Rotating Electric Machine
By minimizing gas flow disturbances through a specific configuration of the outer peripheral surface, the rotating electric machine achieves improved heat dissipation, addressing the issue of insufficient heat dissipation in existing axial gap motors.
Patent Information
- Application Number
- JP2022055637
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2021-09-27
- Filing Date
- 2022-03-30
- Publication Date
- 2025-03-18
- Estimated Expiration
- 2042-03-30
AI Technical Summary
Existing axial gap motors face insufficient heat dissipation, which can lead to reduced performance and reliability.
The design incorporates a rotating electric machine with a stator having a multi-phase coil, a rotor that rotates around the axis of rotation, and an electric housing with heat dissipation fins. The outer peripheral surface of the electric machine is configured to minimize gas flow disturbances, enhancing heat dissipation.
This configuration effectively suppresses the reduction in heat dissipation due to gas flow turbulence, thereby enhancing the overall heat dissipation effect of the rotating electric machine.
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Abstract
Description
[Technical Field]
[0001] The disclosure in this specification relates to rotating electrical machines. [Background technology]
[0002] Patent Document 1 describes an axial gap motor. In the axial gap motor, a rotor and a stator are arranged in the axial direction. In this motor, the rotor and the stator are housed in a motor housing. [Prior art documents] [Patent documents]
[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-96705 Summary of the Invention [Problem to be solved by the invention]
[0004] However, there is a concern that the heat dissipation effect of the motor may be insufficient in the above Patent Document 1.
[0005] A main object of the present disclosure is to provide a rotating electric machine that can improve heat dissipation efficiency. [Means for solving the problem]
[0006] The multiple aspects disclosed in this specification employ different technical means to achieve their respective objectives. Furthermore, the reference symbols in parentheses in the claims and this section are merely examples showing the correspondence between specific means described in the embodiments below as one aspect, and do not limit the technical scope.
[0007] In order to achieve the above purpose, attitude Dear Mr. / Ms. A rotating electric machine (60) driven by a supply of electric power, a stator (200) having a plurality of phase coils (211); a rotor (300a) that rotates around a rotation axis (Cm); an electric machine housing (70) having an electric machine outer peripheral wall (71) extending in a circumferential direction (CD) of the rotation axis and heat dissipation fins (72) provided on an electric machine outer peripheral surface (70a) of the electric machine outer peripheral wall for dissipating heat, the electric machine housing (70) accommodating a stator and a rotor, and fixed to a fixed object (370, 90, 830) arranged on the electric machine outer peripheral wall in an axial direction (AD) of the rotation axis; a seal holding portion (78, 826) provided on the outer peripheral wall of the electric machine, which holds a seal member (402, 828) between the fixed object and the seal holding portion (78, 826) by sandwiching the seal member (402, 828) between the fixed object and the seal holding portion (78, 826) when the fixed object is fixed to the electric housing; Equipped with The electric machine outer peripheral surface is a rotating electric machine that is provided outside the seal retaining portion in the radial direction (RD) of the rotation axis so as to extend axially together with the target outer peripheral surface (370a, 90a, 832a), which is the outer peripheral surface of the fixed object, and so as to be continuously aligned with the target outer peripheral surface in the axial direction when the fixed object is fixed to the electric machine housing.
[0008] According to the first aspect, the outer peripheral surface of the electric machine is arranged so as to be continuously aligned in the axial direction with the outer peripheral surface of the object when the object is fixed to the electric housing. With this configuration, gas flowing in the axial direction is less likely to be disturbed by passing through the boundary between the outer peripheral surface of the electric machine and the outer peripheral surface of the object. Furthermore, the outer peripheral surface of the electric machine is arranged radially outside the seal holder. With this configuration, gas flowing in the axial direction is less likely to be disturbed by passing through the seal holder. Therefore, it is possible to prevent the heat dissipation effect of the heat dissipation fins from being reduced due to flow disturbance, for example. This improves the heat dissipation effect of the rotating electric machine.
[0010] According to the second aspect, the outer peripheral surface of the electric machine is positioned radially inward from the outer peripheral surface of the target when the target is fixed to the electric housing. This configuration prevents the airflow flowing axially from the target toward the electric housing from hitting a stepped surface formed at the boundary between the outer peripheral surface of the electric machine and the outer peripheral surface of the target. Therefore, even if a stepped surface exists at the boundary between the outer peripheral surface of the electric machine and the outer peripheral surface of the target, the airflow is less likely to be disturbed by this stepped surface. Therefore, similar to the first aspect, the heat dissipation effect of the rotating electric machine can be improved.
[0012] According to the third aspect, the outer peripheral surface of the electric machine is positioned radially outward from the outer peripheral surface of the target when the target is fixed to the electric machine housing. This configuration prevents the airflow flowing in the axial direction from the electric machine housing toward the target from hitting a stepped surface facing the target between the outer peripheral surface of the electric machine and the outer peripheral surface of the target. This makes it less likely that the airflow will be disturbed by hitting a stepped surface facing the target. Therefore, similar to the first aspect, the heat dissipation effect of the rotating electric machine can be improved. [Brief explanation of the drawings]
[0013] [Figure 1] FIG. 1 is a diagram showing the configuration of a drive system according to a first embodiment. [Figure 2] FIG. [Figure 3] FIG. [Figure 4] FIG. [Figure 5] FIG. [Figure 6] FIG. [Figure 7] FIG. 2 is a plan view of a motor device in configuration group Aa. [Figure 8] FIG. [Figure 9] FIG. [Figure 10] FIG. 2 is a plan view of a stator showing the configuration of a coil unit. [Figure 11] FIG. [Figure 12] FIG. 10 is a longitudinal cross-sectional view of the rotor and shaft in the structural group Ab. [Figure 13] FIG. [Figure 14] FIG. 10 is a plan view of the stator and motor housing in the structural group Ac. [Figure 15] FIG. [Figure 16] FIG. 2 is a perspective view of a motor device in a structural group Ad. [Figure 17] FIG. [Figure 18] FIG. 4 is a longitudinal cross-sectional view of the periphery of a relay terminal in the motor device. [Figure 19] FIG. 10 is a plan view of the motor device in the configuration group Ae. [Figure 20] FIG. 10 is a longitudinal cross-sectional view of the periphery of a relay terminal in the motor device in the structural group Af. [Figure 21] FIG. [Figure 22] FIG. 2 is a longitudinal cross-sectional view of a motor device in a structural group Ag. [Figure 23] FIG. [Figure 24] FIG. 2 is a longitudinal cross-sectional view of a rotor and a shaft in a structural group Ba. [Figure 25] FIG. 2 is a plan view of the rotor as seen from the rotor first surface side. [Figure 26] FIG. 3 is a plan view of the rotor as viewed from the rotor second surface side. [Figure 27] FIG. 2 is a diagram showing the arrangement of magnets in a motor. [Figure 28] FIG. 10 is a longitudinal cross-sectional view of the rotor and shaft in the structural group Bb. [Figure 29] FIG. 3 is a longitudinal cross-sectional view of the rotor around the magnet. [Figure 30] FIG. 2 is a perspective view of a longitudinal section of the rotor around a magnet. [Figure 31] FIG. 2 is a plan view of the rotor as seen from the rotor first surface side. [Figure 32] FIG. [Figure 33]FIG. 10 is a perspective view of a longitudinal section of the rotor magnet and its surroundings in structural group Bc. [Figure 34] FIG. 2 is a plan view of a gradient magnet unit and a parallel magnet unit. [Figure 35] FIG. 2 is a plan view of the rotor as seen from the rotor first surface side. [Figure 36] FIG. 10 is a longitudinal cross-sectional view of the rotor and shaft in the structural group Bd. [Figure 37] FIG. 3 is a plan view of the rotor as viewed from the rotor second surface side. [Figure 38] FIG. 2 is a plan view of the rotor as seen from the rotor first surface side. [Figure 39] FIG. [Figure 40] FIG. 2 is a longitudinal cross-sectional view of a rotor and a shaft in a structural group Be. [Figure 41] FIG. 2 is a vertical cross-sectional perspective view of a first rotor and a second rotor. [Figure 42] FIG. 10 is a longitudinal cross-sectional view of the rotor and shaft in the structural group Bf. [Figure 43] FIG. 4 is a diagram for explaining the positional relationship between a first holder fixture and a second holder fixture. [Figure 44] FIG. 2 is a perspective view of the motor as seen from the first rotor side. [Figure 45] Plan view of the shaft. [Figure 46] FIG. 10 is a vertical cross-sectional perspective view of the motor housing and the coil protection portion in the structural group Ca. [Figure 47] FIG. [Figure 48] FIG. 2 is a schematic vertical cross-sectional view of a motor housing and a coil protection portion. [Figure 49] FIG. 4 is a schematic cross-sectional view of a motor housing and a coil protection portion. [Figure 50] FIG. 10 is a perspective view of a vertical cross section of a motor housing in the structural group Cb. [Figure 51] FIG. 10 is a longitudinal cross-sectional view of the periphery of a grommet in the motor device in the structural group Cc. [Figure 52] FIG. 2 is a vertical cross-sectional perspective view of a motor housing and a coil protection portion. [Figure 53] FIG. [Figure 54]FIG. 10 is a perspective view of a core unit in structural group Cd. [Figure 55] FIG. 10 is a perspective view of a core unit in the structural group Ce. [Figure 56] FIG. 2 is a vertical cross-sectional perspective view of a motor housing and a coil protection portion. [Figure 57] FIG. 10 is a perspective view of a core unit in the structural group Cf. [Figure 58] FIG. [Figure 59] Cross section of the core. [Figure 60] FIG. [Figure 61] FIG. 10 is a perspective view of a core unit in the structural group Cg. [Figure 62] FIG. 4 is a perspective view of the core unit as viewed from the flange recess side. [Figure 63] FIG. 10 is a side view of the core unit as seen from the flange recess side. [Figure 64] FIG. 4 is a front view of the core unit as seen from the radially inner side. [Figure 65] FIG. [Figure 66] FIG. 4 is a longitudinal cross-sectional view of a motor device unit in the structural group Da. [Figure 67] FIG. [Figure 68] FIG. 10 is a longitudinal cross-sectional view of a rotor and a stator in a structural group Db. [Figure 69] A perspective view of the shaft from the bottom of Figure 68. [Figure 70] Plan view of the shaft from below, Figure 68. [Figure 71] Front view of the shaft. [Figure 72] Cross section taken along line LXXII-LXXII in Figure 71. [Figure 73] FIG. 10 is a longitudinal cross-sectional view of a rotor and a stator in the structural group Dc. [Figure 74] FIG. 3 is a plan view of the rotor as viewed from the rotor second surface side. [Figure 75] FIG. 10 is a plan view of a motor device in a structural group Dd. [Figure 76] FIG. [Figure 77] FIG. 2 is a plan view of a motor device in a configuration group De. [Figure 78] FIG. 10 is a perspective view of a motor device in the structural group Df. [Figure 79] FIG. [Figure 80] FIG. 4 is a plan view of the motor housing as seen from the second rotor side. [Figure 81] FIG. 10 is a perspective view of a motor device in the structural group Dg. [Figure 82] FIG. 4 is a plan view of the motor device as seen from the drive frame side. [Figure 83] FIG. [Figure 84] FIG. 10 is a longitudinal cross-sectional view of the periphery of a grommet in the motor device in configuration group E. [Figure 85] FIG. 2 is a vertical cross-sectional perspective view of a motor housing and a coil protection portion. [Figure 86] FIG. 4 is an enlarged perspective view of the periphery of a grommet in the motor device. [Figure 87] FIG. 4 is a schematic vertical cross-sectional view showing the positional relationship between the outer grommet portion and the outer peripheral lead portion. [Figure 88] FIG. 4 is an enlarged perspective view of the periphery of a grommet in the motor device. [Figure 89] FIG. 10 is a longitudinal cross-sectional view of the vicinity of a rotary rib in the motor device in component group F. [Figure 90] FIG. 3 is a plan view of the rotor as viewed from the rotor second surface side. [Figure 91] FIG. 3 is a longitudinal cross-sectional view of the rotor around the magnet. [Figure 92] FIG. [Figure 93] FIG. 2 is a schematic vertical cross-sectional view of the vicinity of a rotary rib in the motor device. [Figure 94] FIG. 2 is a schematic vertical cross-sectional view of the vicinity of a rotary rib in the motor device. [Figure 95] FIG. 10 is a longitudinal cross-sectional view of the periphery of a fixed block in the motor device in the structural group G. [Figure 96] FIG. 3 is a longitudinal cross-sectional view of the rotor around a fixed block. [Figure 97] FIG. 2 is a plan view of the rotor showing the first surface of the rotor. [Figure 98] FIG. 2 is a schematic cross-sectional view of the rotor in a direction perpendicular to the circumferential direction. [Figure 99] FIG. [Figure 100] FIG. [Figure 101] FIG. 2 is a plan view of the gradient magnet unit and the parallel magnet unit, showing the first unit surface. [Figure 102] FIG. 2 is a plan view of the gradient magnet unit and the parallel magnet unit, looking at the second unit surface. [Figure 103] FIG. 4 is a plan view of the magnet holder and its surrounding magnet projections. [Figure 104] FIG. 10 is a longitudinal cross-sectional view of the grommet and coil protection portion of the motor device in configuration group H. [Figure 105] FIG. 4 is a longitudinal cross-sectional view of the periphery of a grommet in the motor device. [Figure 106] FIG. 2 is a schematic vertical cross-sectional view showing the configuration of a power lead wire, a grommet, and a coil protection portion. [Figure 107] Front view of the grommet. [Figure 108] Side view of the grommet. [Figure 109] FIG. 4 is a view of the periphery of a grommet in the motor device as seen from the radially inner side. [Figure 110] FIG. 10 is a longitudinal cross-sectional view of the rotor and shaft in configuration group I. [Figure 111] FIG. 2 is a diagram for explaining a shaft base material. [Figure 112] FIG. 10 is a longitudinal cross-sectional view of a motor device unit in a structural group K. [Figure 113] FIG. 2 is a longitudinal cross-sectional view of the resolver and its surroundings in the motor device. [Figure 114] FIG. 10 is a plan view of the gradient magnet unit and the parallel magnet unit in the structural group L. [Figure 115] FIG. 2 is a diagram showing the arrangement of magnets in a motor. [Figure 116] FIG. [Figure 117] FIG. [Figure 118] FIG. 3 is a longitudinal cross-sectional view of the rotor around the magnet. [Figure 119]3A to 3C are diagrams showing the steps of a rotor manufacturing process. [Figure 120] 10A and 10B are diagrams for explaining a sintering step and a strip process. [Figure 121] FIG. 2 is a diagram for explaining a magnet base material process. [Figure 122] FIG. 10 is a diagram for explaining a magnet side surface process. [Figure 123] FIG. 10 is a diagram for explaining a unit base material process. [Figure 124] FIG. 4 is a plan view for explaining a first shaping step and a second shaping step. [Figure 125] FIG. 10 is a side view for explaining a first shaping step and a second shaping step. [Figure 126] FIG. 10 is a longitudinal cross-sectional view of the axial gap and its surroundings in the motor device in the structural group M. [Figure 127] FIG. 2 is a schematic vertical cross-sectional view of the periphery of an axial gap in the motor device. [Figure 128] FIG. 3 is a plan view of the rotor as viewed from the rotor second surface side. [Figure 129] FIG. [Figure 130] FIG. 4 is a perspective view of the drive frame as seen from the drive rib side. [Figure 131] FIG. 10 is a longitudinal sectional view of a motor device unit in a structural group N. [Figure 132] FIG. 2 is a schematic vertical cross-sectional view of the motor seal portion and its surroundings in the motor device. [Figure 133] 10 is a schematic vertical cross-sectional view showing the positional relationship between the outer grommet portion and the outer peripheral lead portion in the configuration group E and the third embodiment. FIG. [Figure 134] FIG. 10 is a schematic vertical cross-sectional view of the periphery of a grommet in a motor device according to a fourth embodiment. [Figure 135] FIG. 11 is a schematic vertical cross-sectional view of the periphery of a grommet in a motor device according to a fifth embodiment. [Figure 136] FIG. 13 is a schematic vertical cross-sectional view of the periphery of a grommet in a motor device according to a sixth embodiment. [Figure 137] FIG. 13 is a schematic vertical cross-sectional view of the periphery of a grommet in a motor device according to a seventh embodiment. [Figure 138]FIG. 13 is a schematic vertical cross-sectional view of the rotor rib and its surroundings in the motor device according to the eighth embodiment. [Figure 139] FIG. 13 is a schematic vertical cross-sectional view of the vicinity of a rotary rib in a motor device according to a ninth embodiment. [Figure 140] FIG. 23 is a schematic vertical cross-sectional view of the vicinity of a rotary rib in a motor device according to a tenth embodiment. [Figure 141] FIG. 23 is a schematic vertical cross-sectional view of the vicinity of a rotary rib in a motor device according to an eleventh embodiment. [Figure 142] FIG. 23 is a schematic vertical cross-sectional view of the periphery of a fixed block in a rotor according to a twelfth embodiment. [Figure 143] FIG. 23 is a plan view of the rotor according to the thirteenth embodiment, showing the first surface of the rotor. [Figure 144] FIG. 23 is a plan view of the rotor according to the fourteenth embodiment, showing the first surface of the rotor. [Figure 145] FIG. 22 is a front view of the component group H and the grommet in the fifteenth embodiment. [Figure 146] Side view of the grommet. [Figure 147] 16A and 16B are diagrams for explaining the first base material and the second base material in the structural group I and the sixteenth embodiment. [Figure 148] FIG. 23 is an enlarged plan view of the periphery of a displacement regulating portion in the motor device according to the structural group J and the seventeenth embodiment. [Figure 149] FIG. 4 is a schematic vertical cross-sectional view of the vicinity of a displacement regulation portion in the motor device. [Figure 150] FIG. 23 is an enlarged plan view of the periphery of a displacement restriction portion in a motor device according to an eighteenth embodiment. [Figure 151] FIG. 4 is a schematic vertical cross-sectional view of the vicinity of a displacement regulation portion in the motor device. [Figure 152] FIG. 23 is an enlarged plan view of the periphery of a displacement restriction portion in a motor device according to a nineteenth embodiment. [Figure 153] FIG. 4 is a schematic vertical cross-sectional view of the vicinity of a displacement regulation portion in the motor device. [Fig. 154] FIG. 23 is a plan view of the configuration group L and the gradient magnet unit in the twentieth embodiment. [Figure 155] FIG. [Figure 156] FIG. 3 is a longitudinal cross-sectional view of the rotor around the magnet. [Figure 157] FIG. 23 is a plan view of a gradient magnet unit in the twenty-first embodiment. [Figure 158] FIG. 22 is a diagram showing the arrangement of magnets in the 22nd embodiment. [Figure 159] FIG. 23 is a plan view of a gradient magnet unit in the twenty-third embodiment. [Figure 160] A diagram showing the arrangement of magnets. [Figure 161] FIG. 24 is a schematic vertical cross-sectional view of the motor seal portion and its surroundings in the motor device according to the twenty-fourth embodiment. [Figure 162] FIG. 25 is a schematic vertical cross-sectional view of the motor seal portion and its surroundings in the motor device according to the 25th embodiment. [Figure 163] FIG. 26 is a schematic vertical cross-sectional view of the periphery of a housing seal portion in a motor device according to a 26th embodiment. [Fig. 164] FIG. 27 is a schematic vertical cross-sectional view of the periphery of a housing seal portion in a motor device according to a 27th embodiment. [Figure 165] FIG. 28 is a schematic vertical cross-sectional view of the periphery of a housing seal portion in a motor device according to a 28th embodiment. [Figure 166] FIG. 29 is a schematic vertical cross-sectional view of the motor seal portion and its surroundings in the motor device according to the 29th embodiment. [Figure 167] FIG. 30 is a schematic vertical cross-sectional view of the periphery of a housing seal portion in a motor device according to a 30th embodiment. [Figure 168] FIG. 31 is a schematic vertical cross-sectional view of the periphery of a housing seal portion in a motor device according to a thirty-first embodiment. DETAILED DESCRIPTION OF THE INVENTION
[0014] Hereinafter, several embodiments for carrying out the present disclosure will be described with reference to the drawings. In each embodiment, parts corresponding to matters described in the preceding embodiment will be assigned the same reference numerals, and duplicate descriptions may be omitted. In each embodiment, when only a part of the configuration is described, other previously described embodiments may be applied to the other parts of the configuration. In addition to combinations of parts that are specifically specified as being combinable in each embodiment, it is also possible to partially combine embodiments even if not specified, as long as there is no particular problem with the combination.
[0015] First Embodiment The drive system 30 shown in Fig. 1 is mounted on a moving object such as a vehicle or an aircraft. Vehicles on which the drive system 30 is mounted include, for example, electric vehicles (EVs), hybrid vehicles (HVs), and fuel cell vehicles. Aircraft include aircraft such as vertical take-off and landing aircraft, rotary wing aircraft, and fixed wing aircraft. An example of a vertical take-off and landing aircraft is the eVTOL. eVTOL is an abbreviation for electric Vertical Take-Off and Landing aircraft.
[0016] The drive system 30 is a system that drives the moving body to move it. If the moving body is a vehicle, the drive system 30 drives the vehicle to run, and if the moving body is an aircraft, the drive system 30 drives the aircraft to fly.
[0017] The drive system 30 has a battery 31 and a motor device unit 50. The battery 31 is electrically connected to the motor device unit 50. The battery 31 is a power supply unit that supplies power to the motor device unit 50 and corresponds to a power supply unit. The battery 31 is a DC voltage source that applies a DC voltage to the motor device unit 50. The battery 31 has a rechargeable secondary battery. Examples of this secondary battery include a lithium ion battery and a nickel-metal hydride battery. Note that a fuel cell, a generator, or the like may be used as the power supply unit in addition to or instead of the battery 31.
[0018] The motor device unit 50 is a device that drives the moving body to move, and corresponds to a drive device. The motor device unit 50 has a motor device 60 and an inverter device 80. The motor device 60 has a motor 61. The inverter device 80 has an inverter 81. The battery 31 is electrically connected to the motor 61 via the inverter 81. Power is supplied to the motor 61 from the battery 31 via the inverter 81. The motor 61 is driven in accordance with the voltage and current supplied from the inverter 81.
[0019] The motor 61 is a multi-phase AC motor. The motor 61 is, for example, a three-phase AC motor, and has a U phase, a V phase, and a W phase. The motor 61 is a driving source for moving the moving body, and functions as an electric motor. For example, a brushless motor is used as the motor 61. The motor 61 functions as a generator during regeneration. The motor 61 corresponds to a rotating electric machine, and the motor device unit 50 corresponds to a rotating electric machine unit.
[0020] The motor 61 has coils 211 of multiple phases. The coils 211 are windings and form an armature. A coil 211 is provided for each of the U phase, V phase, and W phase. In the motor 61, the coils 211 of multiple phases are star-connected. A star connection is sometimes called a Y connection. The motor 61 has a neutral point 65. The coils 211 of multiple phases are connected to each other at the neutral point 65.
[0021] The inverter 81 drives the motor 61 by converting the power supplied to the motor 61. The inverter 81 converts the power supplied to the motor 61 from direct current to alternating current. The inverter 81 is a power conversion unit that converts power. The inverter 81 is a multi-phase power conversion unit that performs power conversion for each of the multiple phases. The inverter 81 is, for example, a three-phase inverter that performs power conversion for each of the U phase, V phase, and W phase.
[0022] The inverter device 80 has a P line 141 and an N line 142. The P line 141 and the N line 142 electrically connect the battery 31 and the inverter 81. The P line 141 is electrically connected to the positive electrode of the battery 31. The N line 142 is electrically connected to the negative electrode of the battery 31. In the battery 31, the positive electrode is the high-potential electrode, and the negative electrode is the low-potential electrode. The P line 141 and the N line 142 are power lines for supplying electric power. The P line 141 is a high-potential power line and may be referred to as a high-potential line. The N line 142 is a low-potential power line and may be referred to as a low-potential line.
[0023] The motor device unit 50 has an output line 143. The output line 143 is a power line for supplying electric power. The output line 143 electrically connects the motor 61 and the inverter 81. The output line 143 is laid across the motor device 60 and the inverter device 80.
[0024] The inverter device 80 has a smoothing capacitor 145. The smoothing capacitor 145 is a capacitor that smoothes the DC voltage supplied from the battery 31. The smoothing capacitor 145 is connected to the P line 141 and the N line 142 between the battery 31 and the inverter 81. The smoothing capacitor 145 is connected in parallel to the inverter 81.
[0025] The inverter 81 is a power conversion circuit, for example, a DC-AC conversion circuit. The inverter 81 has arm circuits 85 for a plurality of phases. For example, the inverter 81 has an arm circuit 85 for each of the U phase, V phase, and W phase. The arm circuits 85 may be referred to as legs or upper and lower arm circuits. The arm circuit 85 has an upper arm 85a and a lower arm 85b. The upper arm 85a and the lower arm 85b are connected in series to the battery 31. The upper arm 85a is connected to the P line 141, and the lower arm 85b is connected to the N line 142.
[0026] The output line 143 is connected to the arm circuit 85 for each of the multiple phases. The output line 143 is connected between the upper arm 85a and the lower arm 85b. The output line 143 connects the arm circuit 85 and the coil 211 for each of the multiple phases. The output line 143 is connected to the side of the coil 211 opposite to the neutral point 65.
[0027] The arms 85a and 85b each have an arm switch 86 and a diode 87. The arm switch 86 is formed of a switching element such as a semiconductor element. Examples of this switching element include power elements such as IGBT and MOSFET. IGBT is an abbreviation for Insulated Gate Bipolar Transistor. MOSFET is an abbreviation for Metal-Oxide-Semiconductor Field-Effect Transistor.
[0028] Each of the arms 85a and 85b has one arm switch 86 and one diode 87. In each of the arms 85a and 85b, the diode 87 is connected in anti-parallel to the arm switch 86 for reflux. In the upper arm 85a, the collector of the arm switch 86 is connected to the P line 141. In the lower arm 85b, the emitter of the arm switch 86 is connected to the N line 142. The emitter of the arm switch 86 in the upper arm 85a and the collector of the arm switch 86 in the lower arm 85b are connected to each other. The anode of the diode 87 is connected to the emitter of the corresponding arm switch 86, and the cathode is connected to the collector. The arm switch 86 can also be called a semiconductor switch.
[0029] The motor device unit 50 has a control device 54. The control device 54 is included in the inverter device 80. The control device 54 is, for example, an ECU, and controls the driving of the inverter 81. ECU is an abbreviation for Electronic Control Unit. The control device 54 is mainly composed of, for example, a microcomputer equipped with a processor, memory, I / O, and buses connecting these. The memory is a non-transitory tangible storage medium that non-temporarily stores computer-readable programs and data. The non-transitory tangible storage medium is also a non-transitory tangible storage medium, and is realized by a semiconductor memory, a magnetic disk, or the like. In FIG. 1, the control device 54 is illustrated as a CD.
[0030] The control device 54 executes various processes related to the driving of the inverter 81 by executing a control program stored in the memory. The control device 54 is electrically connected to an external device, the inverter 81, and various sensors. The external device is, for example, a higher-level ECU such as an integrated ECU mounted on a mobile object. The various sensors are provided, for example, in the motor device unit 50. The control device 54 controls the inverter 81 by outputting a command signal to the inverter 81. The control device 54 generates the command signal in response to a control signal input from the external device, a detection signal input from the various sensors, and the like. In the inverter device 80, the inverter 81 is driven in response to the command signal input from the control device 54, and power conversion is performed by the inverter 81.
[0031] The motor device 60 has a resolver 421 and a temperature sensor 431 as various sensors. The resolver 421 is a rotation sensor that detects the rotation angle of the motor 61, and corresponds to a rotation detection unit. The resolver 421 outputs a detection signal according to the rotation angle of the motor 61. The detection signal of the resolver 421 includes information about the number of rotations, such as the rotation angle, of the motor 61. Note that the motor device 60 may have a rotation detection unit different from the resolver 421.
[0032] The temperature sensor 431 is capable of detecting the temperature of the motor 61 and corresponds to a temperature detection unit. The temperature sensor 431 outputs a detection signal corresponding to the temperature of the motor 61. The temperature sensor 431 detects, for example, the temperature of the stator 200 (described later) as the temperature of the motor 61. The temperature sensor 431 may detect the temperature of any part of the motor 61.
[0033] The resolver 421 and the temperature sensor 431 are electrically connected to the control device 54. The resolver 421 is connected to the control device 54 by a signal line 425. A detection signal output by the resolver 421 is input to the control device 54 via the signal line 425. The temperature sensor 431 is connected to the control device 54 by a signal line 435. A detection signal output by the temperature sensor 431 is input to the control device 54 via the signal line 435. The signal lines 425, 435 are included in the motor device unit 50, and are connected to the motor device 60 and the inverter device 80.
[0034] As shown in Figures 2 and 3, in the motor device unit 50, the motor device 60 and the inverter device 80 are arranged along the motor axis Cm. The motor device 60 and the inverter device 80 are fixed to each other with fasteners such as bolts. The motor axis Cm is a virtual line extending linearly. If the direction in which the motor axis Cm extends is referred to as the axial direction AD, the axial direction AD, the radial direction RD, and the circumferential direction CD are perpendicular to each other with respect to the motor axis Cm. Note that the outside of the radial direction RD is sometimes referred to as the radially outer side, and the inside of the radial direction RD is sometimes referred to as the radially inner side. Note that Figure 3 shows a vertical cross section of the motor device unit 50 extending along the motor axis Cm.
[0035] The motor device 60 has a motor housing 70. The motor housing 70 accommodates the motor 61. The motor housing 70 is formed in a cylindrical shape as a whole and extends along the motor axis Cm. The motor housing 70 is formed from a metal material or the like and has thermal conductivity. The motor housing 70 has an outer peripheral surface 70a. The outer peripheral surface 70a is included in the outer surface of the motor housing 70 and extends annularly in the circumferential direction CD as a whole.
[0036] The motor housing 70 has a housing main body 71 and motor fins 72. The housing main body 71 forms an outer peripheral surface 70a. The motor fins 72 are heat dissipation fins provided on the outer peripheral surface 70a. The motor fins 72 increase the surface area of the motor housing 70, thereby improving the heat dissipation effect of the motor housing 70. The motor fins 72 protrude radially outward from the outer peripheral surface 70a. The motor fins 72 extend in the axial direction AD along the outer peripheral surface 70a. Multiple motor fins 72 are arranged in the circumferential direction CD.
[0037] The inverter device 80 has an inverter housing 90. The inverter housing 90 accommodates the inverter 81. The inverter housing 90 is formed into a cylindrical shape as a whole and extends along the motor axis Cm. The inverter housing 90 is formed from a metal material or the like and has thermal conductivity. The inverter housing 90 has an outer peripheral surface 90a. The outer peripheral surface 90a is included in the outer surface of the inverter housing 90 and extends annularly in the circumferential direction CD.
[0038] The motor device 60 and the inverter device 80 are air-cooled devices. The inverter housing 90 has a housing main body 91 and inverter fins 92. The housing main body 91 forms an outer peripheral surface 90a. The inverter fins 92 are heat dissipation fins provided on the outer peripheral surface 90a. The inverter fins 92 increase the surface area of the inverter housing 90 and enhance the heat dissipation effect of the inverter housing 90. The inverter fins 92 protrude radially outward from the outer peripheral surface 90a. The inverter fins 92 extend in the axial direction AD along the outer peripheral surface 90a. Multiple inverter fins 92 are arranged in the circumferential direction CD.
