged at predetermined intervals in the circumferential direction at positions facing the magnet portions, Each of the conductor portions is formed by arranging the conductors in one or more rows in the circumferential direction and in one or more rows in the radial direction, Each of the conductors is formed by bundling a plurality of wires (601), and the plurality of wires (601) are stacked in the circumferential direction and covered with an insulating coating (602), Each of the conductors is configured by connecting the respective element wires constituting the conductor in parallel, In a rotating electric machine, each of the wires has a cross section that is flat and elongated in the radial direction.

2. The wire has a cross section of a flat shape elongated in the radial direction, and includes a conductor (603) through which a current flows, and a fusion layer (604) covering a surface of the conductor, 2. The rotating electric machine according to claim 1, wherein the fusion layer is thinner than the insulating coating, and when a plurality of wires (601) are stacked in the circumferential direction, the fusion layers are in contact with each other and fused together.

3. A rotating electric motor as described in claim 2, wherein the linear expansion coefficient of the bonding layer is smaller than the linear expansion coefficient of the insulating coating.

4. A rotating electric motor as described in claim 2, wherein the linear expansion coefficient of the fusion layer is between the linear expansion coefficient of the conductor and the linear expansion coefficient of the insulating coating.

5. A rotating electric motor as described in claim 2, wherein the adhesive strength between the adhesive layer and the insulating coating is weaker than the adhesive strength between the conductor and the adhesive layer.

6. 6. The rotating electric machine according to claim 1, wherein in each of said conductors, said wires are arranged in only one layer in the radial direction.

7. The rotating electric machine according to any one of claims 1 to 6, wherein the magnet portion is oriented so that the axis of easy magnetization is parallel to the d-axis on the side of the d-axis which is the magnetic pole center, compared to the side of the q-axis which is the magnetic pole boundary, and a magnetic flux path is formed along the axis of easy magnetization.

8. The magnet portion has a first magnet portion (501) arranged radially inside the conductor portion so as to face the conductor portion, and a second magnet portion (502) arranged radially outside the conductor portion so as to face the conductor portion, A rotating electric motor as described in any one of claims 1 to 6, wherein the magnetic poles of the first magnet section and the magnetic poles of the second magnet section radially opposed to the magnetic poles of the first magnet section are different at the d-axis which is the magnetic pole center.

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