[0039] As shown in FIG. 2, the motor device unit 50 has a unit duct 100. The unit duct 100 is made of a resin material or the like. The unit duct 100 houses the motor housing 70 and the inverter housing 90. The unit duct 100 is formed into a cylindrical shape as a whole and extends along the motor axis Cm. The unit duct 100 spans between the motor housing 70 and the inverter housing 90 in the axial direction AD. The unit duct 100 covers the motor housing 70 and the inverter housing 90 from their outer peripheries. The unit duct 100 is fixed to at least one of the motor housing 70 and the inverter housing 90. Openings are formed in the unit duct 100 at both ends in the axial direction AD.
[0040] The inner peripheral surface of the unit duct 100 faces the outer peripheral surfaces 70a, 90a via the motor fins 72 and the inverter fins 92. The inner peripheral surface of the unit duct 100 is spaced radially outward from the outer peripheral surfaces 70a, 90a. In the motor device unit 50, a duct flow path is formed between the outer peripheral surfaces 70a, 90a and the inner peripheral surface of the unit duct 100. This duct flow path is open in the axial direction AD through an opening in the unit duct 100. In the motor device unit 50, gas such as air passes through the duct flow path, which makes it easier for heat to be released from the motor fins 72 and the inverter fins 92.
[0041] The inner peripheral surface of the unit duct 100 is close to or in contact with the tip surfaces of the motor fins 72 and the inverter fins 92. In this configuration, gas passing through the duct flow path in the axial direction AD tends to pass through positions that overlap the motor fins 72 and the inverter fins 92 in the radial direction RD. This tends to improve the heat dissipation effect of the motor fins 72 and the inverter fins 92.
[0042] As shown in Fig. 3, the inverter device 80 has an inverter lid 99 in addition to an inverter housing 90. The inverter lid 99 is made of a metal material or the like and has thermal conductivity. The inverter lid 99 extends in a direction perpendicular to the motor axis Cm. An opening formed on one end of the inverter housing 90 in the axial direction AD is covered by the inverter lid 99.
[0043] The motor device 60 has a drive frame 390 in addition to the motor housing 70. The drive frame 390 is made of a metal material or the like and has thermal conductivity. The drive frame 390 extends in a direction perpendicular to the motor axis Cm. An opening formed on one end of the motor housing 70 in the axial direction AD is covered by the drive frame 390. The drive frame 390 is fixed to the motor housing 70 by a frame fixture 405. The frame fixture 405 is a fixture such as a bolt. The frame fixture 405 is screwed to the drive frame 390 and the motor housing 70 via a washer 406.
[0044] The motor device 60 has an O-ring 401. The O-ring 401 is an elastically deformable sealing member made of a resin material or the like. The O-ring 401 is sandwiched between the motor housing 70 and the drive frame 390. The O-ring 401 extends along the outer periphery of the motor housing 70. The O-ring 401 provides a seal between the motor housing 70 and the drive frame 390.
[0045] In the motor device unit 50, one end in the axial direction AD is formed by the inverter cover part 99. The other end in the axial direction AD is formed by the drive frame 390.
[0046] The motor device unit 50 has a unit housing 51. The unit housing 51 is configured to include an inverter housing 90, an inverter lid portion 99, a motor housing 70, and a drive frame 390. The outer peripheral surface of the unit housing 51 is formed by the inverter housing 90 and the motor housing 70. One of a pair of end faces of the unit housing 51 is formed by the inverter lid portion 99, and the other is formed by the drive frame 390. The unit duct 100 covers the outer peripheral surface of the unit housing 51.
[0047] As shown in Figures 3 and 4, the motor 61 has a stator 200, a rotor 300, and a shaft 340. The rotor 300 rotates relative to the stator 200 around the motor axis Cm. The rotor 300 is a rotor and may be referred to as a rotor sub-assembly. The motor axis Cm is the center line of the rotor 300 and corresponds to the rotation axis. The shaft 340 is fixed to the rotor 300 and rotates together with the rotor 300. The shaft 340 is the rotation axis of the motor 61. The center line of the shaft 340 coincides with the motor axis Cm. The center line of the stator 200 coincides with the motor axis Cm. The stator 200 is a stator and may be referred to as a stator sub-assembly.
[0048] The motor device 60 is an axial gap type rotating electric machine. In the motor 61, a stator 200 and a rotor 300 are arranged in the axial direction AD along the motor axis Cm. The rotor 300 is overlapped with the stator 200 in the axial direction AD, and rotates relative to the stator 200 in this state.
[0049] The motor device 60 is a double-rotor rotating electric machine and has two rotors 300. The two rotors 300 are aligned in the axial direction AD. A stator 200 is provided between the two rotors 300 in the axial direction AD. A shaft 340 is fixed to both of the two rotors 300. The two rotors 300 rotate together with the shaft 340. If the two rotors 300 are referred to as a first rotor 300a and a second rotor 300b, the first rotor 300a is provided on the rear frame 370 side with respect to the stator 200. The second rotor 300b is provided on the opposite side of the stator 200 from the inverter device 80. An axial gap type, double-rotor rotating electric machine is sometimes referred to as a double axial motor.
[0050] As shown in Figs. 3 and 6, the stator 200 extends in the circumferential direction CD around the motor axis Cm and is formed in an annular shape as a whole. The stator 200 has a coil unit 210 and a coil protection part 250. The coil unit 210 has coil parts 215. A plurality of the coil parts 215 are arranged in the circumferential direction CD. In the coil unit 210, a coil 211 is formed by at least one coil part 215. The coils 211 of multiple phases are arranged in the circumferential direction CD in the coil unit 210. Note that the coil protection part 250 is not shown in Fig. 6.
[0051] The coil protection part 250 is formed from a resin material or the like. The coil protection part 250 is formed from, for example, an epoxy-based thermosetting resin. The coil protection part 250 is, for example, a molded resin formed by molding. The coil protection part 250 has electrical insulation properties. The coil protection part 250 has thermal conductivity, which makes it easy for heat to be transferred from the coil part 215. The coil protection part 250 has a thermal conductivity greater than that of, for example, air.
[0052] The coil protection part 250 covers the coil unit 210 and protects the coil unit 210. The coil protection part 250 extends in the circumferential direction CD around the motor axis Cm. The coil protection part 250 is formed in an annular shape as a whole. The coil protection part 250 seals the coil 211 and the coil part 215. The coil protection part 250 is in contact with both the coil part 215 and the motor housing 70. The coil protection part 250 makes it easier to transfer heat from the coil part 215 to the motor housing 70.
[0053] The rotor 300 extends in the circumferential direction CD around the motor axis Cm and is formed in an annular shape overall. The rotor 300 is formed in a plate shape overall. The rotor 300 has magnets 310 and a magnet holder 320. A plurality of the magnets 310 are arranged in the circumferential direction CD. The magnets 310 are permanent magnets and form a field magnet. The magnet holder 320 supports the plurality of magnets 310. The magnet holder 320 extends in the circumferential direction CD around the motor axis Cm. The magnet holder 320 is formed in an annular shape overall.
[0054] The shaft 340 has a shaft body 341 and a shaft flange 342. The shaft body 341 is formed in a columnar shape and extends along the motor axis Cm. The shaft flange 342 extends radially outward from the shaft body 341. The shaft flange 342 extends around the motor axis Cm in the circumferential direction CD. The shaft flange 342 is formed in an annular shape as a whole. The shaft flange 342 is fixed to the rotor 300.
[0055] The motor device 60 has a first bearing 360 and a second bearing 361. The bearings 360 and 361 rotatably support the shaft 340. The rotor 300 is rotatably supported by the bearings 360 and 361 via the shaft 340. The first bearing 360 and the second bearing 361 are aligned in the axial direction AD. A shaft flange 342 is provided between the first bearing 360 and the second bearing 361 in the axial direction AD. The first bearing 360 is attached to a rear frame 370 (described later) and fixed to the motor housing 70 via the rear frame 370. The second bearing 361 is attached to a drive frame 390 and fixed to the motor housing 70 via the drive frame 390.
[0056] 3, 4, and 6, the motor device 60 includes a busbar unit 260, a rear frame 370, a dust cover 380, a retainer plate 410, a resolver 421, and a resolver cover 424. Note that the dust cover 380 is not shown in FIG.
[0057] The rear frame 370 is formed in a plate shape overall and extends in a direction perpendicular to the motor axis Cm. The rear frame 370 is formed from a metal material or the like. The rear frame 370 covers the stator 200 and the rotor 300 from the inverter device 80 side. The rear frame 370 separates the internal space of the motor housing 70 from the inverter device 80 side. The rear frame 370 separates the internal space of the motor housing 70 from the internal space of the inverter housing 90. The rear frame 370 is provided between the motor housing 70 and the inverter housing 90 in the axial direction AD. The rear frame 370 is sandwiched between the motor housing 70 and the inverter housing 90.
[0058] The dustproof cover 380 extends in the circumferential direction CD around the motor axis Cm. The dustproof cover 380 is formed in an annular shape as a whole. The dustproof cover 380 is placed on the rear frame 370 from the inverter device 80 side. The dustproof cover 380 is made of a resin material or the like, and has a structure that prevents foreign matter such as dust from passing through. The dustproof cover 380 prevents foreign matter from entering from one of the internal spaces of the motor housing 70 and the inverter housing 90 to the other.
[0059] As shown in Figures 4 and 5, the busbar unit 260 extends in the circumferential direction CD around the motor axis Cm. The busbar unit 260 is formed in an annular shape as a whole. The busbar unit 260 is located away from the stator 200 toward the rear frame 370 in the axial direction AD. The busbar unit 260 is provided closer to the inverter device 80 than the rear frame 370. The busbar unit 260 extends along the plate surface of the rear frame 370.
[0060] As shown in Figures 3 and 6, the bus bar unit 260 has a power bus bar 261 and a bus bar protector 270. The power bus bar 261 is a conductive member such as a bus bar member for passing current. The power bus bar 261 is provided for each of the multiple phases, and forms at least a part of the output line 143 for each of the multiple phases. The power bus bar 261 is provided in the output line 143 between the coil 211 and the inverter 81, and electrically connects the coil 211 to the inverter 81. The power bus bar 261 extends in the circumferential direction CD around the motor axis Cm. The power bus bar 261 is formed in an annular shape as a whole. The bus bar member is a member having a plate-shaped body covered with an insulator.
[0061] The bus bar protection portion 270 is made of a resin material or the like and has electrical insulation properties. The bus bar protection portion 270 covers the multiple power bus bars 261 and protects the multiple power bus bars 261. The bus bar protection portion 270 extends in the circumferential direction CD around the motor axis Cm. The bus bar protection portion 270 is formed in an annular shape as a whole.
[0062] As shown in Figures 3, 5, and 6, the motor device 60 has a relay terminal 280. The relay terminal 280 is a conductive member such as a bus bar member for passing current. The relay terminal 280 is provided for each of the multiple phases, and forms at least a part of the output line 143 for each of the multiple phases. The relay terminal 280 is provided on the output line 143 between the power bus bar 261 and the inverter 81. The relay terminal 280 electrically connects the power bus bar 261 and the inverter 81. The relay terminal 280 is electrically connected to the power bus bar 261. A plurality of relay terminals 280 are arranged in the circumferential direction CD. The relay terminal 280 is connected to a member that constitutes the inverter 81 in the inverter device 80, for example.
[0063] As shown in Figures 3, 4, and 6, the retainer plate 410 extends in the circumferential direction CD around the motor axis Cm. The retainer plate 410 is formed in an annular shape as a whole. The retainer plate 410 fixes the second bearing 361 to the drive frame 390. The retainer plate 410 is fixed to the drive frame 390 with the second bearing 361 sandwiched between the retainer plate 410 and the drive frame 390.
[0064] The resolver 421 extends in the circumferential direction CD around the motor axis Cm. The resolver 421 is formed in an overall annular shape. The resolver 421 has a resolver rotor and a resolver stator. The resolver rotor rotates relative to the resolver stator. The resolver rotor is provided on the rotor 300 side, and the resolver stator is provided on the motor housing 70 side. For example, the resolver rotor is attached to the shaft 340, and the resolver stator is attached to the rear frame 370. The resolver 421 is provided on the inverter device 80 side of the rear frame 370. The resolver cover 424 is formed in an overall plate shape and extends in a direction perpendicular to the motor axis Cm. The resolver cover 424 covers the resolver 421 from the inverter device 80 side. The resolver cover 424 is attached to the rear frame 370. The resolver cover 424 covers the shaft main body 341 from the inverter device 80 side.
[0065] A reducer 53 is attached to the motor device unit 50. The reducer 53 mechanically connects the motor 61 to an external device. For example, the external device is mechanically connected to the rotating shaft of the motor 61 via the reducer 53. The reducer 53 reduces the rotation of the motor 61 and transmits it to the external device. Examples of external devices include wheels and propellers. The reducer 53 includes multiple gears and is sometimes referred to as a speed change gear and a gearbox. The reducer 53 is structured to match the motor characteristics of the motor 61. The reducer 53 is fixed to the drive frame 390 by a reducer fixture 53a. The reducer fixture 53a is a fixture such as a bolt.
[0066] <Composition group Aa> As shown in Figures 7, 8, and 9, the power bus bar 261 has a bus bar main body 262 and bus bar terminals 263. The bus bar main body 262 extends in the circumferential direction CD around the motor axis Cm. The bus bar main body 262 is formed in an annular shape as a whole. The bus bar main body 262 is formed in a plate shape as a whole and extends in a direction perpendicular to the motor axis Cm. The bus bar terminals 263 extend from the bus bar main body 262 in a direction intersecting the circumferential direction CD. The bus bar terminals 263 extend radially inward from the bus bar main body 262. The bus bar terminals 263 are formed in a plate shape as a whole. Note that the dust cover 380 is not shown in Figure 7.
[0067] The plurality of power bus bars 261 are arranged side by side in the axial direction AD. For example, the plurality of power bus bars 261 include a U-phase power bus bar 261, a V-phase power bus bar 261, and a W-phase power bus bar 261. In the plurality of power bus bars 261, the bus bar bodies 262 are stacked in the axial direction AD. The plurality of bus bar bodies 262 are provided at positions aligned with the stator 200 in the axial direction AD. In the plurality of power bus bars 261, the respective bus bar terminals 263 are positioned spaced apart in the circumferential direction CD.
[0068] The motor device 60 has a stator-side space S1 and an inverter-side space S2. The stator-side space S1 and the inverter-side space S2 are included in the internal space of the motor device 60 and are spaces partitioned by the rear frame 370. The stator-side space S1 and the inverter-side space S2 are aligned in the axial direction AD via the rear frame 370. The stator-side space S1 is a space closer to the stator 200 than the rear frame 370. The stator-side space S1 is a space between the rear frame 370 and the drive frame 390 in the axial direction AD. The inverter-side space S2 is a space closer to the inverter device 80 than the rear frame 370. The inverter-side space S2 is a space between the rear frame 370 and the inverter housing 90 in the axial direction AD. The inverter-side space S2 may include the internal space of the inverter device 80. The stator-side space S1 corresponds to the first space, the inverter-side space S2 corresponds to the second space, and the rear frame 370 corresponds to a space partition.
[0069] The power bus bar 261 is provided in the inverter-side space S2. The bus bar unit 260 is placed on the rear frame 370 from the inverter device 80 side. The bus bar protection part 270 is fixed to the rear frame 370 with fixing devices such as screws.
[0070] As shown in FIG. 8 , the busbar protection portion 270 has a plurality of protective plates 271. The protective plates 271 are made of a resin material or the like and have electrical insulation properties. The protective plates 271 are formed in a plate shape and extend in a direction perpendicular to the axial direction AD. The protective plates 271 extend in the circumferential direction CD around the motor axis Cm. The protective plates 271 are formed in an annular shape as a whole. The multiple protective plates 271 are stacked in the axial direction AD with the busbar main bodies 262 interposed therebetween. The protective plates 271 provide electrical insulation between two busbar main bodies 262 adjacent to each other in the axial direction AD with the protective plates 271 interposed therebetween.
[0071] As shown in FIG. 10 , the motor device 60 has a neutral point bus bar 290. The neutral point bus bar 290 is included in the stator 200. The neutral point bus bar 290 is a conductive member such as a bus bar member for passing current. The neutral point bus bar 290 forms at least the neutral point 65 and electrically connects the coils 211 of multiple phases. The neutral point bus bar 290 extends in the circumferential direction CD around the motor axis Cm. A plurality of neutral point bus bars 290 are arranged in the circumferential direction CD.
[0072] As shown in Fig. 8, the neutral point bus bar 290 is provided at a position spaced apart from the power bus bar 261 in the axial direction AD. The neutral point bus bar 290 is located closer to the drive frame 390 than the rear frame 370 in the axial direction AD. The neutral point bus bar 290 is located on the opposite side of the rear frame 370 from the power bus bar 261 in the axial direction AD. The neutral point bus bar 290 is provided in the stator-side space S1. On the other hand, as described above, the power bus bar 261 is provided in the inverter-side space S2.
[0073] 7 and 10, the neutral point bus bar 290 is provided at a position spaced apart in the radial direction RD from the bus bar main body 262. The neutral point bus bar 290 is located at a position spaced apart from the bus bar main body 262 radially inward.
[0074] As shown in Fig. 10, the coil unit 210 has a neutral point unit 214. A plurality of neutral point units 214 are arranged in the circumferential direction CD. The neutral point unit 214 has a plurality of coil portions 215 and one neutral point bus bar 290. In the neutral point unit 214, the coils 211 of multiple phases are star-connected with a neutral point 65. In the coil unit 210, a plurality of neutral point units 214 are arranged in the circumferential direction CD, and thus a plurality of star-connected coils 211 of multiple phases are arranged in the circumferential direction CD.
[0075] As shown in Fig. 11 , in the neutral point unit 214, the coil portions 215 are arranged in the circumferential direction CD, and thus the coils 211 of the multiple phases are arranged in the circumferential direction CD. In the neutral point unit 214, a power lead-out wire 212 and a neutral lead-out wire 213 extend from the coil 211 for each of the multiple phases. The power lead-out wire 212 is drawn outward in the radial direction from the coil 211 and extends in the axial direction AD toward the power bus bar 261. The power lead-out wire 212 is electrically connected to the power bus bar 261. The neutral lead-out wire 213 is drawn outward in the radial direction from the coil 211. The neutral lead-out wire 213 is electrically connected to the neutral point bus bar 290.
[0076] The coil portion 215 is formed by a wound coil wire 220. The coil wire 220 is a conductive member such as an electric wire for passing an electric current. The coil wire 220 is wound around a core unit 230. In the core unit 230, the coil wire 220 is wound around a core 231 via a bobbin 240. The wound portion of the coil wire 220 forms the coil portion 215, and the portions extending from the coil portion 215 form a first extension wire 216 and a second extension wire 217. In the coil portion 215, the first extension wire 216 extends from one of both ends aligned in the axial direction AD, and the second extension wire 217 extends from the other end.
[0077] The coil wire 220 forms the coil 211 by forming the coil portion 215. In the coil wire 220, the wound portion forms the coil 211, and the portions extending from the coil 211 form the power lead wire 212 and the neutral lead wire 213.
[0078] In each of the multiple phases, one coil 211 is formed by two coil portions 215. In each of the multiple phases, a first extension wire 216 of one of the two coil portions 215 forms a power lead wire 212, and the other first extension wire 216 forms a neutral lead wire 213. The second extension wires 217 of the two coil portions 215 are connected to each other.
[0079] In the neutral point unit 214, the coil 211, the power lead-out 212, and the neutral lead-out 213 are referred to as U-phase, V-phase, and W-phase, respectively. In the neutral point unit 214, the U-phase coils 211U, V-phase coils 211V, and W-phase coils 211W are arranged one by one in the circumferential direction CD. Similarly, the U-phase power lead-out 212U, V-phase power lead-out 212V, and W-phase power lead-out 212W are arranged one by one in the circumferential direction CD. The U-phase neutral lead-out 213U, V-phase neutral lead-out 213V, and W-phase neutral lead-out 213W are arranged one by one in the circumferential direction CD.
[0080] <Constituent group Ab> As shown in Fig. 12, the motor 61 has a first rotor 300a and a second rotor 300b. The motor 61 has a first gap G1 and a second gap G2. The first gap G1 is a gap between the stator 200 and the first rotor 300a. The second gap G2 is a gap between the stator 200 and the second rotor 300b. The first gap G1 and the second gap G2 are aligned in the axial direction AD with the stator 200 interposed therebetween. The motor 61 is sometimes referred to as a double-gap rotating electric machine.
[0081] As shown in FIG. 13 , the coil wire 220 has a conductor portion 221 and a covering portion 222. The conductor portion 221 is conductive and is the portion of the coil wire 220 through which current flows. The covering portion 222 is made of a resin material or the like and is electrically insulating. The covering portion 222 covers the conductor portion 221. The conductor portion 221 has a plurality of strands 223. The strands 223 are made of a conductive material such as copper and are the portion of the conductor portion 221 through which current flows. The coil wire 220 is sometimes called a stranded wire or a split copper wire.
[0082] <Composition group Ac> 14 and 15, in the coil unit 210, the multiple coil portions 215 include first coil portions 215a and second coil portions 215b. The first coil portions 215a and the second coil portions 215b are arranged alternately in the circumferential direction CD. In the coil unit 210, one of two coil portions 215 adjacent to each other in the circumferential direction CD is the first coil portion 215a, and the other is the second coil portion 215b.
[0083] In the coil unit 210, the number of turns of two coil portions 215 adjacent to each other in the circumferential direction CD is different. The number of turns of a coil portion 215 is the number of times that the coil wire 220 is wound around the coil portion 215. The number of turns of the first coil portion 215a is different from that of the second coil portion 215b. For example, the number of turns of the first coil portion 215a is greater than the number of turns of the second coil portion 215b.
[0084] 15, in the first coil portion 215a, both the first extension wire 216 and the second extension wire 217 are drawn out to one side in the radial direction RD. For example, in the first coil portion 215a, both the first extension wire 216 and the second extension wire 217 are drawn out radially inward. On the other hand, in the second coil portion 215b, the first extension wire 216 and the second extension wire 217 are drawn out in opposite directions in the radial direction RD. For example, in the second coil portion 215b, the first extension wire 216 is drawn out radially outward, and the second extension wire 217 is drawn radially inward. Therefore, if the number of turns of the first coil portion 215a is an integer, the number of turns of the second coil portion 215b is approximately 0.5 turns less than the number of turns of the first coil portion 215a.
[0085] <Composition group Ad> 16, 17, and 18, relay terminal 280 and power bus bar 261 are electrically connected. In power bus bar 261, bus bar terminal 263 is connected to relay terminal 280 by a connector such as a screw. The connector is a conductive member for passing current.
[0086] The motor device 60 has a terminal block 285. The terminal block 285 is formed from a resin material or the like and has electrical insulation properties. The terminal block 285 supports the connection portion between the relay terminal 280 and the bus bar terminal 263. For example, a connector is screwed into the terminal block 285, whereby the connection portion between the relay terminal 280 and the bus bar terminal 263 is fixed to the terminal block 285. In other words, the relay terminal 280 and the bus bar terminal 263 are connected by the terminal block 285. The terminal block 285 corresponds to a terminal block. The relay terminal 280 is electrically connected to the inverter 81. The relay terminal 280 is formed from, for example, a bus bar member and corresponds to a relay bus bar.
[0087] As shown in Fig. 18, the terminal base 285 has a base surface 285a. The base surface 285a extends in a direction perpendicular to the motor axis Cm. The relay terminal 280 has a relay connection portion 280a, and the bus bar terminal 263 has a bus bar connection portion 263a. The relay connection portion 280a and the bus bar connection portion 263a are connected by a connector while being placed on the base surface 285a. One of the relay connection portion 280a and the bus bar connection portion 263a is sandwiched between the other and the base surface 285a.
[0088] The relay terminal 280 has a relay extension portion 280b. The relay extension portion 280b extends from the relay terminal 280 toward the inverter device 80. For example, the relay extension portion 280b extends from the relay connection portion 280a in the axial direction AD. The bus bar terminal 263 has a bus bar extension portion 263b. The bus bar extension portion 263b extends from the bus bar terminal 263 toward the bus bar main body 262. For example, the bus bar extension portion 263b has a portion extending in the radial direction RD and a portion extending in the axial direction AD.
[0089] A terminal stand 285 is provided for each of the multiple phases. The terminal stands 285 are lined up in the circumferential direction CD along the bus bar unit 260. For example, the multiple terminal stands 285 include a terminal stand 285 for a U phase, a terminal stand 285 for a V phase, and a terminal stand 285 for a W phase. The terminal stands 285 are provided at positions aligned in the radial direction RD on the bus bar unit 260. The terminal stands 285 are located at a position spaced apart radially inward from the bus bar unit 260.
[0090] <Component group Ae> 19, the multiple relay terminals 280 are arranged at sufficient intervals. The distance between two adjacent relay terminals 280 in the circumferential direction CD is sufficiently large. For example, in a configuration in which three relay terminals 280 are arranged in the circumferential direction CD, the angle between two adjacent relay terminals 280 is approximately 120 degrees.
[0091] In the motor device 60, a plurality of virtual divided regions RE are arranged in the circumferential direction CD. The divided regions RE are regions obtained by dividing the circumference of the motor axis Cm at equal intervals in the circumferential direction CD. The number of divided regions RE is the same as the number of relay terminals 280. For example, if there are three relay terminals 280, there are also three divided regions RE. In this case, the three divided regions RE divide the circumference of the motor axis Cm in the circumferential direction CD at 120 degrees each.
[0092] One relay terminal 280 is arranged in each of the multiple divided regions RE. For example, one relay terminal 280 is arranged in each of three divided regions RE. If the three relay terminals 280 are arranged at 120-degree intervals, one relay terminal 280 will necessarily be arranged in each of the three divided regions RE. Even if the separation angle between the three relay terminals 280 is more or less than 120 degrees, a sufficient separation distance will still be ensured for at least two of the relay terminals 280.
[0093] Similar to the multiple relay terminals 280, the multiple bus bar terminals 263 and the multiple terminal stands 285 are also arranged at sufficient intervals in the circumferential direction CD. For example, when there are three bus bar terminals 263 and three terminal stands 285, one bus bar terminal 263 and one terminal stand 285 are arranged in each of the three divided regions RE.
[0094] <Constituent group Af> 20 and 21, the rear frame 370 supports both the bus bar unit 260 and the first bearing 360. The rear frame 370 has a bus bar support portion 371 and a bearing support portion 372. The rear frame 370 corresponds to the support frame, and the first bearing 360 corresponds to the bearing.
[0095] The bus bar support portion 371 is a portion of the rear frame 370 that supports the bus bar unit 260. The bus bar support portion 371 supports the bus bar protection portion 270, thereby supporting the power bus bar 261. The bus bar support portion 371 includes at least a portion of the rear frame 370 that overlaps with the bus bar unit 260 in the axial direction AD. The bus bar unit 260 is fixed to the bus bar support portion 371 with a fastener such as a bolt. The bus bar support portion 371 extends in the circumferential direction CD around the motor axis Cm. The bus bar support portion 371 is formed in an annular shape as a whole. The bus bar support portion 371 is located at a position spaced radially inward from the outer circumferential edge of the rear frame 370. The bus bar support portion 371 is located at a position spaced radially outward from the inner circumferential edge of the rear frame 370. The bus bar support portion 371 and the bearing support portion 372 are located at a position spaced apart in the radial direction RD.
[0096] The bearing support portion 372 is a portion of the rear frame 370 that supports the first bearing 360. The bearing support portion 372 includes at least a portion of the rear frame 370 that overlaps with the first bearing 360 in the axial direction AD. The bearing support portion 372 extends in the circumferential direction CD around the motor axis Cm. The bearing support portion 372 is formed in an annular shape as a whole. The bearing support portion 372 forms the inner peripheral edge of the rear frame 370.
[0097] The bearing support portion 372 has a support protrusion 372a. The support protrusion 372a protrudes in the axial direction AD from the rear frame 370 toward the drive frame 390. The support protrusion 372a extends in the circumferential direction CD and is formed in an annular shape as a whole. The support protrusion 372a is provided at a position spaced radially outward from the inner peripheral edge of the rear frame 370. The first bearing 360 is fixed to the bearing support portion 372 while fitting inside the support protrusion 372a. The first bearing 360 is fitted into, for example, the inside of the support protrusion 372a. Note that in FIG. 21, the bus bar support portion 371 and the bearing support portion 372 are indicated by dot hatching.
[0098] <Composition group Ag> 22, the resolver 421 is provided in the inverter-side space S2. The resolver 421 is placed on the rear frame 370 from the inverter device 80 side.
[0099] 22 and 23, the resolver 421 is provided with a resolver connector 423. The resolver connector 423 is a connector for electrically connecting the resolver 421 to an external device such as the control device 54. In the resolver connector 423, for example, an electric wire or the like forming a signal line 425 is electrically connected to the resolver 421. The resolver connector 423 protrudes from the resolver 421 in the axial direction AD.
[0100] At least a part of the resolver connector 423 is not covered by the resolver cover 424 and is exposed to the inverter device 80. The resolver cover 424 may be included in the resolver 421.
[0101] As shown in FIG. 22, the neutral point bus bar 290 is located at a position spaced apart from the resolver 421 in the axial direction AD. The neutral point bus bar 290 is located on the opposite side of the resolver 421 in the axial direction AD across the rear frame 370. The neutral point bus bar 290 is provided in the stator side space S1, while the resolver 421 is provided in the inverter side space S2. As shown in FIG. 23, the neutral point bus bar 290 is located at a position spaced apart from the resolver 421 in the radial direction RD. The neutral point bus bar 290 is located at a position spaced apart radially outward from the resolver 421. The rear frame 370 corresponds to the orthogonal frame.
[0102] <Composition group Ba> As shown in Figures 24, 25, and 26, the rotor 300 has a rotor first surface 301 and a rotor second surface 302. The rotor first surface 301 and the rotor second surface 302 extend in a direction perpendicular to the motor axis Cm. The rotor first surface 301 and the rotor second surface 302 extend in the circumferential direction CD around the motor axis Cm and are formed in an annular shape as a whole. In the rotor 300, one of a pair of plate surfaces is the rotor first surface 301, and the other is the rotor second surface 302.
[0103] In the motor device 60, the first rotor 300a and the second rotor 300b are installed with their respective rotor first surfaces 301 facing each other. In the first rotor 300a and the second rotor 300b, their respective rotor second surfaces 302 face in opposite directions. In the first rotor 300a, the rotor second surface 302 faces the rear frame 370.
[0104] 24 and 25, in rotor 300, multiple magnets 310 are arranged along rotor first surface 301. Magnets 310 are exposed on rotor first surface 301 but not on rotor second surface 302. Magnets 310 are covered by magnet holder 320 from the rotor second surface 302 side.
[0105] As shown in Figures 25 and 27, the rotor 300 has a magnet unit 316. The magnet unit 316 has at least one magnet 310. In this embodiment, the magnet unit 316 has a plurality of magnets 310. In the magnet unit 316, the plurality of magnets 310 are arranged in the circumferential direction CD. The magnet unit 316 has, for example, three magnets 310. A plurality of magnet units 316 are arranged in the circumferential direction CD on the rotor 300.
[0106] 27, the rotor 300 has a plurality of magnets 310 including a first circumferential magnet 311a, a second circumferential magnet 311b, a first inner axial magnet 312a, a second inner axial magnet 312b, a first outer axial magnet 313a, and a second outer axial magnet 313b. These circumferential magnets 311a, 311b, inner axial magnets 312a, 312b, and outer axial magnets 313a, 313b are arranged so as to strengthen the magnetic force on the stator 200. Such an arrangement of the magnets 310 is sometimes referred to as a Halbach array. Note that FIG. 27 is a plan view of the arrangement of the magnets 310 when the rotor 300 is viewed from the outside in the radial direction.
[0107] The first circumferential magnets 311a and the second circumferential magnets 311b are arranged in multiples in the circumferential direction CD. The first circumferential magnets 311a and the second circumferential magnets 311b are arranged alternately in the circumferential direction CD. The first circumferential magnets 311a and the second circumferential magnets 311b are magnets oriented in opposite directions to each other in the circumferential direction CD. The first circumferential magnet 311a is oriented toward one side of the circumferential direction CD, and the second circumferential magnet 311b is oriented toward the other side of the circumferential direction CD. For example, when a person views the rotor 300 from the opposite side of the stator 200, the first circumferential magnet 311a is oriented clockwise in the circumferential direction CD. The second circumferential magnet 311b is oriented counterclockwise in the circumferential direction CD. In this embodiment, the orientation direction corresponds to the magnetization direction of the magnet 310. The first circumferential magnet 311a and the second circumferential magnet 311b correspond to circumferential magnets.
[0108] The first inner axial magnets 312a and the second inner axial magnets 312b are arranged alternately in the circumferential direction CD. For example, the first inner axial magnets 312a and the second inner axial magnets 312b are arranged alternately one by one in the circumferential direction CD. The first inner axial magnets 312a and the second inner axial magnets 312b are magnets oriented inclined with respect to the motor axis Cm so as to face the stator 200 in the axial direction AD. In the circumferential direction CD, the first inner axial magnets 312a and the second inner axial magnets 312b are oriented in opposite directions to each other. In the circumferential direction CD, the first inner axial magnet 312a is oriented toward the same side as the first circumferential magnet 311a, and the second inner axial magnet 312b is oriented toward the same side as the second circumferential magnet 311b. The first inner axial magnet 312a and the second inner axial magnet 312b correspond to inner axial magnets.
[0109] The multiple magnets 310 include a pair of inner axial magnets 312a, 312b. The pair of inner axial magnets 312a, 312b are adjacent to each other in the circumferential direction CD. If the boundary between the pair of inner axial magnets 312a, 312b is referred to as an inner boundary portion BI, the first inner axial magnet 312a and the second inner axial magnet 312b forming the inner boundary portion BI constitute the pair of inner axial magnets 312a, 312b. The pair of inner axial magnets 312a, 312b are oriented at an angle with respect to the motor axis Cm so as to face the stator 200 in the axial direction AD and to face each other in the circumferential direction CD.
[0110] The first outer-axis magnets 313a and the second outer-axis magnets 313b are arranged alternately in the circumferential direction CD. The first outer-axis magnets 313a and the second outer-axis magnets 313b are arranged alternately one by one in the circumferential direction CD. The first outer-axis magnets 313a and the second outer-axis magnets 313b are magnets oriented at an angle with respect to the motor axis Cm so as to face the opposite side from the stator 200 in the axial direction AD. In the circumferential direction CD, the first outer-axis magnet 313a and the second outer-axis magnet 313b are oriented in opposite directions to each other. In the circumferential direction CD, the first outer-axis magnet 313a is oriented toward the same side as the first circumferential magnet 311a. In the circumferential direction CD, the second outer-axis magnet 313b is oriented toward the same side as the second circumferential magnet 311b. The first outer-axis magnet 313a and the second outer-axis magnet 313b correspond to outer-axis magnets.
[0111] The multiple magnets 310 include a pair of outer-axis magnets 313a, 313b. The pair of outer-axis magnets 313a, 313b are adjacent to each other in the circumferential direction CD. If the boundary between the pair of outer-axis magnets 313a, 313b is referred to as an outer boundary portion BO, the first outer-axis magnet 313a and the second outer-axis magnet 313b forming the outer boundary portion BO constitute the pair of outer-axis magnets 313a, 313b. The pair of outer-axis magnets 313a, 313b are oriented at an angle with respect to the motor axis Cm so as to face away from the stator 200 in the axial direction AD and to face opposite each other in the circumferential direction CD.
[0112] In the circumferential direction CD, a plurality of pairs of inner axial magnets 312a, 312b and a plurality of pairs of outer axial magnets 313a, 313b are arranged. The pairs of inner axial magnets 312a, 312b and the pairs of outer axial magnets 313a, 313b are arranged alternately in pairs in the circumferential direction CD. The pair of inner axial magnets 312a, 312b and the pair of outer axial magnets 313a, 313b are arranged such that the first inner axial magnet 312a and the first outer axial magnet 313a are adjacent to each other in the circumferential direction CD with the first circumferential magnet 311a interposed between them. In other words, the first circumferential magnet 311a is provided between the first inner axial magnet 312a and the first outer axial magnet 313a in the circumferential direction CD. The pair of inner axial magnets 312a, 312b and the pair of outer axial magnets 313a, 313b are arranged such that the second inner axial magnet 312b and the second outer axial magnet 313b are adjacent to each other in the circumferential direction CD with the second circumferential magnet 311b interposed between them. In other words, the second circumferential magnet 311b is provided between the second inner axial magnet 312b and the second outer axial magnet 313b in the circumferential direction CD.
[0113] The magnets 310 include a pair of circumferential magnets 311a and 311b. The pair of circumferential magnets 311a and 311b are adjacent to each other via a pair of inner axial magnets 312a and 312b. The pair of circumferential magnets 311a and 311b are oriented to face each other in the circumferential direction CD.
[0114] The multiple magnet units 316 include first orientation units 319a and second orientation units 319b. Multiple first orientation units 319a and multiple second orientation units 319b are arranged in the circumferential direction CD. The first orientation units 319a and the second orientation units 319b are arranged alternately one by one in the circumferential direction CD. The first orientation units 319a and the second orientation units 319b are oriented in opposite directions as a whole.
[0115] The first alignment unit 319a has one each of a first circumferential magnet 311a, a first inner axial magnet 312a, and a first outer axial magnet 313a. In the first alignment unit 319a, the first circumferential magnet 311a is disposed between the first inner axial magnet 312a and the first outer axial magnet 313a. In the first alignment unit 319a, the first circumferential magnet 311a, the first inner axial magnet 312a, and the first outer axial magnet 313a are fixed to one another and formed into a unit.
[0116] The second alignment unit 319b has one each of a second circumferential magnet 311b, a second inner axial magnet 312b, and a second outer axial magnet 313b. In the second alignment unit 319b, the second circumferential magnet 311b is disposed between the second inner axial magnet 312b and the second outer axial magnet 313b. In the second alignment unit 319b, the second circumferential magnet 311b, the second inner axial magnet 312b, and the second outer axial magnet 313b are fixed to one another and formed into a unit.
[0117] The first rotor 300a and the second rotor 300b are provided point-symmetrically to each other. The first rotor 300a is arranged in a direction rotated 180 degrees relative to the second rotor 300b. The first rotor 300a and the second rotor 300b face each other with their rotor first faces 301 sandwiched between the stator 200. When viewed from the opposite side of the stator 200, the first rotor 300a and the second rotor 300b have the same arrangement order of the circumferential magnets 311a, 311b, the inner axial magnets 312a, 312b, and the outer axial magnets 313a, 313b in the circumferential direction CD.
[0118] In the first rotor 300a and the second rotor 300b, the first circumferential magnets 311a are aligned in the axial direction AD. In the first rotor 300a and the second rotor 300b, a pair of inner axial magnets 312a, 312b of one rotor and a pair of outer axial magnets 313a, 313b of the other rotor are aligned in the axial direction AD. In this configuration, the first inner axial magnet 312a of one rotor and the first outer axial magnet 313a of the other rotor are aligned in the axial direction AD. Furthermore, the second inner axial magnet 312b of one rotor and the second outer axial magnet 313b of the other rotor are aligned in the axial direction AD. Furthermore, the inner boundary portion BI of one rotor and the outer boundary portion BO of the other rotor are aligned in the axial direction AD.
[0119] <Composition group Bb> As shown in Figures 28, 29, and 30, the rotor 300 includes a fixed block 330 and a magnet fixture 335 in addition to the magnet holder 320 and the magnet 310. The magnet fixture 335 is a fixture such as a bolt and is made of a metal material or the like. The magnet fixture 335 fixes the magnet 310 to the magnet holder 320 via the fixed block 330. In the rotor 300, the magnet 310 and the fixed block 330 are provided on the rotor first surface 301 side of the magnet holder 320. The magnet 310 is overlapped on the magnet holder 320 from the rotor first surface 301 side in the axial direction AD. The magnet 310 is sandwiched between the fixed block 330 and the magnet holder 320 in the axial direction AD. The magnet fixture 335 is threadedly attached to the fixed block 330, passing through the magnet holder 320 from the rotor second surface 302 side.
[0120] The magnet holder 320 has a holder main body 321 and an outer peripheral engagement portion 322. The holder main body 321 extends in a direction perpendicular to the motor axis Cm and is formed in a plate shape overall. The holder main body 321 forms the main portion of the magnet holder 320. The holder main body 321 extends in the circumferential direction CD around the motor axis Cm and is formed in an annular shape overall. The magnet holder 320 has a holder inner peripheral end 320a (see FIG. 31) and a holder outer peripheral end 320b. The holder inner peripheral end 320a is the inner peripheral end of the magnet holder 320, and the holder outer peripheral end 320b is the outer peripheral end of the magnet holder 320. The holder main body 321 forms the holder inner peripheral end 320a and the holder outer peripheral end 320b.
[0121] The outer circumferential engaging portion 322 is a protrusion provided on the holder main body 321, and protrudes from the holder main body 321 toward the rotor first surface 301 in the axial direction AD. The outer circumferential engaging portion 322 is provided on the holder outer circumferential end 320b. The outer circumferential engaging portion 322 has a portion that extends radially inward, with the magnet 310 sandwiched between this portion and the holder main body 321. The outer circumferential engaging portion 322 has an engaging tapered surface 322a. The engaging tapered surface 322a is an inclined surface that is inclined with respect to the motor axis Cm. The engaging tapered surface 322a faces radially inward and is inclined with respect to the motor axis Cm so as to face the holder main body 321. The magnet 310 is inserted between the engaging tapered surface 322a and the holder main body 321 from the radially inner side.
[0122] The fixed block 330 is made of a metal material or the like. The fixed block 330 is provided on the opposite side of the outer circumferential engagement portion 322 with the magnet 310 interposed therebetween in the radial direction RD. The fixed block 330 has a portion that extends radially outward, with the magnet 310 sandwiched between this portion and the holder main body 321. The fixed block 330 has a block tapered surface 330a. The block tapered surface 330a is included in the outer surface of the fixed block 330. The block tapered surface 330a is an inclined surface that is inclined with respect to the motor axis line Cm. The block tapered surface 330a faces radially outward and is inclined with respect to the motor axis line Cm so as to face the holder main body 321. The magnet 310 is inserted between the block tapered surface 330a and the holder main body 321 from the radially outward side.
[0123] The magnet 310 is provided between the outer circumferential engaging portion 322 and the fixed block 330 in the radial direction RD. The magnet 310 is fixed to the holder main body 321 in a state where it is sandwiched between the outer circumferential engaging portion 322 and the fixed block 330 in the radial direction RD.
[0124] As shown in Figure 31, a plurality of fixing blocks 330 and magnet fixing devices 335 are arranged in the circumferential direction CD together with the magnets 310. The fixing blocks 330 are suspended across the plurality of magnets 310 in the circumferential direction CD. The outer circumferential engaging portion 322 extends along the holder outer circumferential end 320b. The outer circumferential engaging portion 322 extends in the circumferential direction CD around the motor axis Cm and is formed in an annular shape as a whole.
[0125] The fixing block 330 and the magnet fixing tool 335 fix the magnet unit 316 to the magnet holder 320, thereby fixing the magnet 310. A plurality of magnet units 316 are arranged in the circumferential direction CD together with the fixing block 330 and the magnet fixing tool 335.
[0126] As shown in Figure 32, the magnet unit 316 has a unit inner peripheral end 316a, a unit outer peripheral end 316b, and a unit side surface 316c. The unit inner peripheral end 316a is the radially inner end of the magnet unit 316 and extends in the circumferential direction CD. The unit inner peripheral end 316a extends linearly, for example, along a tangent line perpendicular to the radial direction RD. The unit outer peripheral end 316b is the radially outer end of the magnet unit 316 and extends in the circumferential direction CD. The unit outer peripheral end 316b extends curvedly, for example, along an arc so as to bulge radially outward.
[0127] The unit side surfaces 316c are arranged in pairs in the circumferential direction CD in the magnet unit 316. The pair of unit side surfaces 316c extend in the radial direction RD. The unit side surfaces 316c are arranged across the unit inner peripheral end 316a and the unit outer peripheral end 316b in the radial direction RD.
[0128] The magnet unit 316 has an inner peripheral tapered surface 316d and an outer peripheral tapered surface 316e. The inner peripheral tapered surface 316d is inclined in the radial direction RD with respect to the motor axis Cm and extends radially outward from the unit inner peripheral end 316a. The outer peripheral tapered surface 316e is inclined in the radial direction RD with respect to the motor axis Cm and extends radially inward from the unit outer peripheral end 316b.
[0129] In the magnet unit 316, a unit inner peripheral end 316a, a unit outer peripheral end 316b, a unit side surface 316c, an inner peripheral tapered surface 316d, and an outer peripheral tapered surface 316e are formed by at least one magnet 310.
[0130] As shown in Figures 29 and 30, the magnet unit 316 is sandwiched between the fixed block 330 and the magnet holder 320, with the inner peripheral tapered surface 316d overlapping the block tapered surface 330a. The fixed block 330 fixes the magnet unit 316 to the magnet holder 320 by having the block tapered surface 330a press the inner peripheral tapered surface 316d toward the magnet holder 320 in the radial direction RD. Furthermore, the magnet unit 316 is sandwiched between the outer peripheral engaging portion 322 and the holder main body 321, with the outer peripheral tapered surface 316e overlapping the engaging tapered surface 322a. The outer peripheral engaging portion 322 and the fixed block 330 fix the magnet unit 316 to the magnet holder 320 in both the axial direction AD and the radial direction RD.
[0131] The fixed block 330 corresponds to the fixed support portion, the block tapered surface 330a corresponds to the support inclined surface, and the inner peripheral tapered surface 316d corresponds to the magnet inclined surface.
[0132] Next, a method for manufacturing the motor device 60 will be described. The process for manufacturing the motor device 60 includes a process for manufacturing the rotor 300. As a preparation process, an operator prepares the magnet unit 316, the magnet holder 320, the fixing block 330, and the magnet fixing tool 335. Then, the operator inserts the magnet unit 316 from the radially inner side between the holder main body 321 and the outer circumferential engagement portion 322 of the magnet holder 320. After that, the operator fixes the fixing block 330 to the holder main body 321 with the magnet fixing tool 335 so that the magnet unit 316 is sandwiched between the fixing block 330 and the holder main body 321 while overlapping the magnet unit 316 on the holder main body 321. As the operator screws the magnet fixing tool 335 into the holder main body 321, the outer circumferential tapered surface 316e is pressed against the engagement tapered surface 322a, and the block tapered surface 330a is pressed against the inner circumferential tapered surface 316d.
[0133] <Composition group Bc> 33, 34, and 35, the multiple magnet units 316 include inclined magnet units 317 and parallel magnet units 318. The inclined magnet units 317 and parallel magnet units 318 are arranged in multiples in the circumferential direction CD on the rotor 300. The inclined magnet units 317 and the parallel magnet units 318 are arranged alternately one by one in the circumferential direction CD.
[0134] As shown in Fig. 34, in the gradient magnet unit 317, a pair of unit side surfaces 316c are inclined so as to move away from each other radially outward. In the gradient magnet unit 317, the distance between the pair of unit side surfaces 316c gradually increases radially outward. In the gradient magnet unit 317, the unit outer peripheral end 316b is longer than the unit inner peripheral end 316a in the radial direction RD. The gradient magnet unit 317 is formed in an overall trapezoidal or sector shape.
[0135] In the parallel magnet unit 318, a pair of unit side surfaces 316c extend parallel to one another. The pair of unit side surfaces 316c extend in a direction perpendicular to the circumferential direction CD. In the parallel magnet unit 318, the distance between the pair of unit side surfaces 316c is uniform in the radial direction RD. In the parallel magnet unit 318, the unit outer peripheral end 316b and the unit inner peripheral end 316a have approximately the same length in the radial direction RD. The parallel magnet unit 318 is formed into a rectangular shape overall.
[0136] Next, a method for manufacturing the rotor 300 among the methods for manufacturing the motor device 60 will be described. In the process of manufacturing the rotor 300, as described above, an operator fixes the magnet unit 316 to the magnet holder 320 using the fixing block 330 and the magnet fixing tool 335. The operator arranges the inclined magnet units 317 and parallel magnet units 318 as the multiple magnet units 316 in the magnet holder 320 so that they are alternately arranged one by one in the circumferential direction CD. The operator inserts the unit outer circumferential ends 316b of both the inclined magnet units 317 and the parallel magnet units 318 between the outer circumferential engagement portion 322 and the holder main body 321. The operator arranges the parallel magnet unit 318 as the last magnet unit 316 to be arranged in the magnet holder 320. The worker inserts the last parallel magnet unit 318 between the two inclined magnet units 317 adjacent to each other in the circumferential direction CD, and inserts the unit outer circumferential end 316b between the outer circumferential engagement portion 322 and the holder main body 321.
[0137] Each time an operator places a magnet unit 316 in the magnet holder 320, the operator may fix the magnet unit 316 to the magnet holder 320 using the fixing block 330 and the magnet fixing tool 335. Alternatively, the operator may fix all of the magnet units 316 to the magnet holder 320 using the fixing block 330 and the magnet fixing tool 335 after placing all of the magnet units 316 in the magnet holder 320.
[0138] For example, unlike the present embodiment, assume a configuration in which all of the multiple magnet units 316 are inclined magnet units 317. In this configuration, during the manufacturing process of the rotor 300, an operator cannot insert the last inclined magnet unit 317 between two inclined magnet units 317 adjacent to each other in the circumferential direction CD. This is because, radially inward of the outer circumferential engagement portion 322, the separation distance between the two inclined magnet units 317 adjacent to each other in the circumferential direction CD is smaller than the width dimension of the unit outer circumferential end 316b of the last inclined magnet unit 317.
[0139] In contrast to this, in this embodiment, by using the parallel magnet unit 318 as the last magnet unit 316, the operator can insert this parallel magnet unit 318 between two inclined magnet units 317 adjacent to each other in the circumferential direction CD. This is because the separation distance between the two inclined magnet units 317 adjacent to each other in the circumferential direction CD is the same in the region radially inward of the outer circumferential engagement portion 322 and the region inside the outer circumferential engagement portion 322.
[0140] <Composition group Bd> As shown in Figures 36, 37, and 38, the rotor 300 has a holder fixture 350. The holder fixture 350 is a fixture such as a bolt, and is made of a metal material or the like. The holder fixture 350 fixes the magnet holder 320 to the shaft flange 342. A plurality of holder fixtures 350 are arranged in the circumferential direction CD. The holder fixture 350 is screwed into the shaft flange 342, for example, while passing through the magnet holder 320 from the rotor second surface 302 side.
[0141] As shown in Figures 36, 38, and 39, the shaft flange 342 has spokes 343 and a rim 344. The spokes 343 extend radially outward from the shaft main body 341. A plurality of the spokes 343 are arranged in the circumferential direction CD. The rim 344 extends in the circumferential direction CD around the motor axis Cm and is formed in an annular shape as a whole. The rim 344 is provided at a position spaced radially outward from the shaft main body 341. The rim 344 connects two spokes 343 that are adjacent to each other in the circumferential direction CD. The spokes 343 connect the shaft main body 341 and the rim 344 in the radial direction RD.
[0142] The rim 344 has a pair of rim tips 344a. The rim 344 extends in both axial directions AD from the spokes 343. The pair of rim tips 344a of the rim 344 are aligned in the axial direction AD. The rim tips 344a are located at positions spaced apart from the spokes 343 in the axial direction AD. In the axial direction AD, the height dimension of the rim 344 is greater than the height dimension of the spokes 343.
[0143] As shown in Figures 36, 37, and 38, the rotor 300 is placed on the shaft flange 342 from one side in the axial direction AD. At least the rim tip 344a of the shaft flange 342 is in contact with the rotor 300. Of the parts of the shaft 340 that are in contact with the rotor 300, the rim tip 344a is the radially outermost part. The rim tip 344a is located in a position on the rotor 300 that is spaced radially inward from the magnet 310. The holder fixture 350 is located in a position spaced radially inward from the rim tip 344a. The holder fixture 350 is located on the opposite side of the rim tip 344a from the magnet 310 in the radial direction RD.
[0144] The holder fixture 350 is inserted into the holder fixing hole 325 and the flange fixing hole 345 to fix the magnet holder 320 and the shaft flange 342. The holder fixing hole 325 is provided in the magnet holder 320. The holder fixing hole 325 passes through the magnet holder 320 in the axial direction AD. A plurality of the holder fixing holes 325 are arranged in the circumferential direction CD. The holder fixing holes 325 are located at a position spaced radially inward from the rim 344. The flange fixing holes 345 are provided in the shaft flange 342. The flange fixing holes 345 are provided in, for example, the spokes 343. The flange fixing holes 345 pass through the shaft flange 342 in the axial direction AD. A plurality of the flange fixing holes 345 are arranged in the circumferential direction CD. The flange fixing holes 345 are located at a position spaced radially inward from the rim 344. For example, the holder fixture 350 is threaded through the holder fixing hole 325 into the flange fixing hole 345 .
[0145] 36, in motor device 60, attractive force F1 is generated with respect to rotor 300. The attractive force F1 is a force that attracts magnet 310 toward coil 211 in axial direction AD, and is generated by the magnetic force of magnet 310. The attractive force F1 is a force that tries to bend the peripheral portion of magnet 310 in rotor 300 toward stator 200.
[0146] In the motor device 60, a bending stress F2 that resists the attractive force F1 is generated in the rotor 300. The bending stress F2 is a force that tries to bend the peripheral portion of the magnet 310 in the rotor 300 in the opposite direction to the stator 200. The bending stress F2 is generated when the holder fixture 350 presses the rotor 300 toward the stator 200. The holder fixture 350 applies a pressing force F3 to the rotor 300. The pressing force F3 is a force that presses the rotor 300 toward the stator 200 in the axial direction AD. In the rotor 300, the rim tip 344a serves as a fulcrum for the pressing force F3, thereby generating the bending stress F2. The holder fixture 350 corresponds to the pressing member, and the rim tip 344a corresponds to the fulcrum.
[0147] For example, assume a configuration in which pressing force F3 is not generated by holder fixture 350, unlike this embodiment. In this configuration, there is a concern that the peripheral portion of magnet 310 in rotor 300 approaches stator 200 in the axial direction AD, causing rotor 300 to deform and warp toward stator 200 with rim tip end 344a as the fulcrum. In contrast, in this embodiment, pressing force F3 generated by holder fixture 350 prevents rotor 300 from deforming and warping toward stator 200 with rim tip end 344a as the fulcrum.
[0148] <Constitution group Be> 40 and 41 , holder fixture 350 is fixed to shaft flange 342 at a location radially inward of rim 344. Holder fixture 350 passes through magnet holder 320 and is screwed onto spokes 343 at a position spaced radially inward from rim 344. A rotor gap GR is provided between the location of magnet holder 320 where holder fixture 350 is fixed and the location of spoke 343 where holder fixture 350 is fixed.
[0149] The portion of the magnet holder 320 where the holder fixture 350 is fixed is the holder fixing hole 325 in the magnet holder 320, into which the holder fixture 350 is inserted. The portion of the spokes 343 where the holder fixture 350 is fixed is the flange fixing hole 345 in the spokes 343, into which the holder fixture 350 is inserted. The rotor gap GR is a separation space formed between the rotor 300 and the shaft flange 342 in the axial direction AD. The rotor gap GR is formed between the magnet holder 320 and the spokes 343 in the axial direction AD. Radially inward of the rim 344, the magnet holder 320 and the spokes 343 are spaced apart in the axial direction AD.
[0150] The holder fixture 350 is capable of increasing or decreasing the width dimension of the rotor gap GR in the axial direction AD. As the amount by which the holder fixture 350 is screwed into the spokes 343 increases, the portion of the magnet holder 320 to which the holder fixture 350 is fixed and the portion of the spokes 343 to which the magnet fixture 335 is fixed approach each other, thereby reducing the rotor gap GR. As the amount by which the holder fixture 350 is screwed increases, the pressing force F3 increases, and the bending stress F2 increases. Therefore, by ensuring the rotor gap GR between the shaft flange 342 and the rotor 300, the bending stress F2 that resists the attractive force F1 can be adjusted.
[0151] For example, assume a configuration in which, unlike this embodiment, the portion of magnet holder 320 where holder fixture 350 is fixed and the portion of spoke 343 where holder fixture 350 is fixed are in contact with each other. In this configuration, it is difficult for holder fixture 350 to further deform magnet holder 320, and it is difficult to further increase pressing force F3. For this reason, even if pressing force F3 is insufficient relative to attractive force F1, there is a concern that this insufficiency cannot be resolved. In contrast, in this embodiment, the portion of magnet holder 320 where holder fixture 350 is fixed and the portion of spoke 343 where holder fixture 350 is fixed are spaced apart in the axial direction AD, making it possible to further increase pressing force F3.
[0152] Next, a method of assembling the rotor 300 and the shaft 340 will be described in the manufacturing method of the motor device 60. In the process of attaching the rotor 300 to the shaft 340, a worker inserts the holder fixture 350 into the holder fixing hole 325 and the flange fixing hole 345. When screwing the holder fixture 350, which has been inserted through the holder fixing hole 325, into the flange fixing hole 345, the worker adjusts the amount of screwing of the holder fixture 350 so that the peripheral portion of the magnet 310 in the magnet holder 320 is warped toward the rotor second surface 302. In other words, the worker adjusts the pressing force F3 using the holder fixture 350.
[0153] Thereafter, in the process of attaching stator 200 to rotor 300 and shaft 340, the worker checks that the peripheral portion of magnet 310 in rotor 300 is not warped in the axial direction AD. If the peripheral portion of magnet 310 in rotor 300 is aligned with axial direction AD, the worker adjusts the screw-in amount of holder fixture 350 to eliminate the warping of rotor 300. That is, the worker adjusts pressing force F3 by holder fixture 350 so that bending stress F2 is equal to attractive force F1.
[0154] <Constitution group Bf> As shown in Figures 43, 44, and 45, in the shaft flange 342, the multiple flange fixing holes 345 formed in the spokes 343 include a first flange fixing hole 345a and a second flange fixing hole 345b. If the holder fixing hole 325 formed in the first rotor 300a is referred to as the first holder fixing hole 325a, the first holder fixing hole 325a and the first flange fixing hole 345a are aligned in the axial direction AD. If the holder fixing hole 325 formed in the second rotor 300b is referred to as the second holder fixing hole 325b, the second holder fixing hole 325b and the second flange fixing hole 345b are aligned in the axial direction AD. The first flange fixing holes 345a and the second flange fixing holes 345b are aligned alternately in, for example, the circumferential direction CD.
[0155] 43 is a schematic diagram of the longitudinal section of the motor 61, in which the first rotor 300a, the second rotor 300b, and the shaft flange 342 are viewed from the radially inner side, and the arrangement of the holder fixtures 350 is developed on a plane.
[0156] As shown in Figures 42, 43, and 44, the motor device 60 has a first holder fixture 350a and a second holder fixture 350b as holder fixtures 350. The first holder fixture 350a fixes the first rotor 300a to the shaft flange 342. The first holder fixture 350a is inserted into the first holder fixing hole 325a and the first flange fixing hole 345a. For example, the first holder fixture 350a is threaded through the first holder fixing hole 325a and into the first flange fixing hole 345a. The first holder fixture 350a corresponds to the first fixture. The first holder fixing hole 325a corresponds to the first rotor hole, and the first flange fixing hole 345a corresponds to the first shaft hole.
[0157] The second holder fixture 350b fixes the second rotor 300b to the shaft flange 342. The second holder fixture 350b is inserted into the second holder fixing hole 325b and the second flange fixing hole 345b. The second holder fixture 350b is, for example, passed through the second holder fixing hole 325b and screwed into the second flange fixing hole 345b. The second holder fixture 350b corresponds to the second fixture. The second holder fixing hole 325b corresponds to the second rotor hole, and the second flange fixing hole 345b corresponds to the second shaft hole.
[0158] The first holder fixing hole 325a and the second holder fixing hole 325b are provided at positions spaced apart in the circumferential direction CD. The first flange fixing hole 345a and the second flange fixing hole 345b are positioned at positions spaced apart in the circumferential direction CD in accordance with the positional relationship between the first holder fixing hole 325a and the second holder fixing hole 325b.
[0159] 42 and 43, the motor device 60 has a positioning pin 355. The positioning pin 355 determines the relative positions of the rotor 300 and the shaft 340 in a direction perpendicular to the axial direction AD. The positioning pin 355 prevents the rotor 300 from shifting relative to the shaft 340 in the direction perpendicular to the axial direction AD. For example, the positioning pin 355 prevents the rotor 300 from shifting relative to the shaft 340 in the circumferential direction CD.
[0160] As shown in Figures 42, 43, and 44, the motor device 60 has holder pin holes 327. The holder pin holes 327 are included in the rotor 300. The holder pin holes 327 are provided in the magnet holder 320. The holder pin holes 327 penetrate the magnet holder 320 in the axial direction AD. A plurality of the holder pin holes 327 are aligned in the circumferential direction CD. The holder pin holes 327 are located at a distance radially inward from the rim 344. In the magnet holder 320, the holder fixing holes 325 and the holder pin holes 327 are aligned in the circumferential direction CD.
[0161] The motor device 60 has flange pin holes 348. The flange pin holes 348 are included in the shaft 340. The flange pin holes 348 are provided in the shaft flange 342. The flange pin holes 348 are provided in, for example, the spokes 343. The flange pin holes 348 penetrate the shaft flange 342 in the axial direction AD. A plurality of the flange pin holes 348 are aligned in the circumferential direction CD. The flange pin holes 348 are located at positions spaced radially inward from the rim 344. In the shaft 340, the flange fixing holes 345 and the flange pin holes 348 are aligned in the circumferential direction CD.
[0162] The holder pin hole 327 and the flange pin hole 348 are aligned in the axial direction AD. The positioning pin 355 is inserted into each of the holder pin hole 327 and the flange pin hole 348 while spanning between them in the axial direction AD. The positioning pin 355 is fitted into each of the holder pin hole 327 and the flange pin hole 348. For example, the positioning pin 355 is press-fit into the flange pin hole 348 and clearance-fit into the holder pin hole 327. The positioning pin 355 is configured to prevent play from occurring in the holder pin hole 327 and the flange pin hole 348. The positioning pin 355 is configured to not move relative to the holder pin hole 327 and the flange pin hole 348 in a direction perpendicular to the axial direction AD. For example, the positioning pin 355 is configured to not move relative to the holder pin hole 327 and the flange pin hole 348 in the circumferential direction CD.
[0163] The holder fixture 350 is prone to rattle relative to the holder fixing hole 325 and the flange fixing hole 345. For example, it is conceivable that the holder fixing hole 325 moves relative to the holder fixing hole 325 and the flange fixing hole 345 in the circumferential direction CD. In this case, there is a concern that the rotor 300 and the shaft 340 may become misaligned relative to each other in the circumferential direction CD. However, because rattle does not occur between the positioning pin 355 and the holder pin hole 327 and the flange pin hole 348, the positioning pin 355 suppresses misalignment between the rotor 300 and the shaft 340. The positioning pin 355, the holder pin hole 327, and the flange pin hole 348 are also shown in Figures 37, 38, and 39.
[0164] The holder pin hole 327 formed in the first rotor 300a is referred to as the first holder pin hole 327a, and the holder pin hole 327 formed in the second rotor 300b is referred to as the second holder pin hole 327b. A plurality of positioning pins 355 are included in the motor device 60. The plurality of positioning pins 355 includes a positioning pin 355 that positions the first rotor 300a and the shaft 340. This positioning pin 355 is fitted into the first holder pin hole 327a. The plurality of positioning pins 355 also includes a positioning pin 355 that positions the second rotor 300b and the shaft 340. This positioning pin 355 is fitted into the second holder pin hole 327b.
[0165] The first holder pin hole 327a and the second holder pin hole 327b are aligned in the axial direction AD via the flange pin hole 348. That is, the first holder pin hole 327a and the second holder pin hole 327b are not spaced apart in the circumferential direction CD. The positioning pin 355 fitted in the first holder pin hole 327a and the positioning pin 355 fitted in the second holder pin hole 327b are aligned in the axial direction AD. This makes it less likely that the positioning pin 355 will cause a difference in balance, such as rotational balance, between the first rotor 300a and the second rotor 300b.
[0166] For example, assume a configuration in which the first holder pin holes 327a and the second holder pin holes 327b are offset in the circumferential direction CD, unlike the present embodiment. In this configuration, there is a concern that a difference in balance may occur between the first rotor 300a and the second rotor 300b due to the offset in the circumferential direction CD of the positioning pins 355.
[0167] The shaft flange 342 has a thick flange portion 347. The thick flange portion 347 is a portion that is thicker than other portions of the shaft flange 342. The thick flange portion 347 protrudes from the spokes 343 on both one side and the other side in the axial direction AD.
[0168] The flange pin holes 348 are provided in the flange thick portion 347 of the shaft flange 342. The flange pin holes 348 penetrate the flange thick portion 347 in the axial direction AD. In the motor device 60, since the flange pin holes 348 are located in the flange thick portion 347, the flange pin holes 348 and the holder pin holes 327 are positioned as close as possible to each other in the axial direction AD. The portion of the positioning pin 355 between the flange pin hole 348 and the holder pin hole 327 in the axial direction AD is made as short as possible. This makes it less likely that the portion of the positioning pin 355 between the flange pin hole 348 and the holder pin hole 327 will deform, causing the rotor 300 to become misaligned relative to the shaft 340 in the circumferential direction CD.
[0169] Because flange pin hole 348 is provided in flange thick portion 347, the portion of positioning pin 355 that fits into flange pin hole 348 is made as long as possible in the axial direction AD. This makes it easier for positioning pin 355 to stand with good positioning accuracy relative to flange pin hole 348. Furthermore, because shaft flange 342 has flange thick portion 347, it is locally thick. Therefore, unlike a configuration in which the entire shaft flange 342 is thick, the weight of shaft flange 342 can be reduced while preventing rattle of positioning pin 355 relative to flange pin hole 348.
[0170] In the motor device 60, the first rotor 300a and the second rotor 300b are in a point-symmetric relationship. Therefore, one of the two components used as the rotor 300 can be the first rotor 300a, and the other can be the second rotor 300b, arranged so as to be point-symmetric with respect to the first rotor 300a. By sharing the same components as the first rotor 300a and the second rotor 300b in this way, the cost of manufacturing the first rotor 300a and the second rotor 300b can be reduced.
[0171] <Constituent group Ca> 46 and 47, the motor housing 70 has an inner circumferential surface 70b. The inner circumferential surface 70b is included in the inner surface of the motor housing 70 and extends annularly in the circumferential direction CD as a whole.
[0172] The motor housing 70 has a stator holding portion 171. The stator holding portion 171 is a protrusion provided on the inner circumferential surface 70b. The stator holding portion 171 protrudes radially inward from the housing main body 71. A plurality of stator holding portions 171 are arranged in at least one of the circumferential direction CD and the axial direction AD. The stator holding portion 171, together with the housing main body 71, form the inner circumferential surface 70b.
[0173] The multiple stator holding portions 171 include a first circumferential holding portion 172, a second circumferential holding portion 173, and a shaft holding portion 174. The first circumferential holding portion 172 and the second circumferential holding portion 173 extend in the circumferential direction CD along the housing main body 71. The first circumferential holding portion 172 and the second circumferential holding portion 173 are aligned in the axial direction AD and are provided parallel to each other. The first circumferential holding portion 172 is provided closer to the rear frame 370 than the second circumferential holding portion 173 in the axial direction AD. The first circumferential holding portion 172 is located at a position spaced apart from the end of the motor housing 70 on the rear frame 370 side toward the second circumferential holding portion 173. The second circumferential holding portion 173 is located at a position spaced apart from the end of the motor housing 70 on the opposite side from the inverter device 80 toward the first circumferential holding portion 172.
[0174] The shaft holding portion 174 extends in the axial direction AD along the housing main body 71. A plurality of the shaft holding portions 174 are arranged in the circumferential direction CD. The shaft holding portion 174 is bridged between the first circumferential holding portion 172 and the second circumferential holding portion 173 in the axial direction AD. The shaft holding portion 174 connects the first circumferential holding portion 172 and the second circumferential holding portion 173.
[0175] The motor housing 70 has a retaining recess 175. The retaining recess 175 is formed by a first circumferential retaining portion 172, a second circumferential retaining portion 173, and a shaft retaining portion 174. The retaining recess 175 is formed between the first circumferential retaining portion 172 and the second circumferential retaining portion 173 in the axial direction AD and between two adjacent shaft retaining portions 174 in the circumferential direction CD. The retaining recess 175 is a recess that is recessed radially outward relative to the first circumferential retaining portion 172, the second circumferential retaining portion 173, and the shaft retaining portion 174. A plurality of the retaining recesses 175 are arranged in the circumferential direction CD together with the shaft retaining portions 174.
[0176] As shown in Figures 48 and 49, inside the motor housing 70, the coil protection part 250 is overlapped on the inner circumferential surface 70b. The coil protection part 250 is in intimate contact with the inner circumferential surface 70b. The coil protection part 250 is inserted between the first circumferential holding part 172 and the second circumferential holding part 173 in the axial direction AD. The coil protection part 250 is inserted between two adjacent axial holding parts 174 in the circumferential direction CD. The coil protection part 250 is inserted inside the holding recess 175 and overlaps the inner surface of the holding recess 175.
[0177] The coil protection portion 250 is in a state of spanning between the first circumferential holding portion 172 and the second circumferential holding portion 173 in the axial direction AD. For example, the coil protection portion 250 is overlapped on the tip end surfaces of the first circumferential holding portion 172 and the second circumferential holding portion 173. Note that the coil protection portion 250 may protrude outward from the first circumferential holding portion 172 and the second circumferential holding portion 173 in the axial direction AD.
[0178] As shown in FIG. 49 , the multiple shaft holders 174 are arranged in the circumferential direction CD in accordance with the positions of the coil portions 215. The number of shaft holders 174 arranged in the circumferential direction CD is the same as the number of coil portions 215 arranged in the circumferential direction CD. The shaft holders 174 and the coil portions 215 are arranged in the axial direction AD and face each other in the axial direction AD. The coil portions 215 are provided at a position where their coil axes Cc pass through the shaft holders 174. The coil axes Cc are straight imaginary lines that pass through the centers of the coil portions 215 and extend in the radial direction RD. For example, the coil portions 215 are arranged at a position where their coil axes Cc pass through the centers of the shaft holders 174 in the circumferential direction CD. Furthermore, the coil portions 215 are arranged at a position where their coil axes Cc pass through the centers of the shaft holders 174 in the axial direction AD.
[0179] 49 is a cross-sectional view of the motor housing 70 and the stator 200, in which the outer circumferential surface 70a extends linearly. The motor housing 70 corresponds to the electric machine housing, and the shaft holding portion 174 corresponds to the shaft protrusion.
[0180] It is preferable that the coil protection part 250 has high thermal conductivity and electrical insulation. However, if it is difficult to increase both the thermal conductivity and the electrical insulation of the coil protection part 250, it is preferable to prioritize increasing the thermal conductivity over the electrical insulation. For example, the thermal conductivity of the coil protection part 250 is higher than that of the bobbin 240. Specifically, the thermal conductivity of the coil protection part 250 is higher than that of the bobbin 240. On the other hand, the electrical insulation of the coil protection part 250 is lower than that of the bobbin 240. Specifically, the dielectric constant of the coil protection part 250 is higher than that of the bobbin 240.
[0181] Next, a method for manufacturing the stator 200 among the methods for manufacturing the motor device 60 will be described. In the process of manufacturing the stator 200, a worker prepares the coil unit 210 and the motor housing 70 as a preparation step. Then, the worker places the coil unit 210 inside the motor housing 70 and mounts the motor housing 70 together with the coil unit 210 in a mold. The worker molds the coil protection part 250 inside the motor housing 70 by injection molding. In this motor device 60 in which the coil unit 210 and the motor housing 70 are integrated into the coil protection part 250 by insert molding, the coil protection part 250 is in intimate contact with both the coil part 215 and the inner circumferential surface 70b.
[0182] <Constitution group Cb> As shown in FIG. 50, the inner circumferential surface 70b of the motor housing 70 includes a housing base surface 176 and a housing rough surface 177. The housing rough surface 177 is rougher than the housing base surface 176. The housing rough surface 177 is roughened, for example, by providing a large number of minute irregularities. The housing rough surface 177 is formed by roughening the motor housing 70. The roughening method for forming the housing rough surface 177 includes mechanical processing and chemical processing.
[0183] The housing base surface 176 is provided outward in the axial direction AD from the stator holding portion 171. For example, the housing base surface 176 is provided outward in the axial direction AD from the first circumferential holding portion 172 and the second circumferential holding portion 173. The housing base surface 176 is formed in an annular shape along the inner circumferential surface 70b.
[0184] The housing rough surface 177 is provided inside the housing base surface 176, including the outer surface of the stator holding portion 171, in the axial direction AD. The housing rough surface 177 is provided on at least the inner surface of the holding recess 175. The housing rough surface 177 is provided on the outer surface of the stator holding portion 171. For example, the housing rough surface 177 is provided on the outer surfaces of the first circumferential holding portion 172, the second circumferential holding portion 173, and the shaft holding portion 174. Note that in Figure 50, the housing rough surface 177 is indicated by dot hatching.
[0185] At least the portion of the inner circumferential surface 70b on which the coil protection part 250 is placed is the housing rough surface 177. The housing rough surface 177 is a surface to which the coil protection part 250 is more likely to adhere than the housing base surface 176. The housing rough surface 177 also tends to have a larger surface area than the housing base surface 176. Therefore, the contact area between the housing rough surface 177 and the coil protection part 250 tends to be larger.
[0186] <Composition group Cc> As shown in Figures 51 and 52, in the stator 200, the power lead-out wire 212 is led out from the coil protection part 250. The grommet 255 is formed from a resin material or the like and has electrical insulation properties. The portion of the power lead-out wire 212 led out from the coil protection part 250 is protected by the grommet 255. The grommet 255 is included in the motor device 60. The grommet 255 covers the power lead-out wire 212, spanning the boundary between the portion of the power lead-out wire 212 embedded inside the coil protection part 250 and the portion of the power lead-out wire 212 exposed from the coil protection part 250. Note that the coil protection part 250 is not shown in Figure 51.
[0187] The grommet 255 has an embedded portion 255a and an exposed portion 255b. The embedded portion 255a is a portion of the grommet 255 that is embedded in the coil protection portion 250. The exposed portion 255b is a portion of the grommet 255 that is exposed from the coil protection portion 250. The exposed portion 255b extends from the embedded portion 255a toward the outside of the coil protection portion 250. The exposed portion 255b extends, for example, from the embedded portion 255a toward the rear frame 370 in the axial direction AD.
[0188] The power lead wires 212 are led out from the coil protection part 250 so as to extend in the axial direction AD along the inner circumferential surface 70b of the motor housing 70. As shown in FIGS. 52 and 53 , the motor housing 70 is provided with lead grooves 171a. The power lead wires 212 are led out from the coil protection part 250 through the lead grooves 171a. The lead grooves 171a are provided in the stator holding part 171. The lead grooves 171a are provided in the first circumferential holding part 172 and penetrate the first circumferential holding part 172 in the axial direction AD while being open radially inward.
[0189] As shown in FIGS. 51 and 52 , the grommet 255 covers at least the portion of the power lead-out wire 212 that passes through the lead-out groove 171a. The grommet 255 is inserted into the lead-out groove 171a from the radially inner side together with the power lead-out wire 212. The grommet 255 is in close contact with the inner surface of the lead-out groove 171a. The grommet 255 fills the gap between the inner surface of the lead-out groove 171a and the power lead-out wire 212. The grommet 255 is, for example, elastically deformable, and is fitted into the lead-out groove 171a by elastic deformation. The power lead-out wire 212 corresponds to a coil lead-out wire, and the grommet 255 corresponds to a lead-out wire protector.
[0190] Next, a method for manufacturing the coil protection part 250 among the methods for manufacturing the stator 200 will be described. In the process of manufacturing the coil protection part 250, a worker prepares the coil unit 210, the motor housing 70, and the grommet 255 as a preparation process. Then, the worker attaches the grommet 255 to the power lead wire 212 of the coil unit 210. The worker installs the coil unit 210 inside the motor housing 70 and fits the grommet 255 together with the power lead wire 212 into the lead groove part 171a.
[0191] An operator mounts the coil unit 210 and the motor housing 70 with the grommet 255 in a mold, and molds the coil protection part 250. In this case, because the grommet 255 is fitted in the drawing groove part 171a, the grommet 255 prevents the molten resin from flowing out of the drawing groove part 171a.
[0192] <Composition group Cd> 54, the core unit 230 has a core 231 and a bobbin 240. The core unit 230, together with the coil 211, is permanently covered by the coil protection part 250 and is protected by the coil protection part 250. The coil protection part 250 is in intimate contact with at least a part of the bobbin 240.
[0193] The bobbin 240 is made of a resin material or the like. The bobbin 240 is made of, for example, an epoxy-based thermosetting resin. The bobbin 240 is, for example, a molded resin formed by molding. The bobbin 240 has electrical insulation properties. The bobbin 240 has thermal conductivity, which allows heat from the core 231 to be easily transferred. The bobbin 240 has a thermal conductivity greater than that of air, for example.
[0194] The bobbin 240 covers at least a portion of the core 231 to protect the core 231. The bobbin 240 covers the core 231 so as to extend in a direction perpendicular to the axial direction AD. The bobbin 240 is formed in an annular shape as a whole. The bobbin 240 is in intimate contact with the outer surface of the core 231. The bobbin 240 facilitates the transfer of heat from the coil 211 to the coil protection part 250.
[0195] It is preferable that the bobbin 240 has high thermal conductivity and electrical insulation. However, if it is difficult to increase both the thermal conductivity and the electrical insulation of the bobbin 240, it is preferable to prioritize increasing the electrical insulation over the thermal conductivity. For example, the electrical insulation of the bobbin 240 is higher than the electrical insulation of the coil protection part 250. Specifically, the dielectric constant of the bobbin 240 is lower than the dielectric constant of the coil protection part 250. On the other hand, the thermal conductivity of the bobbin 240 is lower than the thermal conductivity of the coil protection part 250. Specifically, the thermal conductivity of the bobbin 240 is lower than the thermal conductivity of the coil protection part 250.
[0196] <Composition group Ce> 55, the bobbin 240 has a bobbin body 241 and a bobbin flange 242. The bobbin body 241 is formed in a columnar shape as a whole and extends in the axial direction AD. The outer peripheral surface 241a of the bobbin body 241 is formed in an annular shape so as to extend in a direction perpendicular to the axial direction AD.
[0197] The bobbin flange 242 extends outward from the outer peripheral surface 241a. The bobbin flange 242 extends from the outer peripheral surface 241a in a direction perpendicular to the axial direction AD and is formed in a plate shape as a whole. A pair of bobbin flanges 242 are provided side by side in the axial direction AD. In the bobbin 240, the coil 211 is wound around the bobbin body portion 241 between the pair of bobbin flanges 242.
[0198] The bobbin flange 242 has a flange inner plate surface 243, a flange outer plate surface 244, and a flange end surface 245. Of the pair of plate surfaces of the bobbin flange 242, the plate surface facing the bobbin barrel 241 is the flange inner plate surface 243, and the plate surface opposite the bobbin barrel 241 is the flange outer plate surface 244. The flange inner plate surfaces 243 of the pair of bobbin flanges 242 face each other. The flange end surface 245 is the tip surface of the bobbin flange 242 and extends in a direction perpendicular to the axial direction AD. The flange end surface 245 is located at a position spaced outward from the bobbin barrel 241.
[0199] The outer surface of the bobbin 240 includes a bobbin base surface 246 and a bobbin rough surface 247. The bobbin rough surface 247 is rougher than the bobbin base surface 246. The bobbin rough surface 247 is roughened, for example, by providing a large number of minute irregularities. The bobbin rough surface 247 is formed by roughening the bobbin 240 to form a rough surface. The roughening process for forming the bobbin rough surface 247 can be mechanical processing or chemical processing. In FIG. 55, the bobbin rough surface 247 is indicated by dot hatching.
[0200] The bobbin base surface 246 includes, for example, an outer peripheral surface 241a, a flange inner plate surface 243, and a flange outer plate surface 244. The bobbin rough surface 247 includes, for example, a flange end surface 245. Note that the flange outer plate surface 244 may be included in the rough surface.
[0201] In the bobbin 240, at least the portion on which the coil protection part 250 is overlapped is the bobbin rough surface 247. As shown in FIG. 56 , in the coil unit 210, when the coil 211 is wound around the bobbin 240, at least the flange outer plate surface 244 and the flange end surface 245 are exposed to the outside. Also, in the motor device 60, when the coil unit 210 is covered with the coil protection part 250, the coil protection part 250 covers at least the flange end surface 245. In other words, the coil protection part 250 overlaps the flange end surface 245. The coil protection part 250 basically does not cover the flange outer plate surface 244.
[0202] In the motor device 60, the flange end surface 245 is included in the bobbin rough surface 247, which makes it easier for the coil protection part 250 to come into close contact with the flange end surface 245. In addition, the flange end surface 245, which is the bobbin rough surface 247, tends to have a larger surface area than the bobbin base surface 246. Therefore, the contact area between the flange end surface 245 and the coil protection part 250 tends to be larger.
[0203] <Composition group Cf> 57 and 58, the core 231 has a core body portion 232 and a core flange 233. The core body portion 232 is formed in a plate shape as a whole and extends in the axial direction AD. The outer peripheral surface 232a of the core body portion 232 is formed in an annular shape so as to extend in a direction perpendicular to the axial direction AD.
[0204] The core flange 233 extends outward from the outer peripheral surface 232a. The core flange 233 extends from the outer peripheral surface 232a in a direction perpendicular to the axial direction AD and is formed in a plate shape as a whole. A pair of core flanges 233 are provided side by side in the axial direction AD. In the core 231, the coil 211 is wound around the core body portion 232 between the pair of core flanges 233 via the bobbin body portion 241.
[0205] As shown in Figures 58 and 59, the core 231 as a whole gradually tapers radially inward. The core width of the core 231 gradually decreases radially inward. The core width is the width dimension of the core 231 in the circumferential direction CD. The outer surface of the core 231 includes a core step surface 234. The core step surface 234 extends in a stepped manner in the radial direction RD. The core step surface 234 is provided on each of the core body portion 232 and the core flange 233. A pair of core step surfaces 234 are provided side by side in the circumferential direction CD on each of the core body portion 232 and the core flange 233.
[0206] The core stair surface 234 has a stair base surface 234a and a stair connection surface 234b. A plurality of stair base surfaces 234a and stair connection surfaces 234b are arranged in the radial direction RD. The stair base surfaces 234a extend in a direction perpendicular to the circumferential direction CD. Of two stair base surfaces 234a adjacent to each other in the radial direction RD, the radially inner stair base surface 234a is positioned more inward in the circumferential direction CD than the radially outer stair base surface 234a. The stair connection surface 234b extends in a direction perpendicular to the radial direction RD. The stair connection surface 234b connects two stair base surfaces 234a adjacent to each other in the radial direction RD.
[0207] The core 231 is formed by a plurality of core forming plate materials 236. As shown in FIG. 60 , the core forming plate material 236 is a thin plate-like member. The core forming plate material 236 is formed, for example, from a soft magnetic material. The core 231 is formed by stacking a plurality of core forming plate materials 236. The core 231 includes a plurality of types of core forming plate materials 236 with different sizes and shapes. In the core 231, a plurality of types of core forming plate materials 236 are used to match the core width. In the core 231, the multiple core forming plate materials 236 that form one staircase base surface 234a are one type of core forming plate material 236 with the same size and shape. The core 231 includes at least as many types of core forming plate materials 236 as the number of staircase base surfaces 234a.
[0208] In the core 231, multiple core forming plates 236 are stacked, making it difficult for eddy currents to occur. This reduces eddy current loss that occurs in the core 231. In the core unit 230, the bobbin 240 is stacked on at least the core stepped surface 234. The core 231 includes the core stepped surface 234 on its outer surface, which tends to increase the surface area. In the core unit 230, the core stepped surface 234 tends to increase the contact area between the core 231 and the bobbin 240.
[0209] Among the methods for manufacturing the motor device 60, a method for manufacturing the core 231 and the core unit 230 will be described. In the process of manufacturing the core 231, an operator prepares multiple types of core forming plate materials 236. Then, the operator stacks multiple core forming plate materials 236 of one type to create one staircase base surface 234a, and performs this process for multiple staircase base surfaces 234a, thereby creating the core 231.
[0210] In the process of manufacturing the core unit 230, an operator prepares the core 231 as a preparation process. Then, the operator mounts the core 231 in a mold and forms the bobbin 240 by molding. In the core unit 230 in which the core 231 is integrated with the bobbin 240 by insert molding in this manner, the bobbin 240 is in close contact with the core 231. In the core 231, the bobbin 240 is in close contact with the core stepped surface 234.
[0211] For example, unlike the present embodiment, a configuration is assumed in which the core width of the core 231 continuously decreases radially inward. In this configuration, the outer surface of the core 231 includes a tapered surface rather than a stepped core surface 234. Therefore, forming a tapered surface by stacking multiple core forming plate materials 236 requires a large number of different core forming plate materials 236. Regarding the manufacture of the core 231, there is a concern that the cost of manufacturing the core forming plate materials 236 increases as the number of different core forming plate material 236 increases. In contrast, in the present embodiment, the core width of the core 231 gradually decreases radially inward, so the number of different core forming plate material 236 can be limited. Therefore, regarding the manufacture of the core 231, the cost of manufacturing the core forming plate materials 236 can be reduced.
[0212] <Composition group Cg> As shown in Figures 61, 62, 63, and 64, the bobbin 240 has flange recesses 243a. The flange recesses 243a are provided in each of the pair of bobbin flanges 242. The flange recesses 243a are recesses provided in the flange inner plate surface 243. The flange recesses 243a are provided on one side of the bobbin barrel portion 241 in the circumferential direction CD. The flange recesses 243a are not provided on the other side of the bobbin barrel portion 241 in the circumferential direction CD. The flange recesses 243a extend in the radial direction RD along the bobbin barrel portion 241. Both end ends of the flange recesses 243a are open in the radial direction RD. The flange recesses 243a are open toward the opposite side of the bobbin barrel portion 241 in the circumferential direction CD. The flange recesses 243a provided in each of the pair of bobbin flanges 242 face each other in the axial direction AD. The flange inner plate surface 243 corresponds to the flange surface.
[0213] 65, in the coil unit 210, a flange recess 243a is used to draw out the power lead wire 212 from the coil 211. In the coil section 215, the flange recess 243a is used to draw out the first extension wire 216. In the coil section 215, the coil wire 220 is drawn through the flange recess 243a to form the first extension wire 216.
[0214] On the side opposite the flange recessed portion 243a across the bobbin body portion 241 in the circumferential direction CD, the absence of the flange recessed portion 243a reduces the likelihood of dead space being generated between the coil portion 215 and the flange inner plate surface 243. In this way, the likelihood of dead space being generated between the pair of bobbin flanges 242 can increase the space factor of the coil 211 in the bobbin 240. In the bobbin 240, the smaller the dead space generated between the pair of bobbin flanges 242, the higher the space factor of the coil 211.
[0215] <Constituent group Da> As shown in Figure 66, in the motor device unit 50, the unit housing 51 has a motor housing 70 and an inverter housing 90. The outer peripheral surface of the unit housing 51 includes an outer peripheral surface 70a of the motor housing 70 and an outer peripheral surface 90a of the inverter housing 90. The outer peripheral surface of the unit housing 51 is provided with motor fins 72 and inverter fins 92. The unit housing 51 accommodates a stator 200, a rotor 300, and an inverter 81. In the motor device unit 50, the motor fins 72 and the inverter fins 92 make it easy for heat from the motor 61 and the inverter 81 to be released to the outside.
[0216] In the unit housing 51, the motor housing 70 and the inverter housing 90 are integrated. The motor housing 70 and the inverter housing 90 are arranged in the axial direction AD along the motor axis Cm. The motor housing 70 corresponds to the electric machine housing, and the inverter housing 90 corresponds to the device housing.
[0217] The motor housing 70 and the inverter housing 90 are fixed together by a housing fastener 52. The housing fastener 52 is a fastener such as a bolt. The housing fastener 52 connects a connecting flange 74 of the motor housing 70 to a connecting flange 94 of the inverter housing 90. The connecting flange 74 is provided on the outer peripheral surface 70a of the motor housing 70 and protrudes radially outward from the housing main body 71. The connecting flange 94 is provided on the outer peripheral surface 90a of the inverter housing 90 and protrudes radially outward from the housing main body 91.
[0218] As shown in Figures 66 and 67, the coil protection part 250 is overlapped on the inner circumferential surface 70b of the motor housing 70. The inner circumferential surface 70b of the motor housing 70 is included in the inner circumferential surface of the unit housing 51. The coil protection part 250 is overlapped on the inner circumferential surface of the unit housing 51. The coil protection part 250 is in intimate contact with the inner circumferential surface of the unit housing 51.
[0219] <Configuration group Db> As shown in Figures 68 and 69, in the shaft 340, the rim 344 of the shaft flange 342 is formed in a plate shape as a whole. A pair of plate surfaces of the rim 344 face the radial direction RD. The thickness direction of the rim 344 is the radial direction RD. The rim 344 extends annularly in the circumferential direction CD and corresponds to an annular portion. The rim 344 forms the outer peripheral end of the shaft flange 342. The rim 344 is in a state of spanning between the first rotor 300a and the second rotor 300b in the axial direction AD.
[0220] As shown in FIG. 68, the rim 344 is provided inside the stator 200. The rim 344 is located at a distance radially inward from the stator 200. The rim 344 divides the inner space of the stator 200 in the radial direction RD. The inner space of the stator 200 is a space that exists radially inside the coil protection part 250. This inner space is sometimes referred to as the inner region. The rim 344 extends in the axial direction AD along the inner circumferential surface of the coil protection part 250. In the axial direction AD, the height dimension of the rim 344 and the height dimension of the coil protection part 250 are approximately the same.
[0221] As shown in Figures 69, 70, 71, and 72, the shaft flange 342 has a flange vent 346. The flange vent 346 is provided in the rim 344 and penetrates the rim 344 in the radial direction RD. The flange vent 346 is located at a position spaced apart from both of the pair of rim tip ends 344a in the axial direction AD. For example, the flange vent 346 is located at a middle position of the rim 344 in the axial direction AD.
[0222] A plurality of flange vents 346 are arranged in the circumferential direction CD. In the shaft flange 342, the flange vents 346 and the spokes 343 are arranged in the circumferential direction CD. Each flange vent 346 is provided between two adjacent spokes 343 in the circumferential direction CD. Each of the two spokes 343 adjacent to each other in the circumferential direction CD across a flange vent 346 is located at a distance from the flange vent 346.
[0223] In FIG. 68 , the flange air vents 346 allow ventilation in the radial direction RD in the internal space of the motor device 60. The flange air vents 346 connect a space radially inward of the rim 344 with a space radially outward of the rim 344. In the internal space of the coil protection part 250, heat from the stator 200 is easily released to the inside of the rim 344 through the flange air vents 346. Furthermore, the stator 200 is easily cooled by gaseous air flowing through the flange air vents 346 in the radial direction RD. Inside the motor housing 70, air convection in the radial direction RD is easily generated through the flange air vents 346.
[0224] <Composition group Dc> As shown in Figures 73 and 74, the rotor 300 has holder adjustment holes 326. The holder adjustment holes 326 are provided in the magnet holder 320. The holder adjustment holes 326 penetrate the magnet holder 320 in the axial direction AD, and thereby penetrate the rotor 300 in the axial direction AD. The holder adjustment holes 326 are provided radially inward of the magnets 310. For example, the holder adjustment holes 326 are provided between the holder fixing holes 325 and the magnet fixing device 335 in the radial direction RD. A plurality of holder adjustment holes 326 are arranged in the circumferential direction CD. For example, the number of holder adjustment holes 326 arranged is the same as the number of magnet fixing devices 335.
[0225] The rotor 300 may be out of balance due to, for example, the center of gravity being shifted in the radial direction RD from the motor axis Cm. To achieve balance, a weight member is attached to the magnet holder 320 of the rotor 300. The weight member attached to the rotor 300 is inserted into one of a plurality of holder adjustment holes 326 depending on the balance state of the rotor 300. The weight member is fixed to the holder adjustment hole 326 by, for example, fitting into the holder adjustment hole 326. The balance of the rotor 300 includes static balance when the rotor 300 is not rotating, and rotational balance when the rotor 300 is rotating. The holder adjustment hole 326 corresponds to the balance adjustment hole.
[0226] A portion of the holder adjustment hole 326 is blocked in the axial direction AD by a rim 344. The weight member is inserted into the holder adjustment hole 326 from the rotor second surface 302 side in the axial direction AD. By blocking a portion of the holder adjustment hole 326, the rim 344 prevents the weight member from falling out of the holder adjustment hole 326 toward the rotor first surface 301 side.
[0227] 73, the magnet holder 320 of both the first rotor 300a and the second rotor 300b divides the internal space of the motor housing 70 in the axial direction AD. For example, the magnet holder 320 of the first rotor 300a divides the internal space of the motor housing 70 into a space on the rear frame 370 side and a space on the stator 200 side. The magnet holder 320 of the second rotor 300b divides the internal space of the motor housing 70 into a space on the stator 200 side and a space on the drive frame 390 side.
[0228] The holder adjustment hole 326 allows ventilation in the axial direction AD in the internal space of the motor device 60. The holder adjustment hole 326 connects two spaces that are separated in the axial direction AD by the magnet holder 320. This makes it easier for heat from the stator 200 to be released in the axial direction AD through the holder adjustment hole 326. In addition, air flows through the holder adjustment hole 326 in the axial direction AD, which makes it easier for the stator 200 to be cooled. Inside the motor housing 70, air convection in the axial direction AD is more likely to occur through the holder adjustment hole 326.
[0229] For example, the holder adjustment hole 326 of the first rotor 300a communicates between a space closer to the rear frame 370 than the first rotor 300a and a space closer to the stator 200 than the first rotor 300a. Therefore, heat from the stator 200 is easily released to the rear frame 370 side through the holder adjustment hole 326 of the first rotor 300a. Furthermore, the holder adjustment hole 326 of the second rotor 300b communicates between a space closer to the stator 200 than the second rotor 300b and a space closer to the drive frame 390 than the second rotor 300b. Therefore, heat from the stator 200 is easily released to the drive frame 390 side through the holder adjustment hole 326 of the second rotor 300b.
[0230] <Composition group Dd> As shown in Fig. 75, the rear frame 370 has a frame opening 373. The frame opening 373 penetrates the rear frame 370 in the axial direction AD. The frame opening 373 is an opening that opens the rear frame 370 in the axial direction AD. The frame opening 373 is provided radially outward of the bus bar unit 260 in the radial direction RD. A plurality of the frame openings 373 are arranged in the circumferential direction CD.
[0231] The power lead-out wires 212 are inserted through the frame openings 373 in the axial direction AD. The power lead-out wires 212 are drawn out through the frame openings 373 to the power bus bar 261 side. The portion of the power lead-out wire 212 drawn out from the frame openings 373 is electrically connected to the power bus bar 261. At least one power lead-out wire 212 is inserted through the frame openings 373.
[0232] In the motor device unit 50, the rear frame 370 and the resolver cover 424 divide the interior of the unit housing 51 into an inverter device 80 side and a motor device 60 side. The rear frame 370 and the resolver cover 424 extend as a whole in a direction perpendicular to the axial direction AD. The rear frame 370 and the resolver cover 424 correspond to a housing partition.
[0233] As shown in Figures 75 and 76, the temperature sensor 431 is provided in, for example, the coil unit 210 of the motor 61. For example, a plurality of temperature sensors 431 are provided. The temperature sensor 431 is attached to the neutral point bus bar 290. The neutral point bus bar 290 has a bus bar main body 291 and a sensor support portion 292. The bus bar main body 291 forms the main part of the neutral point bus bar 290. The bus bar main body 291 is suspended across a plurality of coil portions 215 in the neutral point unit 214. The sensor support portion 292 supports the temperature sensor 431. The sensor support portion 292 is, for example, a protrusion protruding from the bus bar main body 291. The temperature sensor 431 is fixed to the sensor support portion 292.
[0234] 75, the motor device 60 has a signal terminal block 440. The signal terminal block 440 is provided on the inverter device 80 side of the rear frame 370 and the resolver cover 424 in the axial direction AD. The signal terminal block 440 is attached to at least one of the rear frame 370 and the resolver cover 424. The signal terminal block 440 is aligned with the resolver connector 423 in a direction perpendicular to the axial direction AD.
[0235] The motor device 60 has a signal wiring 426. The signal wiring 426 extends from the resolver connector 423. The signal wiring 426 is a conductive member such as an electric wire, and forms a signal line 425. The signal wiring 426 is electrically connected to the resolver 421 via the resolver connector 423.
[0236] The motor device 60 has a signal wiring 436. The signal wiring 436 extends from the temperature sensor 431. The signal wiring 436 is a conductive member such as an electric wire, and forms a signal line 435. The signal wiring 436 is electrically connected to the temperature sensor 431.
[0237] The signal terminal block 440 collects the signal wires 426, 436 and corresponds to a wire collecting section. The signal wires 426, 436 are drawn into the signal terminal block 440. The signal terminal block 440 has a plurality of terminal portions and a case that houses these terminal portions. The signal wires 426, 436 drawn into the signal terminal block 440 are electrically connected to the terminal portions, respectively.
[0238] For the resolver 421, a signal wiring 426 is laid between the resolver connector 423 and the signal terminal block 440. The signal wiring 426 extends along the rear frame 370 and the resolver cover 424, closer to the inverter device 80 than the rear frame 370 and the resolver cover 424. The resolver 421 can detect the state of the motor device 60 by detecting the rotation angle of the motor 61. The resolver 421 corresponds to a state detection unit, and the signal wiring 426 corresponds to a detection wiring.
[0239] For the temperature sensor 431, a signal wire 436 is laid between the temperature sensor 431 and a signal terminal block 440. The signal wire 436 is inserted through a frame opening 373, and thereby penetrates the rear frame 370 and the resolver cover 424 in the axial direction AD. The temperature sensor 431 can detect the state of the motor device 60 by detecting the temperature of the motor 61. The temperature sensor 431 corresponds to a state detection unit, and the signal wire 436 corresponds to a detection wire.
[0240] A plurality of inverter wirings of the inverter device 80 are drawn into the signal terminal block 440. The plurality of inverter wirings include inverter wirings that form signal lines 425, 435 together with signal wirings 426, 436. The inverter wirings are electrically connected to the signal wirings 426, 436 via terminal portions in the signal terminal block 440. The inverter wirings connected to the signal wirings 426, 436 are electrically connected to the control device 54 in the inverter device 80, for example.
[0241] <Composition group De> 77, the dustproof cover 380 covers all of the frame openings 373. The dustproof cover 380 is suspended across the multiple frame openings 373 in the circumferential direction CD. The dustproof cover 380 closes the frame openings 373 from the inverter device 80 side in the axial direction AD. The dustproof cover 380 prevents foreign matter from passing through the frame openings 373 in the axial direction AD.
[0242] The dustproof cover 380 covers the power lead-out wire 212 and the bus bar unit 260 from the inverter device 80 side. The dustproof cover 380 has electrical insulation properties, and prevents a decrease in the insulation reliability between the power lead-out wire 212 and the power bus bar 261 and the inverter device 80. The dustproof cover 380 is inserted between the bus bar unit 260 and the bus bar terminal 263 in the axial direction AD.
[0243] The signal wiring 436 extending from the temperature sensor 431 penetrates the dustproof cover 380 and is drawn out to the inverter device 80 side. The dustproof cover 380 has a wiring hole 381. The wiring hole 381 penetrates the dustproof cover 380 in the axial direction AD. The signal wiring 436 penetrates the dustproof cover 380 by passing through the wiring hole 381. The wiring hole 381 has a size and shape that allows it to be blocked by the signal wiring 436. When the signal wiring 436 is passed through the wiring hole 381, foreign matter is less likely to pass through the wiring hole 381. The wiring hole 381 is provided at a position closer to the outer periphery of the dustproof cover 380 than to the inner periphery. A plurality of wiring holes 381 are provided in the dustproof cover 380. One signal wiring 436 is passed through one wiring hole 381.
[0244] The rear frame 370 and the resolver cover 424 correspond to a housing partition, and the dust cover 380 corresponds to a partition cover. The frame opening 373 corresponds to a partition opening, and the power lead wire 212 corresponds to a coil lead wire. The signal wiring 436 may be routed between the dust cover 380 and the rear frame 370 and led out to the inverter device 80 side.
[0245] <Composition group Df> 78 and 79, the motor housing 70 has a connecting flange 74. The connecting flange 74 extends radially outward from the housing main body 71 and corresponds to an electric flange. A plurality of the connecting flanges 74 are arranged in the circumferential direction CD.
[0246] The connecting flange 74 has a flange hole 74a. The flange hole 74a extends in the axial direction AD. The flange hole 74a penetrates the connecting flange 74 in the axial direction AD. The flange hole 74a is a hole for fixing the motor housing 70 to the inverter housing 90 and corresponds to an electric machine fixing hole. Of the housing main body 71 and the connecting flange 74, the flange hole 74a is provided only in the connecting flange 74. The connecting flange 74 is connected to the connecting flange 94 of the inverter housing 90 by screwing the housing fastener 52 into the flange hole 74a. The inverter housing 90 is a fixing object to which the motor housing 70 is fixed and corresponds to a housing fixing object. The connecting flange 74 is sometimes referred to as an ear portion.
[0247] As described above, in the motor housing 70, of the housing main body 71 and the connecting flange 74, the flange hole 74a is formed only in the connecting flange 74. Therefore, the rigidity of the housing main body 71 is not reduced by the flange hole 74a. In the motor housing 70, flange portions where the connecting flange 74 is formed in the housing main body 71 and non-flange portions where the connecting flange 74 is not formed in the housing main body 71 are arranged alternately in the circumferential direction CD. Even though the flange hole 74a is formed in the connecting flange 74, the thickness dimension of the flange portions in the radial direction RD is larger than the thickness dimension of the non-flange portions. The rigidity of the flange portions is higher than the rigidity of the non-flange portions by the thickness dimension of the connecting flange 74.
[0248] For example, assume a configuration different from the present embodiment in which a hole for fixing the housing fastener 52 is provided in the housing main body 71. In this configuration, the housing main body 71 becomes thinner by the amount of the hole for the housing fastener 52. For this reason, there is a concern that the rigidity of the housing main body 71 will be reduced by the hole for the housing fastener 52.
[0249] As shown in Figures 78 and 80, the motor housing 70 has a fixing flange 178. The fixing flange 178 is provided on the outer peripheral surface 70a of the motor housing 70. The fixing flange 178 protrudes radially outward from the housing main body 71 and corresponds to an electric flange. A plurality of fixing flanges 178 are arranged in the circumferential direction CD.
[0250] The fixing flange 178 has a flange hole 178a. The flange hole 178a extends in the axial direction AD. The flange hole 178a penetrates the fixing flange 178 in the axial direction AD. The flange hole 178a is a hole for fixing the motor housing 70 to the drive frame 390 and corresponds to an electric machine fixing hole. The flange hole 178a is provided only in the fixing flange 178 out of the housing main body 71 and the fixing flange 178. The fixing flange 178 is fixed to the drive frame 390 by screwing a frame fixing device 405 into the flange hole 178a. The drive frame 390 is a fixing target to which the motor housing 70 is fixed and corresponds to a housing fixing target. The fixing flange 178 is sometimes referred to as an ear portion. Note that the drive frame 390 is not shown in Figure 80.
[0251] As described above, in the motor housing 70, of the housing main body 71 and the fixed flange 178, the flange hole 178a is formed only in the fixed flange 178. Therefore, the rigidity of the housing main body 71 is not reduced by the flange hole 178a. In the motor housing 70, flange portions where the housing main body 71 is provided with the fixed flange 178 and non-flange portions where the housing main body 71 is not provided with the fixed flange 178 are arranged alternately in the circumferential direction CD. Even though the fixed flange 178 has the flange hole 178a formed in it, the thickness of the flange portions in the radial direction RD is larger than the thickness of the non-flange portions. The rigidity of the flange portions is higher than the rigidity of the non-flange portions by the thickness of the fixed flange 178.
[0252] For example, assume a configuration different from the present embodiment in which a hole for fixing the frame fastener 405 is provided in the housing main body 71. In this configuration, the housing main body 71 becomes thinner by the amount of the hole for the frame fastener 405. For this reason, there is a concern that the rigidity of the housing main body 71 will be reduced by the hole for the frame fastener 405.
[0253] <Composition group Dg> 81, 82, and 83, the drive frame 390 covers the motor 61 from the side opposite the inverter device 80 in the axial direction AD. The drive frame 390 closes the opening of the motor housing 70 from the second rotor 300b side. The motor housing 70 corresponds to the electric machine housing, and the drive frame 390 corresponds to the electric machine cover portion.
[0254] The drive frame 390 has a frame main body 391 and a fixing flange 392. The frame main body 391 is formed in a plate shape overall and extends in a direction perpendicular to the axial direction AD. The frame main body 391 closes the opening of the motor housing 70. The outer peripheral edge of the frame main body 391 extends in the circumferential direction CD along the outer peripheral surface 70a of the motor housing 70.
[0255] The fixing flanges 392 extend radially outward from the frame main body 391. A plurality of the fixing flanges 392 are arranged in the circumferential direction CD. For example, eight fixing flanges 392 are arranged in the circumferential direction CD. The fixing flanges 392 are positioned to be aligned in the axial direction AD with the fixing flanges 178 of the motor housing 70.
[0256] The fixing flange 392 has a first fixing hole 392a and a second fixing hole 392b. The first fixing hole 392a and the second fixing hole 392b extend in the axial direction AD. The first fixing hole 392a and the second fixing hole 392b penetrate the fixing flange 392 in the axial direction AD. The first fixing hole 392a and the second fixing hole 392b are provided only in the fixing flange 392 out of the frame main body 391 and the fixing flange 392. The first fixing hole 392a and the second fixing hole 392b are aligned in the radial direction RD on the fixing flange 392. The first fixing hole 392a is provided radially inward of the second fixing hole 392b. The first fixing hole 392a is located at a position spaced radially inward from the second fixing hole 392b.
[0257] The first fixing holes 392a are holes for fixing the drive frame 390 to the motor housing 70. The fixing flange 392 is fixed to the fixing flange 178 of the motor housing 70 by screwing a frame fixing tool 405 into the first fixing holes 392a. The fixing flange 392 is sometimes referred to as an ear portion.
[0258] The second fixing holes 392b are holes for fixing the drive frame 390 to the reducer 53. The fixing flange 392 is fixed to the reducer 53 by screwing a reducer fixing tool 53a into the second fixing holes 392b. The reducer 53 is a fixing target to which the drive frame 390 is fixed, and corresponds to a cover fixing target.
[0259] As described above, in the drive frame 390, of the frame main body 391 and the fixing flange 392, the first fixing holes 392a and the second fixing holes 392b are provided only in the fixing flange 392. Therefore, the rigidity of the frame main body 391 is not reduced by the first fixing holes 392a and the second fixing holes 392b.
[0260] For example, assume a configuration different from the present embodiment in which holes for fixing the frame fixing device 405 and the reducer fixing device 53a are provided in the frame main body 391. In this configuration, there is a concern that the rigidity of the frame main body 391 will decrease by the amount of holes formed for the frame fixing device 405 and the reducer fixing device 53a.
[0261] The drive frame 390 has an outer peripheral frame portion 393 and an outer peripheral flange 394. The outer peripheral frame portion 393 spans two adjacent fixing flanges 392 in the circumferential direction CD and connects these fixing flanges 392. The outer peripheral frame portion 393 extends in the circumferential direction CD along the outer peripheral edge of the frame main body 391. A plurality of outer peripheral frame portions 393 are arranged in the circumferential direction CD. The outer peripheral frame portion 393 is located at a position spaced radially outward from the frame main body 391. The outer peripheral frame portion 393 is located at a position spaced radially inward from the tip end of the fixing flange 392. The outer peripheral frame portion 393 extends in the circumferential direction CD from a portion of the fixing flange 392 between the first fixing hole 392a and the second fixing hole 392b.
[0262] In the drive frame 390, the fixing flange 392 is reinforced by the outer peripheral frame portion 393. Therefore, even if the rigidity of the fixing flange 392 were reduced due to the formation of the two holes, the first fixing hole 392a and the second fixing hole 392b, the rigidity of the fixing flange 392 is compensated for by the outer peripheral frame portion 393.
[0263] The outer peripheral flange 394 extends radially outward from the outer peripheral frame portion 393. The outer peripheral flange 394 is located at a position spaced apart from the fixing flange 392 in the circumferential direction CD. A plurality of the outer peripheral flanges 394 are arranged in the circumferential direction CD. The outer peripheral flange 394 is fixed to the unit duct 100 (see FIG. 2). The outer peripheral flange 394 has holes for fixing the unit duct 100. The unit duct 100 is fixed to the outer peripheral flange 394 by screwing fixing tools such as bolts into these holes.
[0264] <Composition group E> 51 , 52 , 84 , and 86 , the power lead-out wire 212 is electrically connected to the power bus bar 261. The power lead-out wire 212 is connected to the power bus bar 261 via a bus bar lead-out wire 265. The bus bar lead-out wire 265 is drawn out from the power bus bar 261. The bus bar lead-out wire 265 is a conductive member such as an electric wire for passing current, and is electrically connected to the power bus bar 261. The bus bar lead-out wire 265 extends radially outward from the power bus bar 261. A plurality of bus bar lead-out wires 265 are arranged in the circumferential direction CD. The bus bar lead-out wires 265 are connected to each of the plurality of power bus bars 261. A plurality of bus bar lead-out wires 265 are connected to the power bus bars 261 for each phase. The bus bar lead-out wires 265 are located on the opposite side of the rear frame 370 from the first rotor 300a in the axial direction AD.
[0265] The power bus bar 261 and the bus bar lead wire 265 are provided on the opposite side of the first rotor 300a from the coil 211 in the axial direction AD. The power bus bar 261 and the bus bar lead wire 265 are located at a distance from the first rotor 300a towards the rear frame 370 in the axial direction AD. The power bus bar 261 corresponds to the connection target.
[0266] 84, 86, and 87, the power lead wire 212 has an outer circumferential lead portion 212a, an inner circumferential lead portion 212b, a cross lead portion 212c, an outer circumferential bent portion 212d, and an inner circumferential bent portion 212e. Note that in FIG. 87, the rotors 300a, 300b, the coil protection portion 250, and the like are not shown. Furthermore, with respect to the motor housing 70, the outer circumferential surface 70a may be referred to as the motor outer circumferential surface 70a, and the inner circumferential surface 70b may be referred to as the motor inner circumferential surface 70b.
[0267] The outer circumferential lead portion 212a is a portion of the power lead wire 212 that is provided on the outer circumferential side of the coil 211 and the first rotor 300a. The outer circumferential lead portion 212a extends in the axial direction AD along the motor inner circumferential surface 70b. The outer circumferential lead portion 212a extends, for example, straight in the axial direction AD. The outer circumferential lead portion 212a has a portion that passes between the coil 211 and the motor inner circumferential surface 70b and a portion that passes between the first rotor 300a and the motor inner circumferential surface 70b. The outer circumferential lead portion 212a extends closer to the power bus bar 261 in the axial direction AD than the coil 211. The outer circumferential lead portion 212a is located at a position spaced radially outward from the first rotor 300a. The outer circumferential lead portion 212a may or may not extend closer to the power bus bar 261 in the axial direction AD than the first rotor 300a.
[0268] The inner circumferential lead-out portion 212b is a portion of the power lead-out wire 212 that is provided radially inward of the outer circumferential lead-out portion 212a. The inner circumferential lead-out portion 212b extends in the axial direction AD, similar to the outer circumferential lead-out portion 212a. The inner circumferential lead-out portion 212b extends, for example, straight in the axial direction AD. The inner circumferential lead-out portion 212b is positioned to be aligned with the first rotor 300a in the axial direction AD. The inner circumferential lead-out portion 212b is positioned away from the first rotor 300a toward the power bus bar 261 in the axial direction AD. The inner circumferential lead-out portion 212b is electrically connected to the bus bar lead-out wire 265. The inner circumferential lead-out portion 212b extends toward the first rotor 300a more than the bus bar lead-out wire 265 in the axial direction AD.
[0269] The intersecting lead-out portion 212c is a portion of the power lead-out wire 212 that extends in a direction inclined with respect to the axial direction AD. The intersecting lead-out portion 212c extends in a direction intersecting the outer peripheral lead-out portion 212a and the inner peripheral lead-out portion 212b. The intersecting lead-out portion 212c extends, for example, straight in a direction intersecting the axial direction AD. The intersecting lead-out portion 212c is perpendicular to the circumferential direction CD and extends in the axial direction AD and the radial direction RD. In the intersecting lead-out portion 212c, in the axial direction AD, the end portion on the inner peripheral lead-out portion 212b side is located closer to the power bus bar 261 than the end portion on the outer peripheral lead-out portion 212a side.
[0270] The outer circumferential bend portion 212d is a portion of the power lead wire 212 that is located between the outer circumferential lead portion 212a and the intersecting lead portion 212c. The outer circumferential bend portion 212d connects the outer circumferential lead portion 212a and the intersecting lead portion 212c in a bent state. The outer circumferential bend portion 212d is bent so as to bulge outward in the radial direction, for example, is bent. The outer circumferential bend portion 212d is bent to connect the outer circumferential lead portion 212a and the intersecting lead portion 212c. The outer circumferential bend portion 212d is sometimes referred to as an outer circumferential bend portion. Note that the outer circumferential bend portion 212d does not have to be bent as long as it is bent, and may be curved, for example.
[0271] The inner circumferential bend portion 212e is a portion of the power lead wire 212 between the intersecting lead portion 212c and the inner circumferential lead portion 212b. The inner circumferential bend portion 212e is located away from the outer circumferential bend portion 212d toward the power bus bar 261 in the axial direction AD. The inner circumferential bend portion 212e connects the intersecting lead portion 212c and the inner circumferential lead portion 212b in a bent state. The inner circumferential bend portion 212e is bent so as to bulge radially inward, for example, is bent. The inner circumferential bend portion 212e is bent to connect the intersecting lead portion 212c and the inner circumferential lead portion 212b. The inner circumferential bend portion 212e is sometimes referred to as an inner circumferential bend portion. Note that the inner circumferential bend portion 212e does not have to be bent as long as it is bent, and may be curved, for example.
[0272] The grommet 255 is made of an insulating material and has electrical insulation properties. In other words, the grommet 255 is made of a non-conductive material and has non-conductivity. Examples of insulating materials include resin materials and rubber materials. The grommet 255 is made of a material that mainly contains, for example, synthetic resin.
[0273] As shown in Figures 84, 85, and 86, the grommet 255 has a grommet main body 256, an inner grommet portion 257, and an outer grommet portion 258. The grommet main body 256, the inner grommet portion 257, and the outer grommet portion 258 are aligned in the axial direction AD. The grommet main body 256 covers and protects the outer peripheral drawn portion 212a. The grommet main body 256 extends in the axial direction AD while surrounding all four sides of the outer peripheral drawn portion 212a. The grommet main body 256 has a portion that is inserted between the motor inner circumferential surface 70b and the coil 211 in the radial direction RD.
[0274] The inner grommet portion 257 extends in the axial direction AD along the outer periphery drawn portion 212a. The inner grommet portion 257 extends from the grommet body 256 toward the cross drawn portion 212c. The inner grommet portion 257 protects the outer periphery drawn portion 212a by covering it from the inside in the radial direction. The inner grommet portion 257 has a portion that is indented between the outer periphery drawn portion 212a and the first rotor 300a in the radial direction RD. The inner grommet portion 257 does not extend further toward the power bus bar 261 than the first rotor 300a in the axial direction AD. The inner grommet portion 257 corresponds to an inner protection portion.
[0275] The outer grommet portion 258 extends in the axial direction AD along the outer peripheral lead-out portion 212a. The outer grommet portion 258 extends from the grommet body 256 toward the cross lead-out portion 212c. The outer grommet portion 258 protects the outer peripheral lead-out portion 212a by covering it from the outside in the radial direction. The outer grommet portion 258 has a portion that is inserted between the outer peripheral lead-out portion 212a and the motor inner circumferential surface 70b in the radial direction RD. The outer grommet portion 258 is in a state where it overlaps the motor inner circumferential surface 70b. The outer grommet portion 258 corresponds to an outer insulating portion and an outer protective portion.
[0276] The outer grommet portion 258 extends closer to the power bus bar 261 than the inner grommet portion 257 in the axial direction AD. As shown in FIGS. 84 and 87 , the outer grommet portion 258 extends closer to the power bus bar 261 than the outer peripheral led portion 212a in the axial direction AD. The outer grommet portion 258 bridges between the outer peripheral led portion 212a and the cross led portion 212c in the axial direction AD. The outer grommet portion 258 extends closer to the power bus bar 261 than the outer peripheral bent portion 212d in the axial direction AD. On the other hand, the outer grommet portion 258 does not reach the inner peripheral led portion 212b in the axial direction AD. That is, the outer grommet portion 258 is located away from the inner peripheral led portion 212b toward the coil 211 in the axial direction AD. The outer grommet portion 258 may or may not reach the inner peripheral bent portion 212e in the axial direction AD.
[0277] In the grommet 255, the outer peripheral lead portion 212a is sandwiched between the inner grommet portion 257 and the outer grommet portion 258 in the radial direction RD. In this embodiment, the outer peripheral lead portion 212a is inserted into the inner grommet portion 257 from the radially outer side. Therefore, the inner grommet portion 257 has a portion that extends radially outward from the portion inserted between the outer peripheral lead portion 212a and the first rotor 300a. Note that the outer peripheral lead portion 212a may be inserted into the outer grommet portion 258 from the radially inner side.
[0278] 85 shows a state in which the power lead wire 212 is not bent. Also, in FIG. 87, the grommet body 256 and the inner grommet portion 257 of the grommet 255 are not shown.
[0279] 84 and 86 , outer peripheral drawn portion 212a extends further toward power bus bar 261 in the axial direction AD than inner grommet portion 257. Furthermore, outer peripheral drawn portion 212a extends further toward drive frame 390 in the axial direction AD than grommet 255. That is, outer peripheral drawn portion 212a extends further toward the opposite side from power bus bar 261 in the axial direction AD than outer grommet portion 258. In the axial direction AD, the length dimension of outer peripheral drawn portion 212a is greater than the length dimension of outer grommet portion 258.
[0280] As shown in FIG. 88 , in grommet 255, outer grommet portion 258 extends toward both sides in the circumferential direction CD from inner grommet portion 257. In the circumferential direction CD, width dimension Wa1 of outer grommet portion 258 is larger than width dimension Wa2 of inner grommet portion 257. Furthermore, outer grommet portion 258 extends toward both sides in the circumferential direction CD further than outer peripheral led portion 212a. In the circumferential direction CD, width dimension Wa1 of outer grommet portion 258 is larger than width dimension Wa3 of outer peripheral led portion 212a. Width dimension Wa3 is a dimension indicating the thickness of outer peripheral led portion 212a. Like outer grommet portion 258, inner grommet portion 257 extends toward both sides in the circumferential direction CD further than outer peripheral led portion 212a. In the circumferential direction CD, the width dimension Wa2 of the inner grommet portion 257 is larger than the width dimension Wa3 of the outer peripheral lead-out portion 212a.
[0281] As shown in Figures 84 and 86, grommet 255 has a grommet hole 450. Grommet hole 450 penetrates grommet 255 in the axial direction AD. Grommet hole 450 penetrates grommet body 256 in the axial direction AD. Grommet hole 450 extends in the axial direction AD along the boundary between inner grommet portion 257 and outer grommet portion 258. Grommet hole 450 is formed by inner grommet portion 257 and outer grommet portion 258. Outer peripheral lead portion 212a is inserted through grommet hole 450, thereby penetrating grommet 255 in the axial direction AD.
[0282] The grommet hole 450 penetrates both the embedded portion 255a and the exposed portion 255b of the grommet 255 in the axial direction AD. The outer peripheral lead portion 212a is inserted through the grommet hole 450, thereby penetrating both the embedded portion 255a and the exposed portion 255b in the axial direction AD. In the grommet 255, at least a portion of the grommet body 256 is included in the embedded portion 255a. The inner grommet portion 257 and the outer grommet portion 258 may or may not be included in the embedded portion 255a. Furthermore, at least a portion of the inner grommet portion 257 and at least a portion of the outer grommet portion 258 are included in the exposed portion 255b. The grommet body 256 may or may not be included in the exposed portion 255b.
[0283] The grommet 255 is fixed to the motor housing 70 by the coil protection part 250 in which the embedded part 255a is embedded. In the grommet 255, a grommet body 256 and an outer grommet part 258 are fixed to the motor inner peripheral surface 70b.
[0284] Next, a description will be given of a method for manufacturing the coil protection part 250 among the methods for manufacturing the motor device 60. In the manufacturing process of the coil protection part 250, an operator prepares the coil unit 210, the motor housing 70, and the grommet 255 as a preparation step.
[0285] After the preparation step, the worker performs a molding step in which the coil unit 210, the motor housing 70, and the grommet 255 are attached to a mold. In the molding step, the worker attaches the grommet 255 to the coil unit 210. The worker attaches the grommet 255 to the outer peripheral lead portion 212a by inserting the power lead wire 212 into the grommet hole 450. For example, as shown in FIG. 85 , the worker may insert the power lead wire 212 into the grommet hole 450 without bending the power lead wire 212. The worker also installs the coil unit 210 inside the motor housing 70. The worker may install the coil unit 210 with the grommet 255 inside the motor housing 70. The worker then sets the coil unit 210, the motor housing 70, and the grommet 255 in a mold.
[0286] After the molding process, workers perform a molding process. In the molding process, workers form the coil protection part 250 by injection molding, for example by injecting molten resin into the motor housing 70. The molten resin fills the motor housing 70 and the interior of the mold so as to seal the coil 211. The grommet 255 prevents the molten resin from leaking from around the power lead wire 212. The grommet 255 maintains the state in which the molten resin seals the coil 211. In the grommet 255, at least the grommet body 256 is immersed in the molten resin. In the grommet 255, even if the molten resin enters the grommet hole 450 in the grommet body 256, the inner grommet part 257 and the outer grommet part 258 prevent the molten resin from entering the grommet hole 450.
[0287] The molten resin solidifies to form coil protection portion 250. Coil protection portion 250 seals coil 211 and corresponds to the sealing resin portion. In grommet 255, at least grommet body 256 is embedded in coil protection portion 250. Grommet 255 is a member for maintaining the state in which coil 211 is sealed by the molten resin and corresponds to the sealing holding portion. Outer grommet portion 258 is included in the sealing holding portion.
[0288] <Composition group F> As shown in Figure 89, the first rotor 300a and the second rotor 300b have holder ribs 323. The holder ribs 323 are included in the magnet holder 320. The holder ribs 323 extend from the holder main body 321 in the axial direction AD. The holder ribs 323 protrude from the holder main body 321 in the axial direction AD toward the opposite side to the stator 200. In the first rotor 300a, the holder ribs 323 protrude toward the power bus bar 261. In the second rotor 300b, the holder ribs 323 protrude toward the drive frame 390.
[0289] In the magnet holder 320, the holder main body 321 and the holder ribs 323 are integrally formed. For example, the holder main body 321 and the holder ribs 323 are integrally molded from the material that forms the magnet holder 320. The magnet holder 320 is a non-magnetic member and is formed from a non-magnetic material. Non-magnetic materials that form the magnet holder 320 include aluminum alloy, titanium, resin, and CFRP. CFRP is a carbon fiber reinforced plastic.
[0290] 90 and 91, holder inner peripheral end 320a and holder outer peripheral end 320b of magnet holder 320 are formed by holder main body 321. Both the inner peripheral end and outer peripheral end of holder main body 321 extend annularly in circumferential direction CD. The inner peripheral end of holder main body 321 is holder inner peripheral end 320a, and the outer peripheral end of holder main body 321 is holder outer peripheral end 320b. Holder main body 321 extends in a plate shape along stator 200 in a direction perpendicular to axial direction AD. Holder main body 321 corresponds to the rotor plate portion, and holder ribs 323 correspond to the rotor ribs. Holder inner peripheral end 320a corresponds to the inner peripheral end of the rotor plate portion, and holder outer peripheral end 320b corresponds to the outer peripheral end of the rotor plate portion.
[0291] The holder main body 321 has a main body outer plate surface 321a. Of the pair of plate surfaces of the holder main body 321, the main body outer plate surface 321a is the plate surface on the power bus bar 261 side. The main body outer plate surface 321a extends in a direction perpendicular to the axial direction AD. The holder ribs 323 are provided on the main body outer plate surface 321a. The holder main body 321 has a magnet 310 provided on the plate surface side opposite the main body outer plate surface 321a.
[0292] The holder rib 323 extends in the radial direction RD along the holder main body 321. The holder rib 323 extends radially inward from the holder outer peripheral end 320b. The holder rib 323 is a portion of the rotor 300 that extends elongatedly in the radial direction RD. The holder rib 323 extends in the radial direction RD so as to bridge between the holder outer peripheral end 320b and the holder inner peripheral end 320a. The holder rib 323 extends radially outward from the holder inner peripheral end 320a. The holder rib 323 is provided on the rotor second surface 302, but is not provided on the rotor first surface 301.
[0293] A plurality of holder ribs 323 are arranged in the circumferential direction CD. The plurality of holder ribs 323 extend radially from the motor axis Cm. A protrusion that protrudes radially inward is provided at the inner peripheral end of the holder main body 321. A plurality of these protrusions are arranged in the circumferential direction CD. The plurality of holder ribs 323 includes holder ribs 323 that are arranged in the radial direction RD at this protrusion.
[0294] The holder rib 323 has a rib inner peripheral end 323a and a rib outer peripheral end 323b. The rib inner peripheral end 323a is the radially inner end of a pair of ends of the holder rib 323, and the rib outer peripheral end 323b is the radially outer end. The rib inner peripheral end 323a is aligned with the holder inner peripheral end 320a in the axial direction AD. The rib outer peripheral end 323b is aligned with the holder outer peripheral end 320b in the axial direction AD.
[0295] The holder rib 323 has a rib parallel portion 323c and a rib tapered portion 323d. The rib parallel portion 323c and the rib tapered portion 323d are included in the tip portion of the holder rib 323. Of a pair of ends of the holder rib 323 aligned in the axial direction AD, the end opposite the holder main body 321 is the tip portion. The tip portion of the holder rib 323 is, for example, a tip surface. The rib parallel portion 323c extends radially outward from the rib inner circumferential end 323a. The rib parallel portion 323c extends parallel to the main body outer plate surface 321a. The rib parallel portion 323c is, for example, a surface extending in a direction perpendicular to the axial direction AD, and is a flat surface.
[0296] The rib tapered portion 323d extends radially inward from the rib outer peripheral end 323b. The rib tapered portion 323d is inclined relative to the main body outer plate surface 321a so as to face radially outward. The rib tapered portion 323d gradually moves away from the main body outer plate surface 321a from the rib outer peripheral end 323b toward the radially inward direction. The rib tapered portion 323d is an inclined surface extending in a direction inclined relative to the holder main body 321. The rib tapered portion 323d extends straight and tapered in a direction inclined relative to the main body outer plate surface 321a, and is sometimes referred to as a tapered surface. The rib tapered portion 323d corresponds to a rib inclined portion.
[0297] The rib tapered portion 323d extends radially outward from the rib parallel portion 323c. The rib tapered portion 323d spans between the rib parallel portion 323c and the rib outer peripheral end 323b. In the radial direction RD, the rib tapered portion 323d is longer than the rib parallel portion 323c. The boundary between the rib tapered portion 323d and the rib parallel portion 323c is closer to the rib inner peripheral end 323a than to the rib outer peripheral end 323b.
[0298] The width of the holder rib 323 in the circumferential direction CD gradually decreases radially outward. In the holder rib 323, the width of the rib outer peripheral end 323b is smaller than the width of the rib inner peripheral end 323a. In the holder rib 323, the width of the rib inner peripheral end 323a is the largest, and the width of the rib outer peripheral end 323b is the smallest.
[0299] The holder rib 323 is provided at a position overlapping the magnet 310 in the axial direction AD. The holder rib 323 extends radially outward beyond the magnet 310. The rib outer peripheral end 323b is located at a position spaced radially outward from the magnet 310. The rib inner peripheral end 323a is located at a position spaced radially inward from the magnet 310. In addition, the boundary between the rib parallel portion 323c and the rib tapered portion 323d is located radially inward beyond the magnet 310.
[0300] As shown in Figures 89 and 92, the rear frame 370 extends in a plate shape in a direction perpendicular to the axial direction AD, and is provided between the first rotor 300a and the power bus bar 261. The rear frame 370 is made of an aluminum alloy, titanium, resin, CFRP, or the like. A frame opening 373 is provided in the rear frame 370 so as to penetrate the rear frame 370 in the axial direction AD. The power lead wire 212 is inserted through the frame opening 373 and is led out to the power bus bar 261 side through the frame opening 373. The power lead wire 212 is electrically connected to the power bus bar 261 via a bus bar lead wire 265. The rear frame 370 corresponds to an intermediate plate portion, and the frame opening 373 corresponds to a lead insertion hole.
[0301] The bus bar lead-out wire 265 is drawn out from the bus bar unit 260. The bus bar lead-out wire 265 is electrically connected to the power bus bar 261 and the power lead-out wire 212. The portion where the bus bar lead-out wire 265 and the power bus bar 261 are connected is protected by a bus bar protector 270. A lead-out connection portion 266 where the bus bar lead-out wire 265 and the power lead-out wire 212 are connected is provided outside the bus bar protector 270. The lead-out connection portion 266 is located at a position spaced from the frame opening 373 towards the power bus bar 261 in the axial direction AD. The lead-out connection portion 266 is located next to the frame opening 373 in the axial direction AD. The bus bar lead-out wire 265 corresponds to the connection lead-out portion, and the lead-out connection portion 266 corresponds to the connection portion.
[0302] The bus bar unit 260 is fixed to a rear frame 370. A bus bar protection portion 270 is fixed to the rear frame 370. The bus bar protection portion 270 is supported by a bus bar support portion 371 of the rear frame 370. The bus bar protection portion 270 is made of an electrically insulating material. Materials that form the bus bar protection portion 270 include resin and CFRP. The rear frame 370 is fixed to a motor housing 70. The motor housing 70 is made of an aluminum alloy, titanium, resin, CFRP, or the like.
[0303] As shown in Figures 89 and 93, a portion of the power lead wire 212 is positioned to be aligned with the holder rib 323 in the axial direction AD. The power lead wire 212 has a parallel lead portion that is positioned to be aligned with the holder rib 323 in the axial direction AD. The parallel lead portion includes an inner peripheral lead portion 212b, a cross lead portion 212c, and an inner peripheral bent portion 212e. The parallel lead portion is located on the opposite side of the stator 200 across the first rotor 300a in the axial direction AD. The parallel lead portion is provided on the opposite side of the holder body 321 across the holder rib 323 that the first rotor 300a has.
[0304] In the power lead wire 212, the inner circumferential lead portion 212b is inserted into the frame opening 373. In the lead connection portion 266, the inner circumferential lead portion 212b is connected to the bus bar lead wire 265. Note that the first rotor 300a and the like are not shown in Figures 93 and 94.
[0305] In the motor device 60, when the rotor 300 rotates, the holder ribs 323 generate an airflow as an airflow. The holder ribs 323 rotate together with the holder main body 321 around the motor axis Cm as the rotor 300 rotates. The holder ribs 323 rotate together with the holder main body 321 to send air toward the power lead-out wires 212 and the like. The airflow generated by the holder ribs 323 serves as cooling air to cool the power lead-out wires 212 and the like. The cooling air generated by the holder ribs 323 hits, for example, the portion of the power lead-out wire 212 exposed from the coil protection portion 250 and the grommet 255. This cooling air hits the portion of the outer peripheral lead-out portion 212a exposed from the grommet 255, the lead-out portions 212b and 212c, and the bent portions 212d and 212e.
[0306] 5, the cooling airflow generated by the holder ribs 323 of the first rotor 300a includes an airflow Fa1 flowing out from the frame opening 373. The airflow Fa1 flows radially outward from the holder ribs 323 toward the power lead-out wires 212, and reaches the frame opening 373 while cooling the power lead-out wires 212. The airflow Fa1 then flows in the axial direction AD, passing through the frame opening 373 and cooling the lead-out connection portion 266, the power bus bar 261, and the like.
[0307] 6, the airflow generated by the holder ribs 323 of the first rotor 300a includes a circulating airflow Fa2. The airflow Fa2 flows radially outward along the holder ribs 323 toward the power lead-out wires 212, cooling the power lead-out wires 212, and reaches the motor inner circumferential surface 70b. The airflow Fa2 then flows radially inward along the rear frame 370 while cooling the power lead-out wires 212. The airflow Fa2 flows along the rear frame 370, thereby cooling the bus bar unit 260 via the rear frame 370. In the bus bar unit 260, the power bus bar 261 is indirectly cooled by the airflow Fa2 via the rear frame 370 and the bus bar protection portion 270.
[0308] Furthermore, air currents such as air currents Fa1 and Fa2 that flow in the radial direction RD along the holder ribs 323 can cool the magnets 310 via the holder body 321. In addition, air currents that pass over the first rotor 300a and flow into the stator 200 side can cool the coil protection part 250 and the coil 211.
[0309] <Composition group G> As shown in Figures 95 and 96, the motor device 60 has an axial gap 475. The axial gap 475 is a gap between the stator 200 and the rotor 300, and corresponds to an axial gap. The axial gap 475 extends in a direction perpendicular to the axial direction AD. Like the stator 200 and the rotor 300, the axial gap 475 extends annularly in the circumferential direction CD. The axial gap 475 is located at least between the coil 211 and the magnet 310. The axial gap 475 extends further in the radial direction RD than the coil 211 and the magnet 310. The axial gap 475 extends at least one of radially inward and radially outward than at least one of the coil 211 and the magnet 310.
[0310] The axial gap 475 is a gap between the stator surface 201 and the rotor first surface 301. The stator surfaces 201 are end surfaces of the stator 200, and are arranged in pairs in the axial direction AD. One of the pair of stator surfaces 201 faces the first rotor 300a, and the other faces the second rotor 300b. The stator surfaces 201 are included in the outer surface of the stator 200. The stator surface 201 extends in a direction perpendicular to the axial direction AD and extends annularly in the circumferential direction CD. The stator surface 201 is formed by at least one of the core unit 230 and the coil protection part 250.
[0311] In the axial gap 475, the larger the gap area, the stronger the magnetic field tends to be. The gap area is the cross-sectional area of the axial gap 475 in a direction perpendicular to the motor axis Cm. For example, when the axial gap 475 is expanded radially outward by a predetermined dimension, the increase in the gap area is greater than when the axial gap 475 is expanded radially inward by the same predetermined dimension.
[0312] As described above in relation to structural group Bb, in rotor 300, magnet unit 316 is fixed to magnet holder 320 by fixed block 330. Fixed block 330 holds magnet unit 316 together with outer circumferential engaging portion 322 so as to embrace it. Fixed block 330 and outer circumferential engaging portion 322 hold magnet unit 316 so that magnet unit 316 does not fall off magnet holder 320.
[0313] 96, 97, and 99, the holder main body 321 has a main body inner plate surface 321b. The main body inner plate surface 321b is the plate surface opposite to the main body outer plate surface 321a, of a pair of plate surfaces that the holder main body 321 has. The main body inner plate surface 321b faces the axial gap 475, and extends, together with the axial gap 475, in a direction perpendicular to the axial direction AD.
[0314] In the magnet unit 316, the unit outer peripheral end 316b is fitted between the main body inner plate surface 321b and the engaging tapered surface 322a. The outer peripheral engagement portion 322 and the engaging tapered surface 322a extend annularly in the circumferential direction CD along the holder outer peripheral end 320b. The engaging tapered surface 322a is inclined with respect to the motor axis Cm so as to face the side opposite the axial gap 475. The outer peripheral tapered surface 316e is hooked onto the engaging tapered surface 322a. The outer peripheral engagement portion 322 supports the magnet unit 316 with the unit outer peripheral end 316b hooked onto it, and corresponds to an outer peripheral support portion.
[0315] The magnet holder 320 has a holder receiving portion 328. The holder receiving portion 328 is a portion of the magnet holder 320 that receives the fixed block 330. The holder receiving portion 328 is located radially inward of the fixed block 330. The holder receiving portion 328 is provided at a position spaced radially inward from the outer circumferential engaging portion 322 via the magnet unit 316 and the fixed block 330. Similar to the outer circumferential engaging portion 322, the holder receiving portion 328 is a protrusion provided on the main body inner plate surface 321b. The holder receiving portion 328 extends in the axial direction AD from the holder main body 321 toward the axial gap 475. The holder receiving portion 328 extends annularly in the circumferential direction CD along the holder inner circumferential end 320a.
[0316] The holder receiving portion 328 has a holder receiving surface 328a. The holder receiving surface 328a is an inclined surface inclined with respect to the motor axis Cm. The holder receiving surface 328a faces radially outward and is inclined with respect to the motor axis Cm so as to face the axial gap 475. The holder receiving surface 328a extends annularly in the circumferential direction CD along the holder inner peripheral end 320a. The holder receiving surface 328a is annular.
[0317] The fixed block 330 fixes the magnet unit 316 to the magnet holder 320 and corresponds to a fixed member. The fixed block 330 is a non-magnetic member and is made of a non-magnetic material. Non-magnetic materials that can be used to form the fixed block 330 include aluminum alloy, titanium, resin, and CFRP.
[0318] The fixing blocks 330 are provided individually for the multiple magnet units 316. For example, one fixing block 330 fixes one magnet unit 316. That is, there is a one-to-one correspondence between the fixing blocks 330 and the magnet units 316. The multiple fixing blocks 330 include a tilt fixing block 330 for fixing the tilt magnet unit 317 and a parallel fixing block 330 for fixing the parallel magnet unit 318. The tilt fixing block 330 and the parallel fixing block 330 differ in at least one of their shapes and sizes. For example, in the circumferential direction CD, the width dimension of the tilt fixing block 330 is larger than the width dimension of the parallel fixing block 330. Note that the tilt fixing block 330 and the parallel fixing block 330 may have the same shape and size.
[0319] 96 and 100, the fixed block 330 has a block receiving surface 330b and a block facing surface 330c in addition to a block tapered surface 330a. The block tapered surface 330a, the block receiving surface 330b, and the block facing surface 330c are included in the outer surface of the fixed block 330.
[0320] The block receiving surface 330b is an inclined surface inclined with respect to the motor axis Cm. The block receiving surface 330b faces radially inward and is inclined with respect to the motor axis Cm so as to face the opposite side to the axial gap 475. The block receiving surface 330b is placed over the holder receiving surface 328a. The block receiving surface 330b is curved so as to be concave radially outward. The curved surface of the block receiving surface 330b makes it easy for it to be placed over the annular holder receiving surface 328a. The block receiving surface 330b corresponds to the opposite fixed surface.
[0321] The pair of block opposing surfaces 330c are arranged side by side in the circumferential direction CD. The pair of block opposing surfaces 330c spans between the block tapered surface 330a and the block receiving surface 330b. The pair of block opposing surfaces 330c extend parallel to each other.
[0322] As shown in Figure 97, a plurality of fixing blocks 330 are arranged in the circumferential direction CD. The plurality of fixing blocks 330 are arranged in a row along the circumferential direction CD. The row of fixing blocks 330 as a whole extends in an annular shape in the circumferential direction CD. There is a gap between two fixing blocks 330 adjacent to each other in the circumferential direction CD. In these fixing blocks 330, the block opposing surfaces 330c are inclined relative to each other, thereby forming the gap. The fixing blocks 330 correspond to divided members.
[0323] As shown in Figures 96 and 100, the fixed block 330 has a block inner end face 331 and a block outer end face 332. The block inner end face 331 and the block outer end face 332, together with the block tapered face 330a, etc., are included in the outer surface of the fixed block 330. The block inner end face 331 and the block outer end face 332 extend in a direction perpendicular to the axial direction AD. The block inner end face 331 is provided inside the magnet holder 320 and faces away from the axial gap 475. The block outer end face 332 is provided outside the magnet holder 320 and faces the axial gap 475. The block outer end face 332 faces the stator surface 201 across the axial gap 475. A block tapered surface 330a, a block receiving surface 330b, and a block opposing surface 330c are bridged between the block inner end surface 331 and the block outer end surface 332.
[0324] The fixed block 330 has a block hole 333. The block hole 333 penetrates the fixed block 330 in the axial direction AD. The block hole 333 extends in the axial direction AD so as to bridge between the block inner end face 331 and the block outer end face 332. The block hole 333 is a threaded hole into which a magnet fixing device 335 is screwed. The block hole 333 has an internal thread. The internal thread is provided on the inner circumferential surface of the block hole 333.
[0325] The magnet holder 320 has a block hole 329. The block hole 329 penetrates the holder main body 321 in the axial direction AD. The block hole 329 is provided between 322 and the holder receiving portion 328 in the radial direction RD. A plurality of the block holes 329 are arranged in the circumferential direction CD. The block holes 329 are arranged in the axial direction AD with the block hole 333 and communicate with the block hole 333.
[0326] Magnet fixture 335 screws fixedly fastens fixed block 330 to magnet holder 320. Magnet fixture 335 is a non-magnetic member and is made of a non-magnetic material. Examples of non-magnetic materials that can be used to form magnet fixture 335 include aluminum alloy, titanium, resin, and CFRP.
[0327] The magnet fixing device 335 has a fixing shaft portion 336 and a fixing head portion 337. The fixing shaft portion 336 extends from the fixing head portion 337 in the axial direction AD. The fixing shaft portion 336 has a male thread. The male thread is provided on the outer peripheral surface of the fixing shaft portion 336. The fixing shaft portion 336 passes through the block hole 329 and is screwed into the block hole 333. The fixing head portion 337 is hooked on the holder main body 321 from the side opposite the fixing block 330. The fixing head portion 337 is configured not to protrude beyond the holder rib 323 in the axial direction AD. The magnet fixing device 335 screws the fixing block 330 to the magnet holder 320 via the holder main body 321 from the side opposite the fixing block 330. The magnet fixing device 335 corresponds to a screw member, the fixing shaft portion 336 corresponds to a threaded portion, and the fixing head portion 337 corresponds to a screw head.
[0328] The magnet fixture 335 allows the position of the fixed block 330 to be adjusted in the axial direction AD by adjusting the degree to which the fixed shaft portion 336 is screwed into the block hole 333. Furthermore, the holder receiving surface 328a and the block receiving surface 330b are inclined with respect to the motor axis Cm, allowing the position of the fixed block 330 to be adjusted in the radial direction RD. For example, even if the position of the fixed block 330 is shifted in the radial direction RD due to the shape and size of the magnet unit 316, the holder receiving surface 328a and the block receiving surface 330b can easily come into contact with each other by adjusting the position of the fixed block 330 in the axial direction AD. Both the holder receiving surface 328a and the block receiving surface 330b correspond to adjustment surfaces.
[0329] For example, unlike the present embodiment, assume a configuration in which the holder receiving surface 328a and the block receiving surface 330b extend parallel to the motor axis Cm. In this configuration, for example, if the position of the fixed block 330 shifts radially outward, there is a concern that the holder receiving surface 328a and the block receiving surface 330b will become separated in the radial direction RD. Furthermore, if the position of the fixed block 330 shifts radially inward, there is a concern that the fixed block 330 will get caught on the holder receiving portion 328, making it impossible for the fixed block 330 to fit between the magnet unit 316 and the holder receiving portion 328.
[0330] As shown in Figures 96, 101, and 102, the magnet unit 316 has a first unit surface 316g and a second unit surface 316h. The magnet unit 316 is formed in a plate shape overall and extends in a direction perpendicular to the axial direction AD. The first unit surface 316g and the second unit surface 316h are a pair of plate surfaces of the magnet unit 316. The first unit surface 316g and the second unit surface 316h extend in a direction perpendicular to the axial direction AD. The first unit surface 316g faces the axial gap 475. The first unit surface 316g faces the stator 200 across the axial gap 475 and corresponds to a unit facing surface. The second unit surface 316h faces the side opposite the axial gap 475. The second unit surface 316h is superimposed on the main body inner plate surface 321b. The first unit surface 316g and the second unit surface 316h extend parallel to each other.
[0331] The peripheral surface of the magnet unit 316 extends along the peripheral portions of the first unit surface 316g and the second unit surface 316h. The peripheral surface of the magnet unit 316 extends in the axial direction AD to span between the first unit surface 316g and the second unit surface 316h. The peripheral surface of the magnet unit 316 includes a unit inner peripheral end 316a, a unit outer peripheral end 316b, and a unit side surface 316c.
[0332] The unit inner peripheral end 316a is the radially inner end face of the magnet unit 316. The unit inner peripheral end 316a includes an inner peripheral tapered surface 316d. The inner peripheral tapered surface 316d corresponds to the magnet inclined surface, and the unit inner peripheral end 316a corresponds to the inner end face. The unit outer peripheral end 316b is the radially outer end face of the magnet unit 316. The unit outer peripheral end 316b includes an outer peripheral tapered surface 316e. The outer peripheral tapered surface 316e corresponds to the outer peripheral inclined surface, and the unit outer peripheral end 316b corresponds to the outer end face.
[0333] The inner peripheral tapered surface 316d and the outer peripheral tapered surface 316e are inclined at an angle of, for example, less than 45 degrees with respect to the motor axis Cm. The length dimension of the inner peripheral tapered surface 316d and the outer peripheral tapered surface 316e in the circumferential direction CD is smaller than the length dimension of the inner peripheral tapered surface 316d and the outer peripheral tapered surface 316e in the axial direction AD.
[0334] As shown in Figure 96, in the magnet unit 316, the unit inner peripheral end 316a is inserted between the main body inner plate surface 321b and the block tapered surface 330a. The block tapered surface 330a is inclined with respect to the motor axis Cm so as to face away from the axial gap 475. The block tapered surface 330a is hooked onto the inner peripheral tapered surface 316d so as to overlap it. The block tapered surface 330a corresponds to a fixed inclined surface.
[0335] The rotor first surface 301 includes a first unit surface 316g. The rotor first surface 301 includes a tip surface of an outer circumferential engagement portion 322. The tip surface of the outer circumferential engagement portion 322 forms an axial gap 475 together with the first unit surface 316g. The tip surface of the outer circumferential engagement portion 322 is aligned contiguously with the first unit surface 316g in the radial direction RD. The tip surface of the outer circumferential engagement portion 322 is configured not to pass over the first unit surface 316g and approach the axial gap 475. The tip surface of the outer circumferential engagement portion 322 may be located far from the axial gap 475, passing over the first unit surface 316g.
[0336] The rotor first surface 301 includes a block inner end surface 331. The block inner end surface 331 forms an axial gap 475 together with the first unit surface 316g. The block inner end surface 331 is aligned contiguously with the first unit surface 316g in the radial direction RD. The block inner end surface 331 is configured not to extend beyond the first unit surface 316g and approach the axial gap 475. The block inner end surface 331 may extend beyond the first unit surface 316g and be located far from the axial gap 475.
[0337] In the rotor 300, the axial gap 475 is determined by the position of the magnet unit 316 in the axial direction AD. As described above, the outer circumferential engaging portion 322 and the fixed block 330 do not move beyond the first unit surface 316g and approach the axial gap 475, thereby preventing the axial gap 475 from narrowing.
[0338] The magnet unit 316 is adhered to the holder main body 321 with an adhesive. The adhesive is made of a resin material or the like. As shown in FIGS. 99 and 103, the magnet holder 320 has an adhesive recess 481 and a magnet base 482. The adhesive recess 481 is a recess provided in the main body inner plate surface 321b. The magnet base 482 is a convex portion protruding from the bottom surface of the adhesive recess 481. The tip surface of the magnet base 482 is flush with the main body inner plate surface 321b. The magnet unit 316 is provided so as to span the magnet base 482 and the main body inner plate surface 321b. The adhesive is provided inside the adhesive recess 481 and adheres the inner surface of the adhesive recess 481 to the second unit surface 316h.
[0339] As shown in Figures 98, 99, and 103, the magnet holder 320 has a magnet protrusion 483. The magnet protrusion 483 protrudes from the holder main body 321 toward the magnet unit 316. The magnet protrusion 483 is, for example, a protrusion provided on the magnet stand 482. A plurality of magnet protrusions 483 are arranged in the circumferential direction CD. The magnet protrusions 483 are provided between the outer circumferential engagement portion 322 and the holder receiving portion 328, and extend in the radial direction RD. The magnet protrusions 483 determine the position of the magnet unit 316 in the circumferential direction CD and correspond to a positioning portion. The magnet protrusions 483 hook onto the magnet unit 316, thereby preventing the magnet unit 316 from shifting in the circumferential direction CD relative to the magnet holder 320.
[0340] As shown in Figures 98 and 102, the magnet unit 316 has a side tapered surface 316f. The side tapered surface 316f is included in the unit side surface 316c. The side tapered surface 316f is an inclined surface inclined with respect to the motor axis Cm. The side tapered surface 316f is inclined with respect to the motor axis Cm so as to face the holder main body 321. The magnet protrusion 483 is fitted between the side tapered surface 316f and the holder main body 321. The magnet protrusion 483 positions the magnet unit 316 by coming into contact with the side tapered surface 316f. The magnet protrusion 483 restricts misalignment of the magnet unit 316 by being caught on the side tapered surface 316f.
[0341] As described above in the configuration group Bc, the multiple magnet units 316 include a gradient magnet unit 317 and a parallel magnet unit 318. In the gradient magnet unit 317, the width dimension in the circumferential direction CD increases radially outward. In the gradient magnet unit 317, the portion with the smallest width dimension is the unit inner peripheral end 316a, and the portion with the largest width dimension is the unit outer peripheral end 316b. The gradient magnet unit 317 corresponds to an expansion unit.
[0342] In the parallel magnet unit 318, the width dimension in the circumferential direction CD is uniform in the radial direction RD. In the parallel magnet unit 318, the width dimension of the unit inner peripheral end 316a is the same as the width dimension of the unit outer peripheral end 316b. The parallel magnet unit 318 corresponds to a uniform unit.
[0343] The inclined magnet units 317 and the parallel magnet units 318 are arranged alternately one by one in the circumferential direction CD. As shown in FIG. 103, when the unit boundary is extended radially inward, it passes through a position shifted in the radial direction RD from the motor axis Cm. The unit boundary is a boundary between the inclined magnet unit 317 and the parallel magnet unit 318, and multiple unit boundaries are arranged in the circumferential direction CD. The magnet bases 482 and magnet protrusions 483 extend in the radial direction RD along the unit boundary. For example, a magnet base 482 is provided individually for each unit boundary. The multiple magnet bases 482 include magnet bases 482 with protrusions that are provided with magnet protrusions 483 and magnet bases 482 without protrusions that are not provided with magnet protrusions 483. For example, the magnet bases 482 with protrusions and magnet bases 482 without protrusions are arranged alternately one by one in the circumferential direction CD.
[0344] As described for the structural group Ba above, a Halbach array is used to arrange the magnets 310. As shown in FIG. 98 , the multiple magnet units 316 are arranged in the circumferential direction CD so that the multiple magnets 310 are aligned in the circumferential direction CD in a Halbach array. The Halbach array makes it easier for the magnetic flux generated by the magnets 310 to extend toward the axial gap 475. Furthermore, the magnet holder 320, the fixing block 330, and the magnet fixing device 335 are nonmagnetic. This makes it difficult for the magnet holder 320, the fixing block 330, and the magnet fixing device 335 to obstruct the magnetic flux from the magnets 310. Furthermore, the magnet holder 320 makes it difficult for the magnetic flux from the magnets 310 to leak to the outside. This prevents the magnetic flux from the magnets 310 from extending toward the magnet holder 320, the fixing block 330, and the magnet fixing device 335.
[0345] In rotor 300, a Halbach array is used to arrange magnets 310, resulting in a configuration that does not require a yoke. With this configuration, there is no need to provide a yoke between magnet holder 320 and magnet 310. In other words, there is no need to configure magnet 310 indirectly fixed to magnet holder 320 via a yoke. Therefore, magnet 310 can be fixed directly to magnet holder 320. This can improve the positional accuracy of magnet 310. Furthermore, the fixing strength of magnet 310 to magnet holder 320 can be improved.
[0346] Next, a description will be given of a method for manufacturing the rotor 300. In the process of manufacturing the rotor 300, an operator prepares the magnet holder 320, the magnet unit 316, the fixing block 330, and the magnet fixing tool 335 as a preparation process.
[0347] After the preparation step, the worker performs a fixing step in which the magnet unit 316 is fixed to the magnet holder 320. In the fixing step, the worker first applies adhesive to the adhesive recess 481 of the magnet holder 320. Then, the worker temporarily places the magnet unit 316 on the magnet holder 320, aligning it with the magnet protrusion 483. For example, for both the inclined magnet unit 317 and the parallel magnet unit 318, the worker assembles them to the magnet holder 320 by shifting them in the circumferential direction CD so that they abut the magnet protrusion 483. The worker attaches the fixing block 330 to the magnet holder 320 so that the unit inner peripheral end 316a is sandwiched between the holder main body 321 and the fixing block 330, with the unit outer peripheral end 316b inserted between the engagement tapered surface 322a and the main body inner plate surface 321b. Then, the worker fixes the fixing block 330 to the magnet holder 320 with the magnet fixing tool 335.
[0348] <Composition group H> 104, 105, and 106, the power lead-out wire 212 is electrically connected to the power bus bar 261. The power lead-out wire 212 has a connecting bent portion 212f in addition to an outer peripheral lead-out portion 212a, etc. Note that the rotors 300a, 300b, etc. are not shown in FIG.
[0349] The connection bent portion 212f is a portion of the power lead-out wire 212 that is between the outer peripheral lead-out portion 212a and the coil 211. The connection bent portion 212f is located at a position away from the outer peripheral lead-out portion 212d on the opposite side from the power bus bar 261 in the axial direction AD. The connection bent portion 212f connects the outer peripheral lead-out portion 212a and the coil 211 in a bent state. The connection bent portion 212f is bent so as to bulge outward in the radial direction, for example, is bent. The connection bent portion 212f is bent to connect the outer peripheral lead-out portion 212a and the coil 211. The connection bent portion 212f corresponds to a connection bent portion. Note that the connection bent portion 212f does not have to be bent as long as it is bent, and may be curved, for example.
[0350] The power lead wire 212 has a lead base end 212g. The lead base end 212g is the end of the power lead wire 212 on the coil 211 side. The lead base end 212g is also the end of the connection bent portion 212f on the coil 211 side. The lead base end 212g is included in the boundary between the power lead wire 212 and the coil 211.
[0351] In the grommet 255, the power lead wire 212 is inserted through the grommet hole 450. In the power lead wire 212, the outer peripheral lead portion 212a is inserted through the grommet hole 450. The grommet 255 is heat resistant. The grommet 255 can withstand the molding temperature when the coil protection part 250 is molded. The molding temperature is the temperature of the molten resin used to resin mold the coil protection part 250. The grommet 255 can withstand the heat of the molten resin. The coil protection part 250 is sometimes referred to as molded resin.
[0352] When the motor device 60 is in operation, the temperature of the power lead-out wire 212 is likely to rise due to the current flowing through the power lead-out wire 212. The grommet 255 can withstand the temperature of the power lead-out wire 212 that rises as the motor device 60 is in operation. The grommet 255 can withstand the heat of the power lead-out wire 212.
[0353] As shown in Figures 106 and 107, in grommet 255, grommet hole 450 has a tightening hole portion 451 and an expanded hole portion 452. The tightening hole portion 451 and the expanded hole portion 452 are aligned in the axial direction AD. The expanded hole portion 452 extends from the tightening hole portion 451 toward the coil protection portion 250 in the axial direction AD. The expanded hole portion 452 is a hole expanded with respect to the tightening hole portion 451. The expanded hole portion 452 is a hole that is thicker than the tightening hole portion 451. The inner diameter of the expanded hole portion 452 is larger than the inner diameter of the tightening hole portion 451. The tightening hole portion 451 and the expanded hole portion 452 have, for example, a circular cross section.
[0354] The grommet 255 has a grommet cylindrical body 460 and a grommet rib 465. The grommet cylindrical body 460 is a cylindrical portion of the grommet 255 and extends in the axial direction AD. The grommet cylindrical body 460 has a pair of end portions aligned in the axial direction AD. One end portion is located inside the coil protection portion 250 and is included in the embedded portion 255a. The other end portion is located away from the coil protection portion 250 towards the outer circumferential bending portion 212d and is included in the exposed portion 255b. The grommet cylindrical body 460 corresponds to the protective cylindrical portion.
[0355] The grommet rib 465 extends from the grommet cylindrical body 460 in a direction perpendicular to the axial direction AD. The grommet rib 465 is provided between a pair of end portions of the grommet cylindrical body 460. The grommet rib 465 is located closer to the end portion of the pair of end portions that is included in the exposed portion 255b than to the end portion that is included in the embedded portion 255a. The grommet rib 465 extends from the grommet cylindrical body 460 toward both sides in the circumferential direction CD. The grommet rib 465 also extends radially inward from the grommet cylindrical body 460. The grommet rib 465 has a portion that extends from the grommet cylindrical body 460 toward one side in the circumferential direction CD, a portion that extends toward the other side in the circumferential direction CD, and a portion that extends radially inward.
[0356] The grommet cylindrical body 460 has a tightening cylindrical portion 461 and an expanding cylindrical portion 462. The tightening cylindrical portion 461 forms a tightening hole portion 451. The tightening hole portion 451 is formed by the inner circumferential surface of the tightening cylindrical portion 461. The expanding cylindrical portion 462 forms an expanding hole portion 452. The expanding hole portion 452 is formed by the inner circumferential surface of the expanding cylindrical portion 462. The tightening cylindrical portion 461 and the expanding cylindrical portion 462 are aligned in the axial direction AD. The expanding cylindrical portion 462 extends from the tightening cylindrical portion 461 toward the coil protection portion 250 in the axial direction AD. The expanding cylindrical portion 462 is thinner-walled than the tightening cylindrical portion 461. The thick portion of the expanding cylindrical portion 462 is thinner than the thick portion of the tightening cylindrical portion 461.
[0357] In grommet 255, a portion of grommet tubular body 460 and grommet rib 465 are included in grommet main body 256. In grommet tubular body 460, a portion of tightening tubular portion 461 and extension tubular portion 462 are included in grommet main body 256. The remaining portion of tightening tubular portion 461 is included in inner grommet portion 257. Outer grommet portion 258 extends from grommet rib 465 toward tightening tubular portion 461 in the axial direction AD.
[0358] As shown in FIG. 107 , in the grommet hole 450, the tightening tube portion 461 is shorter than the extension tube portion 462. In the axial direction AD, the length dimension Lb1 of the tightening tube portion 461 is smaller than the length dimension Lb2 of the extension tube portion 462. The tightening tube portion 461 is shorter than half the length of the grommet cylindrical body 460. In the axial direction AD, the length dimension Lb1 of the tightening tube portion 461 is smaller than half the length dimension Lb3 of the grommet cylindrical body 460. The length dimension Lb1 of the tightening tube portion 461 is larger than, for example, the outer diameter of the tightening hole portion 451. Furthermore, the length dimension Lb1 is larger than, for example, the outer diameter of the tightening tube portion 461. The tightening tube portion 461 is longer than the inner grommet portion 257. In the grommet 255, the grommet rib 465 straddles the boundary between the tightening tube portion 461 and the extension tube portion 462 in the axial direction AD. The length Lb1 of the clamping cylindrical portion 461 is sometimes referred to as an interference.
[0359] 106, in grommet 255, embedded portion 255a is embedded in coil protection portion 250, and exposed portion 255b is exposed from coil protection portion 250. Grommet 255 is embedded in coil protection portion 250 so that grommet body 256 forms embedded portion 255a, and so that inner grommet portion 257 and outer grommet portion 258 form exposed portions 255b. Grommet 255 covers and protects power lead wire 212 with at least embedded portion 255a. Embedded portion 255a corresponds to the protective embedded portion.
[0360] The embedded portion 255a extends inside the coil protection portion 250 beyond the protected axis Cp toward the opposite side from the power bus bar 261. The protected axis Cp is a straight imaginary line that passes through the center of the coil protection portion 250 and extends in the radial direction RD. The protected axis Cp corresponds to the center line of the coil protection portion 250. In the axial direction AD, the length dimension La2 of the embedded portion 255a is greater than half the length dimension La1 of the coil protection portion 250. The length dimension La2 of the embedded portion 255a is greater than the length dimension La3 of a portion of the coil protection portion 250 that is aligned with the embedded portion 255a in the axial direction AD. The embedded portion 255a is longer than the inner grommet portion 257. The length dimension La2 of the embedded portion 255a is greater than the length dimension La4 of the inner grommet portion 257 in the axial direction AD. Note that the outer grommet portion 258 is not shown in FIG. 106.
[0361] In the grommet 255, a portion of the grommet cylindrical body 460 is in close contact with the power lead wire 212. In the grommet cylindrical body 460, the tightening cylindrical portion 461 is in close contact with the outer peripheral lead portion 212a. The tightening cylindrical portion 461 covers the outer peripheral lead portion 212a while being in close contact with the outer peripheral lead portion 212a. The inner diameter of the tightening cylindrical portion 461 is slightly smaller than the outer diameter of the outer peripheral lead portion 212a. The tightening cylindrical portion 461 is attached to the outer peripheral lead portion 212a in an elastically deformed state, and is in close contact with the outer peripheral lead portion 212a due to the restoring force of the grommet 255. The restoring force of the grommet 255 makes it difficult for a gap to form between the tightening cylindrical portion 461 and the outer peripheral lead portion 212a. The tightening cylindrical portion 461 corresponds to a tight-fitting cover portion.
[0362] In the grommet cylindrical body 460, the extension cylindrical portion 462 is spaced outward from the outer peripheral drawn portion 212a. The extension cylindrical portion 462 is spaced outward from the outer peripheral drawn portion 212a in the radial direction of the extension cylindrical portion 462. The extension cylindrical portion 462 covers the outer peripheral drawn portion 212a while being spaced from the outer peripheral surface of the outer peripheral drawn portion 212a. A gap is created between the extension cylindrical portion 462 and the outer peripheral drawn portion 212a. The inner diameter of the extension cylindrical portion 462 is larger than the outer diameter of the outer peripheral drawn portion 212a. The extension cylindrical portion 462 corresponds to a gap covering portion.
[0363] A portion of the coil protection part 250 is inserted between the extension tube part 462 and the outer circumferential drawn part 212a. The coil protection part 250 has a protection main body 251 and a protection entry part 252. The protection entry part 252 is inserted so as to enter the gap between the extension tube part 462 and the outer circumferential drawn part 212a. The protection entry part 252 extends from the protection main body 251 in the axial direction AD. The protection entry part 252 is in close contact with both the inner surface of the extension tube part 462 and the outer surface of the outer circumferential drawn part 212a. The protection entry part 252 is in a state where the inner surface of the extension tube part 462 and the outer surface of the outer circumferential drawn part 212a are joined together. The protection entry part 252 is in a state where it fills the gap between the extension tube part 462 and the outer circumferential drawn part 212a. The protection entry part 252 corresponds to the entry part.
[0364] The protective entry portion 252 covers the outer peripheral drawn portion 212a. The protective entry portion 252 extends in an annular shape along the outer peripheral surface of the outer peripheral drawn portion 212a. The thickness of the protective entry portion 252 is thinner than the thickness of the expansion tubular portion 462. The thickness of the protective entry portion 252 is smaller than the outer diameter of the outer peripheral drawn portion 212a.
[0365] The coil protection part 250 has a first protection end 250a and a second protection end 250b. The coil protection part 250 has a pair of ends aligned in the axial direction AD as the protection ends 250a, 250b. Of the pair of ends, the end on the power bus bar 261 side in the axial direction AD is the first protection end 250a, and the end on the opposite side from the power bus bar 261 is the second protection end 250b. The protection ends 250a, 250b are end faces of the coil protection part 250 and extend in a direction perpendicular to the axial direction AD.
[0366] The coil 211 has a first coil end 211a and a second coil end 211b. The coil 211 has a pair of ends aligned in the axial direction AD as the coil ends 211a, 211b. Of the pair of ends, the end on the power bus bar 261 side in the axial direction AD is the first coil end 211a, and the end on the opposite side from the power bus bar 261 is the second coil end 211b. The coil ends 211a, 211b are formed from a coil wire 220. The first coil end 211a is on the first rotor 300a side in the axial direction AD and corresponds to the rotor-side end. The second coil end 211b is on the opposite side from the first rotor 300a in the axial direction AD and corresponds to the opposite end.
[0367] The coil ends 211a, 211b are located between the first protective end 250a and the second protective end 250b in the axial direction AD. The first coil end 211a is located away from the first protective end 250a toward the second coil end 211b. The first coil end 211a is located away from the first protective end 250a by at least the thickness of the bobbin flange 242 (see FIG. 63, etc.). The second coil end 211b is located away from the second protective end 250b toward the first coil end 211a. The second coil end 211b is located away from the second protective end 250b by at least the thickness of the bobbin flange 242.
[0368] The power lead wire 212 is led out from the second coil end 211b of the coil 211. The connection bent portion 212f including the lead base end 212g has a portion extending radially outward from the coil 211 and a portion extending from the outer circumferential lead portion 212a toward the second coil end 211b in the axial direction AD.
[0369] The connection bend portion 212f is located at a position spaced from the first coil end 211a toward the second coil end 211b in the axial direction AD. Therefore, the lead-out base end 212g is located at a position spaced from the first coil end 211a toward the second coil end 211b. Furthermore, the connection bend portion 212f is located at a position spaced from the protected axis Cp toward the second coil end 211b. Therefore, the lead-out base end 212g is located at a position spaced from the protected axis Cp toward the second coil end 211b. Furthermore, the connection bend portion 212f is located at a position spaced from the grommet 255 toward the second coil end 211b in the axial direction AD.
[0370] The grommet 255 is provided at a position straddling the first protection end 250a in the axial direction AD. The exposed portion 255b extends from the first protection end 250a in the axial direction AD toward the opposite side from the coil 211. The buried portion 255a extends from the first protection end 250a toward the coil 211 in the axial direction AD.
[0371] The grommet 255 is provided at a position straddling the first coil end 211a in the axial direction AD. The exposed portion 255b is located at a position spaced apart from the first coil end 211a on the side opposite the coil 211. The buried portion 255a is located at a position straddling the first coil end 211a in the axial direction AD. The grommet 255 extends beyond the protected axis Cp toward the second coil end 211b in the axial direction AD.
[0372] As shown in Figures 107 and 108, the grommet 255 has a grommet groove 466. The grommet groove 466 is a recess provided in the outer surface of the grommet 255. The outer surface of the grommet 255 includes a tube side surface 460b. The tube side surface 460b is included in the outer surface of the grommet cylindrical body 460. The tube side surfaces 460b extend in a direction perpendicular to the circumferential direction CD and are arranged in pairs in the circumferential direction CD via the grommet holes 450. The tube side surfaces 460b are included in the outer surface of the extending tube portion 462. The tube side surfaces 460b extend from the grommet rib 465 toward the opposite side from the fastening tube portion 461. The portion of the extending tube portion 462 where the grommet groove 466 is provided is included in the embedded portion 255a. The grommet groove 466 is provided in the outer surface of the embedded portion 255a.
[0373] A grommet groove 466 is provided on each of the pair of cylinder side surfaces 460b. A plurality of grommet grooves 466 are provided on the cylinder side surface 460b. The plurality of grommet grooves 466 are arranged in the axial direction AD on each of the pair of cylinder side surfaces 460b. The grommet grooves 466 are groove portions that are open in the circumferential direction CD. The grommet grooves 466 extend in the radial direction RD. The grommet grooves 466 are open to both the radially inward and radially outward sides.
[0374] The grommet 255 has a cylindrical tapered surface 460a. The cylindrical tapered surface 460a is included in the outer surface of the grommet cylindrical body 460. The cylindrical tapered surface 460a faces radially inward. The cylindrical tapered surface 460a is inclined with respect to the rib intersection surface 465b so as to face the opposite side from the rib intersection surface 465b in the axial direction AD. The cylindrical tapered surface 460a is sometimes referred to as a cylindrical inclined surface. The cylindrical tapered surface 460a is included in the outer surface of the fastening cylindrical portion 461. The cylindrical tapered surface 460a extends tapered from the grommet rib 465 in the axial direction AD. Due to the cylindrical tapered surface 460a, the thickness dimension of the fastening cylindrical portion 461 in the radial direction RD gradually decreases toward the opposite side from the grommet rib 465 in the axial direction AD.
[0375] 109, a portion of coil protection part 250 is inserted into grommet groove 466. Grommet 255 and coil protection part 250 are engaged with each other. The engagement part where grommet 255 and coil protection part 250 are engaged with each other prevents grommet 255 from coming off coil protection part 250.
[0376] The coil protection part 250 has a protection engagement part 253. The protection engagement part 253 is fitted into the grommet groove 466. The protection engagement part 253 extends from the protection main body 251 toward the inside of the grommet groove 466. The protection engagement part 253 is in close contact with the inner surface of the grommet groove 466. The protection engagement part 253 is in a state of engagement with the grommet groove 466. The grommet groove 466 opens in a direction perpendicular to the axial direction AD, called the circumferential direction CD, and extends in a direction perpendicular to the axial direction AD, called the radial direction RD. The grommet groove 466 corresponds to the embedded engagement part, and the protection engagement part 253 corresponds to the engaged part.
[0377] The grommet 255 is hooked onto the first circumferential retaining portion 172 in the motor housing 70. The first circumferential retaining portion 172 has a first recess 172a, a first inner circumferential surface 172b, and a first extending surface 172c. The first inner circumferential surface 172b and the first extending surface 172c are included in the outer surface of the first circumferential retaining portion 172. The first inner circumferential surface 172b is the surface of the outer surface of the first circumferential retaining portion 172 that faces radially inward. The first extending surface 172c is the surface of the outer surface of the first circumferential retaining portion 172 that faces the power bus bar 261 in the axial direction AD. The first recess 172a is a recess provided in the first inner circumferential surface 172b and is recessed radially outward from the first inner circumferential surface 172b. The first recess 172a opens toward the first extending surface 172c in the axial direction AD. The first recess 172a extends from the drawn-out groove portion 171a toward the first extending surface 172c in the axial direction AD.
[0378] The grommet 255 is fitted inside the pull-out groove 171a and the first recess 172a. In the grommet 255, the extension tube portion 462 is fitted inside the pull-out groove 171a. The grommet rib 465 is fitted inside the first recess 172a. The grommet rib 465 is hooked on the first recess 172a from the opposite side to the shaft holding portion 174 in the axial direction AD. The grommet rib 465 is in close contact with the inner surface of the first recess 172a.
[0379] The grommet 255 has a rib extension surface 465a and a rib intersection surface 465b. The rib extension surface 465a and the rib intersection surface 465b are included in the outer surface of the grommet rib 465. The rib extension surface 465a extends from the grommet cylindrical body 460 in a direction perpendicular to the axial direction AD. The grommet 255 is integrated with the first circumferential retaining portion 172. The rib extension surface 465a extends in the circumferential direction CD as if integrated with the first extension surface 172c. For example, the rib extension surface 465a and the first extension surface 172c form surfaces that extend continuously with each other. The rib intersection surface 465b extends in the circumferential direction CD as if integrated with the first inner circumferential surface 172b. For example, the rib intersection surface 465b and the first inner circumferential surface 172b form surfaces that extend continuously with each other.
[0380] Next, a method for manufacturing the coil protection part 250 with the grommet 255 will be described among the methods for manufacturing the motor device 60. In the process of manufacturing the coil protection part 250 with the grommet 255, an operator prepares the coil unit 210, the motor housing 70, and the grommet 255 as a preparation step. At the preparation step, the power lead wire 212 of the coil unit 210 extends linearly in the axial direction AD.
[0381] After the preparation step, the worker performs the grommet step, the attachment step, and the molding step. In the grommet step, the worker attaches the grommet 255 to the power lead wire 212 of the coil unit 210. The worker inserts the power lead wire 212 into the grommet hole 450 from the expanded hole portion 452 side. In the grommet 255, the inner circumferential surface of the tightening tube portion 461 is likely to come into close contact with the power lead wire 212, while a gap is likely to form between the inner circumferential surface of the expanded tube portion 462 and the power lead wire 212. Therefore, unlike the present embodiment, the area of close contact between the grommet 255 and the power lead wire 212 is smaller than in a configuration in which the entire inner circumferential surface of the grommet cylindrical body 460 is in close contact with the power lead wire 212. This reduces the difficulty of the worker inserting the power lead wire 212 into the grommet hole 450.
[0382] In the installation process, the worker installs the coil unit 210 and the grommet 255 into the motor housing 70. With the coil unit 210 installed inside the motor housing 70, the worker fits the grommet 255, with the power lead-out wire 212 passing through it, into the lead-out groove 171a and the first recess 172a. The grommet 255 is in close contact with the inner surfaces of the lead-out groove 171a and the first recess 172a due to a restoring force generated by elastic deformation. With the grommet 255 fitted into the lead-out groove 171a and the first recess 172a, the grommet 255 is located at a position spaced apart from the connection bent portion 212f in the axial direction AD with respect to the power lead-out wire 212. The worker inserts the grommet 255 and the power lead-out wire 212 into the lead-out groove 171a.
[0383] In the molding process, an operator attaches a mold to the motor housing 70 to which the coil unit 210 and the grommet 255 are attached. Before the operator attaches the mold to the motor housing 70, the grommet 255 protrudes from the drawing groove portion 171a and the first recess 172a. The mold has an axial pressing surface that presses the grommet 255 in the axial direction AD. The axial pressing surface faces the rib extension surface 465a in the axial direction AD and presses the rib extension surface 465a so that the rib extension surface 465a and the first extension surface 172c are flush with each other. The axial pressing surface elastically deforms the grommet 255 in the axial direction AD so that the grommet rib 465 enters the inside of the first recess 172a.
[0384] The mold has a radial pressing surface that presses the grommet 255 radially outward. The radial pressing surface faces radially outward and presses the rib intersection surface 465b so that the rib intersection surface 465b and the first inner circumferential surface 172b are flush with each other. The radial pressing surface elastically deforms the grommet 255 in the radial direction RD so that the grommet rib 465 fits into the inside of the first recess 172a.
[0385] The worker inserts the mold into the motor housing 70 in the axial direction AD from the clamping cylinder portion 461 side toward the extending cylinder portion 462. The worker performs work to hook the mold onto the first circumferential retaining portion 172 so that the shaft pressing surface contacts the first extending surface 172c while pressing the rib extending surface 465a, and so that the diameter pressing surface contacts the first inner circumferential surface 172b while pressing the rib intersection surface 465b. During this work, because the cylinder tapered surface 460a is inclined with respect to the rib intersection surface 465b, it is unlikely that the shaft pressing surface will get caught on the cylinder tapered surface 460a before reaching the rib extending surface 465a.
[0386] After the molding process, the worker performs a molding process to mold the coil protection part 250. In the molding process, the worker pours molten resin into the motor housing 70 and the mold. The molten resin is sometimes referred to as a resin mold. In the motor housing 70, the grommet 255 prevents the molten resin from leaking out of the first recess 172a. Because the grommet rib 465 is in close contact with the inner surface of the first recess 172a, the molten resin is prevented from entering between the grommet rib 465 and the first recess 172a. In the grommet 255, a gap is formed between the extension tube portion 462 and the power lead wire 212, allowing the molten resin to enter the extension hole portion 452. On the other hand, because the tightening tube portion 461 is in close contact with the power lead wire 212, the molten resin is prevented from entering the tightening hole portion 451. This prevents the molten resin from leaking out of the grommet hole 450.
[0387] When molten resin is injected into the motor housing 70 and the mold, an injection pressure is applied to the coil unit 210 and the grommet 255. The injection pressure is the pressure used to inject the molten resin into the motor housing 70 and the mold. In the coil unit 210, the grommet 255 prevents the power lead wire 212 from being pressed by the injection pressure of the molten resin and being unintentionally deformed. For example, the buried portion 255a prevents the portion of the power lead wire 212 between the connection bent portion 212f and the exposed portion 255b from being unintentionally deformed. This prevents the power lead wire 212 from coming into contact with the motor housing 70, thereby preventing a case short circuit from occurring. A case short circuit occurs when the conductor portion 221 of the power lead wire 212 comes into contact with the motor housing 70.
[0388] In the embedded portion 255a, a gap is provided between the extension tube portion 462 and the power lead wire 212, which allows the extension tube portion 462 to deform relative to the power lead wire 212. Therefore, the injection pressure of the molten resin applied to the extension tube portion 462 is less likely to be applied to the power lead wire 212 due to the deformation of the extension tube portion 462.
[0389] After the molten resin has solidified and the coil protection portion 250 has been formed, the worker removes the mold from the motor housing 70. Thereafter, the worker performs the work of bending the power lead wire 212 to form the inner circumferential lead portion 212b and the like.
[0390] <Composition group I> As described above for the structural groups Bd and Be, in the rotor 300, the rotor 300 is attached to the shaft 340. The shaft 340 is made of an aluminum alloy, titanium, resin, CFRP, or the like. In this embodiment, the shaft 340 is made of titanium.
[0391] In FIG. 110, the spokes 343 extend radially outward from the shaft body 341 and correspond to rotational extension portions. The spokes 343 are provided between the shaft body 341 and the rim 344. The spokes 343 connect the shaft body 341 and the rim 344 while extending in the radial direction RD. The spokes 343 are suspended between the shaft body 341 and the rim 344 via a rim inner peripheral hole 349. The spokes 343 are provided between the first rotor 300a and the second rotor 300b in the axial direction AD. The spokes 343 are connected to the rim 344 at a location between the first rotor 300a and the second rotor 300b.
[0392] As shown in Figure 37, a plurality of spokes 343 are arranged in the circumferential direction CD. The plurality of spokes 343 extend radially from the motor axis Cm. Two spokes 343 adjacent to each other in the circumferential direction CD are spaced apart from each other in the circumferential direction CD. In the axial direction AD, the height dimension of the spokes 343 is smaller than the height dimension of the rim 344.
[0393] In FIG. 110, the rim 344 is formed in a plate shape overall and extends in a direction perpendicular to the radial direction RD. The rim 344 extends in the circumferential direction CD along the holder inner peripheral end 320a. The rim 344 extends from the spokes 343 toward both sides in the axial direction AD. For example, the rim 344 protrudes from the spokes 343 toward the first rotor 300a side and from the spokes 343 toward the second rotor 300b side. The rim 344 supports the rotor 300 against the attractive force F1 between the coil 211 and the magnet 310 and corresponds to a rotation support portion. The rim 344 supports each of the first rotor 300a and the second rotor 300b against the attractive force F1 generated by each of the first rotor 300a and the second rotor 300b.
[0394] The rim 344 is provided at a position closer to the holder outer peripheral end 320b than to the motor axis Cm in the radial direction RD. That is, the rim 344 is provided at a position closer to the outer peripheral end of the rotor 300. For example, the distance LI1 between the rim 344 and the outer peripheral imaginary line Vm1 is smaller than the distance LI2 between the rim 344 and the motor axis Cm. The outer peripheral imaginary line Vm1 is a straight imaginary line that passes through the holder outer peripheral end 320b and extends parallel to the motor axis Cm.
[0395] The distance LI2 is smaller than the distance LI3 between the outer periphery virtual line Vm1 and the motor axis Cm, but larger than the distance LI4 between the intermediate virtual line Vm2 and the motor axis Cm. The intermediate virtual line Vm2 is a straight virtual line that passes through the center between the outer periphery virtual line Vm1 and the motor axis Cm in the radial direction RD and extends parallel to the motor axis Cm. The distance LI1 is smaller than both the distances LI3 and LI4. The distance LI1 is the separation distance between the rim 344 and the holder outer periphery end 320b in the radial direction RD. Both the distances LI1 and LI2 are the distance to the center of the rim 344. The holder outer periphery end 320b is the outer periphery end of the magnet holder 320 and the outer periphery end of the rotor 300.
[0396] The rim 344 is located closer to the magnet 310 in the radial direction RD than the shaft body 341. For example, the distance LI5 between the rim 344 and the magnet 310 is smaller than the distance LI6 between the rim 344 and the shaft body 341. The distance LI5 is the distance between the center of the rim 344 and the unit inner circumferential end 316a in the radial direction RD. The distance LI6 is the distance between the center of the rim 344 and the inner circumferential end of the spoke 343 in the radial direction RD.
[0397] The rim 344 is located closer to the holder inner peripheral end 320a than to the holder outer peripheral end 320b in the radial direction RD. For example, the distance LI8 between the rim 344 and the holder inner peripheral end 320a is smaller than the distance LI7 between the rim 344 and the holder outer peripheral end 320b. Both distances LI7 and LI8 are distances to the center of the rim 344.
[0398] The rim 344 is provided between the holder inner circumferential end 320a and the magnet 310 in the radial direction RD. The rim 344 is located away from both the holder inner circumferential end 320a and the magnet 310. The holder inner circumferential end 320a is the inner circumferential end of the magnet holder 320 and also the inner circumferential end of the rotor 300. The rim 344 is located closer to the magnet 310 in the radial direction RD than the holder inner circumferential end 320a. For example, the distance LI5 between the rim 344 and the magnet 310 is smaller than the distance LI8 between the rim 344 and the holder inner circumferential end 320a.
[0399] As described above for the structural groups Bd and Be, the holder fixture 350 fixes the magnet holder 320 to the shaft flange 342. In the shaft flange 342, the magnet holder 320 is fixed to the spokes 343. The holder fixture 350 is screwed into the flange fixing holes 345. The flange fixing holes 345 are the portions of the spokes 343 where the magnet holder 320 is fixed. The holder fixture 350 is provided at a position away from the rim 344 on the opposite side to the magnet 310 in the radial direction RD. The holder fixture 350 corresponds to a rotation fixing part.
[0400] The holder fixture 350 fixes the magnet holder 320 to the spokes 343 while pressing the magnet holder 320 toward the spokes 343. The holder fixture 350 applies a pressing force F3 to the magnet holder 320 in a direction that moves the magnet holder 320 toward the spokes 343. In the magnet holder 320, a bending stress F2 that acts to move the magnet holder 320 away from the coil 211 is generated by the pressing force F3. This bending stress F2 resists the attractive force F1 between the coil 211 and the magnet 310 and restricts the magnet holder 320 from bending in a direction that moves toward the coil 211. In the rotor 300, the position where the attractive force F1 acts becomes the point of application.
[0401] In the magnet holder 320, the rim tip 344a serves as a fulcrum for the pressing force F3, generating a bending stress F2. The rim tip 344a serves as the contact surface that contacts the magnet holder 320. Because the attractive force F1, the bending stress F2, and the pressing force F3 are all forces directed in the axial direction AD, the force applied to the rim 344 also tends to be a force directed in the axial direction AD. For this reason, even if the rim 344 has a thin shape in the radial direction RD, the rim 344 is unlikely to be deformed by the force applied to it. Therefore, by making the rim 344 as thin as possible, the weight of the shaft 340 is reduced.
[0402] For example, the rim 344 is thinner than the spokes 343. Specifically, the thickness of the rim 344 in the radial direction RD is smaller than the thickness of the spokes 343 in the axial direction AD. The thickness of the rim 344 is also smaller than the distance LI5 between the magnet 310 and the rim 344 in the radial direction RD.
[0403] Next, a method for manufacturing the shaft 340 among the methods for manufacturing the motor device 60 will be described. In the process of manufacturing the shaft 340, an operator prepares a shaft base material 490 as shown in FIG. 111 as a preparation process. The shaft base material 490 is a base material for manufacturing the shaft 340, and is, for example, a rectangular parallelepiped member. The shaft base material 490 is formed from an aluminum alloy, titanium, resin, CFRP, or the like. In this embodiment, a titanium base material is used as the shaft base material 490.
[0404] After the preparation step, the worker performs a processing step in which the shaft base material 490 is processed into the shape of the shaft 340. In the processing step, the worker performs a cutting process to cut the shaft base material 490, and manufactures the shaft 340 from the shaft base material 490. The processing step may also include a grinding process. In manufacturing the shaft 340, using as small a base material as possible as the shaft base material 490 tends to improve the material yield.
[0405] <Composition group K> As described in the above configuration group Ag, the motor device 60 has a resolver 421. As shown in Figures 112 and 113, the resolver 421 is provided on the shaft main body 341. The resolver 421 detects the rotational state of the rotor 300 by detecting the rotational state of the shaft main body 341. The resolver 421 detects the rotation angle as the rotational state of the shaft main body 341. The resolver 421 corresponds to the rotation detection unit, and the shaft main body 341 corresponds to the rotating shaft unit. The resolver 421 as a whole extends in the circumferential direction CD along the main body outer peripheral surface 341a. The main body outer peripheral surface 341a is the outer peripheral surface of the shaft main body 341. The resolver 421 is formed in an annular shape and is provided radially outside the shaft main body 341.
[0406] The resolver 421 has a resolver stator 421a and a resolver rotor 421b. In the resolver 421, the resolver rotor 421b rotates relative to the resolver stator 421a, thereby detecting the rotation angle of the shaft main body 341.
[0407] The resolver stator 421a is provided on the motor housing 70 side. The resolver stator 421a is fixed to, for example, the rear frame 370. The resolver stator 421a extends in the circumferential direction CD along the rear frame 370. The resolver stator 421a is formed in an annular shape and is provided radially outside the shaft main body 341.
[0408] The resolver rotor 421b is provided on the rotor 300 side. The resolver rotor 421b is fixed to the shaft main body 341 and rotates together with the shaft main body 341 around the motor axis Cm. The resolver rotor 421b extends in the circumferential direction CD along the main body outer circumferential surface 341a. The resolver rotor 421b is formed in an annular shape and is provided, for example, radially inside the resolver stator 421a.
[0409] The resolver 421 is provided between the power bus bar 261 and the shaft main body 341 in the radial direction RD. The resolver 421 is located at a distance radially inward from the power bus bar 261. The resolver 421 is located closer to the shaft main body 341 than the power bus bar 261 in the radial direction RD. In the radial direction RD, the positional relationship between the resolver 421 and the power bus bar 261 is substantially the same as the positional relationship between the resolver 421 and the bus bar unit 260. For example, the resolver 421 is located at a distance radially inward from the power bus bar 261, and therefore at a distance radially inward from the bus bar unit 260.
[0410] The bus bar unit 260 has a rectangular cross section. In the cross section of the bus bar unit 260, the long sides extend in the radial direction RD and the short sides extend in the axial direction AD. In the cross section of the bus bar unit 260, the length dimension in the radial direction RD is greater than the length dimension in the axial direction AD. The outer surface of the bus bar unit 260 is formed by a bus bar protection part 270. In the bus bar unit 260, the bus bar protection part 270 is fixed to the rear frame 370.
[0411] The resolver 421 is accommodated in the unit space 264. The unit space 264 is an inner space of the busbar unit 260. The unit space 264 is a space surrounded on all sides by the unit inner peripheral surface 260a. The unit space 264 is a space between the unit inner peripheral surface 260a and the main body outer peripheral surface 341a in the radial direction RD. The unit inner peripheral surface 260a is the inner peripheral surface of the busbar unit 260. The unit inner peripheral surface 260a extends in a direction perpendicular to the radial direction RD and extends annularly in the circumferential direction CD. At least a portion of the resolver 421 is accommodated in the unit space 264. In this embodiment, almost the entire resolver 421 is accommodated in the unit space 264 in the axial direction AD. The resolver connector 423 and at least a portion of the resolver cover 424 are accommodated in the unit space 264. The resolver connector 423 and the resolver cover 424 do not necessarily have to be housed in the unit space 264 .
[0412] The resolver 421 is fitted radially inside the power bus bar 261. In the bus bar unit 260, a plurality of bus bar bodies 262 are stacked in the axial direction AD. The resolver 421 extends in the axial direction AD so as to straddle the plurality of bus bar bodies 262. The resolver 421 extends both toward the stator 200 side and away from the stator 200 beyond the plurality of bus bar bodies 262. The resolver 421 is fitted between the bus bar body 262 and the shaft body 341. The inner space of the power bus bar 261 is included in the unit space 264. At least a portion of the resolver 421 is accommodated in the inner space of the power bus bar 261, and is thereby accommodated in the unit space 264.
[0413] The power bus bar 261 is connected to the coil 211 so that electricity can be conducted therethrough. The power bus bar 261 is connected to the coil 211 via, for example, a power lead wire 212 and a bus bar lead wire 265. The power bus bar 261 is provided at a position spaced apart radially outward from the resolver 421. The power bus bar 261 is located closer to the motor inner circumferential surface 70b in the radial direction RD than the resolver 421. The power bus bar 261 corresponds to a current-carrying bus bar. The power bus bar 261 may also be referred to as a current-carrying conductor and a power conductor.
[0414] The resolver 421 and the power bus bar 261 are arranged in the radial direction RD along the rear frame 370. The resolver 421 and the power bus bar 261 are on the opposite side of the rear frame 370 from the stator 200 and the rotor 300. The rear frame 370 covers the stator 200 and the rotor 300 in the axial direction AD. The resolver 421 and the power bus bar 261 are fixed to the motor housing 70 via the rear frame 370. The motor housing 70 corresponds to an electric machine housing, and the rear frame 370 corresponds to an electric machine cover.
[0415] The power bus bar 261 is provided at a position aligned with the coil portion 215 in the axial direction AD. The power bus bar 261 extends in the direction in which the multiple coil portions 215 are aligned. The multiple coil portions 215 are aligned in a row along the circumferential direction CD. The power bus bar 261 extends in the circumferential direction CD along the row of the coil portions 215.
[0416] As described above for the configuration group Aa, the motor device 60 has the neutral point bus bar 290. The resolver 421 and the power bus bar 261 are located on the opposite side of the first rotor 300a from the neutral point bus bar 290. The resolver 421 and the power bus bar 261 are provided at a position spaced apart from the neutral point bus bar 290 in the axial direction AD. In the axial direction AD, in addition to the first rotor 300a, a rear frame 370 and spokes 343 are provided between the resolver 421 and the power bus bar 261 and the neutral point bus bar 290. The spokes 343 support the rotor 300 while extending radially outward from the shaft main body 341. The spokes 343 correspond to a rotor support portion.
[0417] The neutral point bus bar 290 is electrically connected to the neutral point 65. The neutral point bus bar 290 is located on the opposite side of the resolver 421 and the power bus bar 261 in the axial direction AD across the first rotor 300a, the rear frame 370, and the spokes 343. The neutral point bus bar 290 is provided between the first rotor 300a and the second rotor 300b in the axial direction AD. The neutral point bus bar 290 is located closer to the second rotor 300b than to the first rotor 300a in the axial direction AD.
[0418] The neutral point bus bar 290 is located between the resolver 421 and the power bus bar 261 in the radial direction RD. The neutral point bus bar 290 is located at a position spaced radially outward from the resolver 421. The neutral point bus bar 290 is located at a position spaced radially inward from the power bus bar 261. The neutral point bus bar 290 is located closer to the power bus bar 261 than the resolver 421 in the radial direction RD. The neutral point bus bar 290 is located between the coil section 215 and the shaft flange 342 in the radial direction RD. The neutral point bus bar 290 is located radially inward from the coil section 215. The neutral point bus bar 290 is located at a position spaced radially outward from the shaft flange 342.
[0419] The shaft flange 342 is positioned between the resolver 421 and the neutral point bus bar 290. For example, if an imaginary line is drawn between the resolver 421 and the neutral point bus bar 290 at the shortest distance, this imaginary line will intersect with the shaft flange 342. The shaft 340 is a non-magnetic member and is formed of a non-magnetic material. Examples of non-magnetic materials that form the shaft 340 include aluminum alloy, titanium, resin, and CFRP. At least the shaft flange 342 is a non-magnetic portion of the shaft 340. The shaft 40 easily prevents a magnetic field generated by a current flowing through the neutral point bus bar 290 from reaching the resolver 421. For example, the shaft flange 342 prevents electromagnetic waves generated when current is applied to the neutral point bus bar 290 from reaching the resolver 421, thereby causing noise in the detection signal of the resolver 421.
[0420] The rear frame 370 is a non-magnetic member and is made of a non-magnetic material. Examples of non-magnetic materials that form the rear frame 370 include aluminum alloy, titanium, resin, and CFRP. The rear frame 370 helps to prevent a magnetic field generated by energizing the neutral bus bar 290 and the coil 211 from reaching the resolver 421. The rear frame 370 also helps to prevent a magnetic field generated by the magnet 310 from reaching the resolver 421.
[0421] In rotor 300, the Halbach array of magnets 310 makes it difficult for magnetic flux from magnets 310 to leak out of magnet holder 320. For example, leakage magnetic flux to the inside in the radial direction is difficult to occur in rotor 300. Also, in rotor 300, leakage magnetic flux to the opposite side of magnet 310 via magnet holder 320 in the axial direction AD is difficult to occur.
[0422] <Composition group L> As shown in FIG. 114, magnet 310 has magnet inner peripheral end 310a, magnet outer peripheral end 310b, magnet side surface 310c, inner peripheral tapered surface 310d, and outer peripheral tapered surface 310e. Magnet 310 also has first magnet surface 310g and second magnet surface 310h. Magnet inner peripheral end 310a, magnet outer peripheral end 310b, magnet side surface 310c, tapered surfaces 310d, 310e, and magnet surfaces 310g, 310h are included in the outer surface of magnet 310. Magnet inner peripheral end 310a is the radially inner end surface of magnet 310. Inner peripheral tapered surface 310d is included in magnet inner peripheral end 310a. Magnet outer peripheral end 310b is the radially outer end surface of magnet 310. Outer peripheral tapered surface 310e is included in magnet outer peripheral end 310b.
[0423] As described in the above configuration group Bb, the magnet unit 316 has a unit inner peripheral end 316a, a unit outer peripheral end 316b, a unit side surface 316c, an inner peripheral tapered surface 316d, and an outer peripheral tapered surface 316e. Also, as described in the above configuration group G, the magnet unit 316 has a first unit surface 316g and a second unit surface 316h.
[0424] The outer surface of the magnet unit 316 is formed by the multiple magnets 310 that the magnet unit 316 has. The outer surface of the magnet unit 316 includes the outer surfaces of the multiple magnets 310. The magnet inner peripheral end 310a is included in the unit inner peripheral end 316a. The magnet outer peripheral end 310b is included in the unit outer peripheral end 316b. The magnet side surface 310c is included in the unit side surface 316c. The inner peripheral tapered surface 310d of the magnet 310 is included in the inner peripheral tapered surface 316d of the magnet unit 316. The outer peripheral tapered surface 310e of the magnet 310 is included in the outer peripheral tapered surface 316e of the magnet unit 316. The first magnet surface 310g is included in the first unit surface 316g. The second magnet surface 310h is included in the second unit surface 316h.
[0425] The magnet unit 316 has a side tapered surface 316f (see FIG. 98). The magnet 310 has a portion included in the side tapered surface 316f. This portion is included in the outer surface of the magnet 310.
[0426] In the magnet unit 316, multiple magnets 310 are bonded together with an adhesive. The adhesive is made of a resin material, an adhesive agent, or the like. In each magnet 310, a pair of magnet side surfaces 310c are aligned in the circumferential direction CD. Two magnets 310 adjacent to each other in the circumferential direction CD are bonded together with their magnet side surfaces 310c overlapping each other.
[0427] As shown in FIG. 115, the rotor 300 has a magnet boundary portion 501. The magnet boundary portion 501 is the boundary portion between two magnets 310 adjacent in the circumferential direction CD. A plurality of magnet boundary portions 501 are arranged in the circumferential direction CD. The plurality of magnet boundary portions 501 include an intra-unit boundary portion 501a and an extra-unit boundary portion 501b.
[0428] The unit intra-boundary portion 501a is included in the magnet unit 316. The unit intra-boundary portion 501a is the boundary portion between two magnets 310 adjacent in the circumferential direction CD in one magnet unit 316. Multiple unit intra-boundary portions 501a are arranged in the circumferential direction CD in the rotor 300. The unit outer boundary portion 501b is not included in the magnet unit 316. The unit outer boundary portion 501b is also the boundary portion between two magnet units 316 adjacent in the circumferential direction CD. Multiple unit outer boundary portions 501b are arranged in the circumferential direction CD in the rotor 300. The multiple unit outer boundary portions 501b include inner boundary portions BI and outer boundary portions BO. The unit outer boundary portion 501b is either an inner boundary portion BI or an outer boundary portion BO.
[0429] Two magnets 310 adjacent to each other in the circumferential direction CD across an intra-unit boundary 501a are oriented toward the same side in the circumferential direction CD. The orientation of these magnets 310 faces, for example, toward the inner boundary BI in the circumferential direction CD. In one magnet unit 316, all magnets 310 are oriented toward the inner boundary BI in the circumferential direction CD. In this way, repulsive force is unlikely to occur between two magnets 310 adjacent to each other in the circumferential direction CD across an intra-unit boundary 501a. The orientation of the magnets 310 refers to the magnetization direction of the magnets 310.
[0430] The two magnets 310 adjacent to each other in the circumferential direction CD across the unit outer boundary 501b are oriented in opposite directions in the circumferential direction CD. For example, the first inner magnet 312a and the second inner magnet 312b, which are adjacent to each other across the inner boundary BI as the unit outer boundary 501b, are oriented toward each other. In this way, the first inner magnet 312a and the second inner magnet 312b are oriented facing each other. Furthermore, the first outer magnet 313a and the second outer magnet 313b, which are adjacent to each other across the outer boundary BO as the unit outer boundary 501b, are oriented away from each other. In this way, the first outer magnet 313a and the second outer magnet 313b are oriented in opposite directions. As such, a repulsive force is likely to be generated between the two magnets 310 adjacent to each other in the circumferential direction CD across the unit outer boundary 501b.
[0431] As shown in FIG. 114, the magnet unit 316 has at least one of an inclined magnet 314 and a parallel magnet 315 as the magnet 310. For example, the inclined magnet unit 317 has both the inclined magnet 314 and the parallel magnet 315. In the inclined magnet unit 317, the inclined magnet 314 and the parallel magnet 315 are aligned in the circumferential direction CD. The parallel magnet unit 318 has only the parallel magnet 315 out of the inclined magnet 314 and the parallel magnet 315. In the parallel magnet unit 318, a plurality of parallel magnets 315 are aligned in the circumferential direction CD.
[0432] In the inclined magnet 314, a pair of magnet side surfaces 310c are inclined toward each other. The pair of magnet side surfaces 310c are inclined, for example, so as to move away from each other radially outward. In the inclined magnet 314, the distance between the pair of magnet side surfaces 310c gradually increases radially outward. In the inclined magnet 314, the magnet outer peripheral end 310b is longer than the magnet inner peripheral end 310a in the radial direction RD. The inclined magnet 314 is formed in an overall trapezoidal or sector shape.
[0433] In the parallel magnet 315, a pair of magnet side surfaces 310c extend parallel to each other. The pair of magnet side surfaces 310c extend in a direction perpendicular to the circumferential direction CD. In the parallel magnet 315, the distance between the pair of magnet side surfaces 310c is uniform in the radial direction RD. In the parallel magnet 315, the magnet outer peripheral end 310b and the magnet inner peripheral end 310a are approximately the same length in the radial direction RD. The parallel magnet 315 is formed into an overall rectangular shape.
[0434] In the rotor 300, one of the inclined magnet unit 317 and the parallel magnet unit 318 is the first orientation unit 319a, and the other is the second orientation unit 319b. For example, if the inclined magnet unit 317 is the first orientation unit 319a, the parallel magnet unit 318 is the second orientation unit 319b. In this configuration, of the two inclined magnets 314 included in the inclined magnet unit 317, one is the first inner-axis magnet 312a, and the other is the first outer-axis magnet 313a. The parallel magnet 315 included in the inclined magnet unit 317 is the first circumferential magnet 311a. Of the parallel magnets 315 at both ends of the parallel magnet unit 318, one is the second inner-axis magnet 312b, and the other is the second outer-axis magnet 313b. The middle parallel magnet 315 in the parallel magnet unit 318 is the second circumferential magnet 311b.
[0435] In the inclined magnet unit 317, the width dimension of the parallel magnets 315 in the circumferential direction CD is smaller than the width dimension of the inclined magnets 314. In the parallel magnet unit 318, the width dimension of the middle parallel magnet 315 is smaller than the width dimensions of the parallel magnets 315 on both ends. That is, in the first alignment unit 319a and the second alignment unit 319b, the width dimensions of the circumferential magnets 311a, 311b are smaller than the width dimensions of the inner axial magnets 312a, 312b and the width dimensions of the outer axial magnets 313a, 313b.
[0436] As shown in Figures 116 and 117, the magnet 310 has magnet pieces 505. The magnet pieces 505 are magnet pieces that form the magnet 310 and correspond to the magnet member. The magnet 310 includes multiple magnet pieces 505. The multiple magnet pieces 505 are joined together with an adhesive to form the magnet 310. The magnet pieces 505 are permanent magnets. The multiple magnet pieces 505 are stacked in the radial direction RD. The radial direction RD corresponds to the stacking direction. The magnet pieces 505 are formed in a plate shape and extend in a direction perpendicular to the radial direction RD. Two magnet pieces 505 adjacent to each other in the radial direction RD are stacked on top of each other. The thickness dimension of the multiple magnet pieces 505 is approximately the same.
[0437] In the magnet 310, the orientation direction of the magnet pieces 505 is the same across the multiple magnet pieces 505. That is, in the magnet 310, the magnetization direction of the magnet pieces 505 is the same across the multiple magnet pieces 505. The orientation direction of the multiple magnet pieces 505 in one magnet 310 is the same. For example, in the magnet 310 oriented to face one side in the circumferential direction CD, all of the multiple magnet pieces 505 are oriented to face one side in the circumferential direction CD.
[0438] The magnet piece 505 has an inner piece surface 505a, an outer piece surface 505b, a piece side surface 505c, a first piece surface 505g, and a second piece surface 505h. The inner piece surface 505a, the outer piece surface 505b, the piece side surface 505c, the first piece surface 505g, and the second piece surface 505h are included in the outer surface of the magnet piece 505. The inner piece surface 505a and the outer piece surface 505b are a pair of plate surfaces of the magnet piece 505. In the magnet piece 505, the plate surface on the radially inner side is the inner piece surface 505a, and the plate surface on the radially outer side is the outer piece surface 505b. The inner piece surface 505a and the outer piece surface 505b extend parallel to each other. In two magnet pieces 505 adjacent to each other in the radial direction RD, one inner piece surface 505a and the other outer piece surface 505b are bonded together.
[0439] The outer surface of magnet 310 is formed by multiple magnet pieces 505 that magnet 310 has. The outer surface of magnet 310 includes the outer surfaces of multiple magnet pieces 505. Piece side surface 505c is included in magnet side surface 310c. First piece surface 505g is included in first magnet surface 310g. Second piece surface 505h is included in second magnet surface 310h.
[0440] The piece side surface 505c, the first piece surface 505g, and the second piece surface 505h are included on the outer peripheral surface of the magnet piece 505. The piece side surface 505c, the first piece surface 505g, and the second piece surface 505h extend in the radial direction RD so as to connect the inner peripheral piece surface 505a and the outer peripheral piece surface 505b. A pair of piece side surfaces 505c are included on the outer peripheral surface of the magnet piece 505. The pair of piece side surfaces 505c are aligned in the circumferential direction CD.
[0441] The innermost magnet piece 505 of the magnet 310 forms the magnet inner peripheral end 310a. The innermost magnet piece 505 is located at the radially innermost position of the multiple magnet pieces 505 that the magnet 310 has. The inner peripheral piece surface 505a of the innermost magnet piece 505 is included in the magnet inner peripheral end 310a. The outermost magnet piece 505 of the magnet 310 forms the magnet outer peripheral end 310b. The outermost magnet piece 505 is located at the radially outermost position of the multiple magnet pieces 505 that the magnet 310 has. The outer peripheral piece surface 505b of the outermost magnet piece 505 is included in the magnet outer peripheral end 310b.
[0442] In the magnet 310, the inner circumferential tapered surface 310d is bridged over multiple magnet pieces 505. In the radial direction RD, the width dimension of the inner circumferential tapered surface 310d is greater than the thickness dimension of the magnet pieces 505. The inner circumferential tapered surface 310d is provided at a position spanning the boundary between two magnet pieces 505 adjacent in the radial direction RD in the radial direction RD. The inner circumferential tapered surface 310d is formed by multiple magnet pieces 505.
[0443] The outer peripheral tapered surface 310e is bridged over multiple magnet pieces 505. In the radial direction RD, the width dimension of the outer peripheral tapered surface 310e is greater than the thickness dimension of the magnet pieces 505. The outer peripheral tapered surface 310e is provided at a position spanning the boundary between two magnet pieces 505 adjacent in the radial direction RD in the radial direction RD. The outer peripheral tapered surface 310e is formed by multiple magnet pieces 505.
[0444] As shown in FIG. 118, in magnet 310, multiple magnet pieces 505 are hooked to magnet holder 320 and fixed block 330. Of the multiple magnet pieces 505 possessed by magnet 310, the multiple magnet pieces 505 forming inner peripheral tapered surface 310d are hooked to fixed block 330. The multiple magnet pieces 505 hooked to fixed block 330 are in contact with block tapered surface 330a. Of the multiple magnet pieces 505 possessed by magnet 310, the multiple magnet pieces 505 forming outer peripheral tapered surface 316e are hooked to outer peripheral engaging portion 322. The multiple magnet pieces 505 hooked to outer peripheral engaging portion 322 are in contact with engaging tapered surface 322a.
[0445] As shown in FIG. 114, in the rotor 300, the magnet center line C310 and the unit center line C316 extend in the radial direction RD. The unit center line C316 is a straight imaginary line that passes through the center of the magnet unit 316 and extends in the radial direction RD. The unit center line C316 passes through the center of the magnet unit 316, as well as the center of the unit inner circumferential end 316a and the center of the unit outer circumferential end 316b. The magnet center line C310 is a straight imaginary line that passes through the center of the magnet 310 and extends in the radial direction. The magnet center line C310 passes through the center of the magnet 310, as well as the center of the magnet inner circumferential end 310a and the center of the magnet outer circumferential end 310b.
[0446] In the magnet unit 316, one unit center line C316 and multiple magnet center lines C310 extend. In the magnet unit 316, the magnet center line C310 of the middle magnet 310 of the three magnets 310 coincides with the unit center line C316. In the tilted magnet unit 317, the magnet center line C310 of the tilted magnet 314 is inclined with respect to the unit center line C316. In the tilted magnet unit 317, the magnet center line C310 of one of the two tilted magnets 314 is inclined with respect to the magnet center line C310 of the other. In the parallel magnet unit 318, the magnet center lines C310 of all the parallel magnets 315 extend parallel to the unit center line C316.
[0447] As shown in Figures 116 and 117, in the gradient magnet unit 317 and the parallel magnet unit 318, the magnet pieces 505 extend in a direction perpendicular to the unit center line C316. In the gradient magnet unit 317 and the parallel magnet unit 318, the magnet pieces 505 of the gradient magnet 314 and the magnet pieces 505 of the parallel magnet 315 are aligned in a straight line. Note that the magnet pieces 505 of the gradient magnet 314 and the magnet pieces 505 of the parallel magnet 315 may be positioned so as not to be offset in the radial direction, or may be offset in the radial direction RD. The gradient magnet unit 317 and the parallel magnet unit 318 correspond to a common unit.
[0448] In the parallel magnet 315 of the gradient magnet unit 317, the magnet piece 505 is perpendicular to the magnet center line C310. On the other hand, in the gradient magnet 314 of the gradient magnet unit 317, the magnet piece 505 is not perpendicular to the magnet center line C310. In the multiple parallel magnets 315 of the parallel magnet unit 318, the magnet piece 505 is perpendicular to the magnet center line C310.
[0449] The outer surface of magnet 310 includes a ground surface. At least magnet side surface 310c, inner tapered surface 310d, outer tapered surface 310e, first magnet surface 310g, and second magnet surface 310h are ground surfaces of magnet 310. Of the outer surface of magnet 310, the surface that has been ground to extend in a flat plane is the ground surface. The ground surface of magnet 310 is considered to be flat even if it is curved, such as bulging or recessed. An example of a state in which the ground surface extends in a flat plane on the outer surface of magnet 310 is a state in which there are no steps.
[0450] The magnet side surface 310c extends in the radial direction RD so as to span multiple magnet pieces 505. The magnet side surface 310c is a ground surface and corresponds to the magnet ground surface and ground laminate surface. The magnet side surface 310c includes multiple piece side surfaces 505c. The multiple piece side surfaces 505c are arranged on the same plane, forming the magnet side surface 310c in a flat shape. For example, two piece side surfaces 505c adjacent in the radial direction RD are not offset in the circumferential direction CD, preventing steps from occurring on the magnet side surface 310c. On the magnet side surface 310c, the multiple piece side surfaces 505c are flush with each other. The piece side surfaces 505c correspond to the component ground surface.
[0451] Like the magnet side surface 310c, the first magnet surface 310g extends in the radial direction RD so as to span the multiple magnet pieces 505. The first magnet surface 310g is a ground surface and corresponds to a magnet ground surface and a ground laminate surface. The first magnet surface 310g includes multiple first piece surfaces 505g. The multiple first piece surfaces 505g are arranged on the same plane, forming the first magnet surface 310g in a flat shape. For example, two first piece surfaces 505g adjacent to each other in the radial direction RD are not offset in the axial direction AD, preventing steps from occurring on the first magnet surface 310g. On the first magnet surface 310g, the multiple first piece surfaces 505g are flush with each other. The first piece surfaces 505g correspond to component ground surfaces.
[0452] Like the magnet side surface 310c, the second magnet surface 310h extends in the radial direction RD so as to span the multiple magnet pieces 505. The second magnet surface 310h is a ground surface and corresponds to a magnet ground surface and a ground laminate surface. The second magnet surface 310h includes multiple second piece surfaces 505h. The multiple second piece surfaces 505h are arranged on the same plane, forming the second magnet surface 310h in a flat shape. For example, two second piece surfaces 505h adjacent to each other in the radial direction RD are not offset in the axial direction AD, preventing steps from occurring on the second magnet surface 310h. On the second magnet surface 310h, the multiple second piece surfaces 505h are flush with each other. The second piece surfaces 505h correspond to component ground surfaces.
[0453] At least a portion of the magnet inner peripheral end 310a is a ground surface. In this embodiment, the inner peripheral tapered surface 310d is a ground surface as part of the magnet inner peripheral end 310a. The inner peripheral tapered surface 310d extends in the radial direction RD and the circumferential direction CD so as to span multiple magnet pieces 505. The inner peripheral tapered surface 310d is inclined with respect to the magnet side surface 310c, the first magnet surface 310g, and the second magnet surface 310h. The inner peripheral tapered surface 310d corresponds to the magnet ground surface and the ground inclined surface.
[0454] The inner tapered surface 310d includes a plurality of first piece surfaces 505g. The first piece surfaces 505g included in the inner tapered surface 310d are inclined relative to the first piece surfaces 505g included in the first magnet surface 310g. The inner tapered surface 310d is formed flat by arranging the plurality of first piece surfaces 505g on the same plane. For example, two first piece surfaces 505g adjacent in the radial direction RD are not misaligned in the axial direction AD, preventing steps from occurring on the inner tapered surface 310d. The inner tapered surface 310d includes a plurality of first piece surfaces 505g that are flush with each other. The first piece surfaces 505g included in the inner tapered surface 310d also correspond to the member grinding surface.
[0455] At least a portion of the magnet outer peripheral end 310b is a ground surface. In this embodiment, the outer peripheral tapered surface 310e is a ground surface as part of the magnet outer peripheral end 310b. The outer peripheral tapered surface 310e extends in the radial direction RD and the circumferential direction CD so as to span the multiple magnet pieces 505. The outer peripheral tapered surface 310e is inclined with respect to the magnet side surface 310c, the first magnet surface 310g, and the second magnet surface 310h. The outer peripheral tapered surface 310e corresponds to the magnet ground surface and the ground inclined surface.
[0456] The outer peripheral tapered surface 310e includes a plurality of first piece surfaces 505g. The first piece surfaces 505g included in the outer peripheral tapered surface 310e are inclined relative to the first piece surfaces 505g included in the first magnet surface 310g. In the outer peripheral tapered surface 310e, the plurality of first piece surfaces 505g are arranged on the same plane, thereby forming the outer peripheral tapered surface 310e in a flat shape. For example, two first piece surfaces 505g adjacent in the radial direction RD are not misaligned in the axial direction AD, preventing steps from occurring in the outer peripheral tapered surface 310e. In the outer peripheral tapered surface 310e, the plurality of first piece surfaces 505g are flush with each other. The first piece surfaces 505g included in the outer peripheral tapered surface 310e also correspond to the member grinding surface.
[0457] In magnet 310, side tapered surface 316f is a ground surface, similar to inner peripheral tapered surface 310d and outer peripheral tapered surface 310e. Therefore, side tapered surface 316f can be said to correspond to a magnet ground surface and a ground inclined surface.
[0458] The outer surface of the magnet unit 316 includes a ground surface. In the magnet unit 316, at least the unit side surface 316c, the inner tapered surface 316d, the outer tapered surface 316e, the first unit surface 316g, and the second unit surface 316h are ground surfaces. The ground surfaces of the magnet unit 316 are similar to the ground surfaces of the magnet 310. For example, a surface of the outer surface of the magnet unit 316 that has been ground to extend in a flat plane is a ground surface. The ground surface of the magnet unit 316 is considered to be flat even if it is curved, such as bulging or recessed. An example of a state in which the ground surface extends in a flat plane on the outer surface of the magnet unit 316 is a state in which there are no steps.
[0459] Unit side surface 316c is formed by magnet side surface 310c of one magnet 310. Magnet side surface 310c is a ground surface, and therefore unit side surface 316c is a ground surface.
[0460] The first unit surface 316g extends in the circumferential direction CD so as to span the multiple magnets 310. The first unit surface 316g is a ground surface and corresponds to a unit ground surface. The first unit surface 316g includes multiple first magnet surfaces 310g. The multiple first magnet surfaces 310g are arranged on the same plane, forming the first unit surface 316g in a flat shape. For example, two first magnet surfaces 310g adjacent in the circumferential direction CD are not offset in the axial direction AD, preventing steps from occurring on the first unit surface 316g. The multiple first magnet surfaces 310g are flush with each other on the first unit surface 316g.
[0461] Like the first unit surface 316g, the second unit surface 316h extends in the circumferential direction CD so as to span the multiple magnets 310. The second unit surface 316h is a ground surface and corresponds to a unit ground surface. The second unit surface 316h includes multiple second magnet surfaces 310h. The multiple second magnet surfaces 310h are arranged on the same plane, forming the second unit surface 316h in a flat shape. For example, two second magnet surfaces 310h adjacent in the circumferential direction CD are not misaligned in the axial direction AD, preventing steps from occurring on the second unit surface 316h. The multiple second magnet surfaces 310h are flush with each other on the second unit surface 316h.
[0462] At least a portion of the unit inner peripheral end 316a is a ground surface. In this embodiment, an inner peripheral tapered surface 316d is a part of the unit inner peripheral end 316a and is a ground surface. The inner peripheral tapered surface 316d extends in the radial direction RD and the circumferential direction CD so as to span the multiple magnets 310. The inner peripheral tapered surface 316d is inclined with respect to the unit side surface 316c, the first unit surface 316g, and the second unit surface 316h. The inner peripheral tapered surface 316d corresponds to the unit ground surface.
[0463] The inner circumferential tapered surface 316d includes a plurality of inner circumferential tapered surfaces 310d. The plurality of inner circumferential tapered surfaces 310d are arranged on the same plane, thereby forming the inner circumferential tapered surface 316d in a flat plane. For example, two inner circumferential tapered surfaces 310d adjacent to each other in the circumferenti...
Claims
1. A rotating electric machine (60) driven by a supply of electric power, A stator (200) having a multi-phase coil (211); A rotor (300a) that rotates around a rotation axis (Cm); an electric housing (70) that includes an electric outer peripheral wall (71) extending in a circumferential direction (CD) of the rotation axis and a heat dissipation fin (72) that is provided on an electric outer peripheral surface (70a) of the electric outer peripheral wall and dissipates heat, the electric housing (70) houses the stator and the rotor, and is fixed to a fixed object (370, 90, 830) arranged on the electric outer peripheral wall in the axial direction (AD) of the rotation axis; a seal holding portion (78, 826) provided on the outer peripheral wall of the electric machine, the seal holding portion (78, 826) sandwiching and holding a seal member (402, 828) between the seal holding portion and the fixed object by fixing the fixed object to the electric housing; Equipped with A rotating electric machine in which the electric outer peripheral surface is provided outside the seal retaining portion in a radial direction (RD) of the rotation axis so as to extend in the axial direction together with a target outer peripheral surface (370a, 90a, 832a), which is the outer peripheral surface of the fixed object, and so as to be continuously aligned with the target outer peripheral surface in the axial direction when the fixed object is fixed to the electric housing.
2. The rotating electric machine according to claim 1 , wherein the seal retaining portion is provided on the electric outer peripheral wall so that the seal member sandwiched between the fixed object and the fixed object when the fixed object is fixed to the electric housing is positioned inside the electric outer peripheral wall in the radial direction.
3. a coil lead wire (212) that is drawn out from the coil, passes through an outer periphery of the rotor arranged in the axial direction on the stator, and is electrically connected to a connection target (261) that is provided on the opposite side of the coil via the rotor in the axial direction; 3 . The rotating electric machine according to claim 1 , wherein the coil lead wire is bent so as to pass inside the seal member in the radial direction. 4 .
4. The coil lead wire is an outer peripheral lead-out portion (212a) provided on an outer peripheral side of the rotor and extending in the axial direction toward the seal member; an inner peripheral lead-out portion (212b) that is provided on the connection target side of the rotor in the axial direction and extends in the axial direction on an inner peripheral side of the seal member; a through-drawn portion (212c) extending radially inward from the outer peripheral drawn portion toward the inner peripheral drawn portion so as to pass between the seal member and the rotor in the axial direction; 4. The rotating electric machine according to claim 3, further comprising:
5. The fixed target has a target holding portion (376, 825, 835) that holds the seal member so as to prevent the seal member from shifting in position, The rotating electric machine according to any one of claims 1 to 4, wherein the seal holding portion sandwiches the seal member held by the target holding portion between the target holding portion and the seal holding portion when the fixed target is fixed to the electric housing.
6. The target holding portion has a target recess (376a, 825a, 835a) that is recessed so as to open toward the seal holding portion, The rotating electric machine according to claim 5 , wherein the seal holding portion sandwiches the seal member, which is provided to enter the target recess, between the seal holding portion and the target recess when the target is fixed to the electric machine housing.
7. The rotating electric machine according to claim 5 , wherein the target holder is provided inside the seal holder in the radial direction in a state in which the fixed target is fixed to the electric machine housing.
8. The rotating electric machine according to any one of claims 1 to 7, further comprising, as the fixed object, a cover member (370) fixed to the electric housing and covering the inner space of the electric outer peripheral wall from the axial direction.
9. The rotating electric machine according to any one of claims 1 to 8, wherein the fixed object is a device housing (90) included in a power conversion device (80) that converts the power supplied to the rotating electric machine and extends in the circumferential direction along the outer peripheral wall of the electric machine, and is fixed to the electric machine housing.
10. The rotating electric machine according to any one of claims 1 to 9, wherein a housing (832) of another rotating electric machine (830) is fixed to the electric machine housing as the fixing target.
11. A rotating electric machine as described in any one of claims 1 to 10, further comprising an outer duct (100) arranged to cover the electric machine outer peripheral wall from the outer peripheral side of the heat dissipation fin, and forming an outer circumferential flow path (105) through which gas flows in the axial direction between the outer circumferential duct and the electric machine outer peripheral surface.
12. A rotating electric machine according to any one of claims 1 to 11, further comprising a blower (840) arranged in the axial direction on the outer peripheral wall of the electric machine and configured to blow air so as to flow in the axial direction along the outer peripheral surface of the electric machine.
13. 13. The rotating electric machine according to claim 1, which is mounted on an aircraft as a drive source for driving and rotating a rotor of the aircraft.
Citation Information
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