Method for manufacturing rotary electric machine

Abstract

A rotary electric machine (10) comprises: a stator unit (SU) including a stator (20) that has a stator winding (22) and a housing (11) that houses the stator; and a rotor (30) disposed so as to face the stator in the radial direction and capable of rotating integrally with a rotating shaft (12). The method for manufacturing the rotary electric machine (10) includes: a first step of attaching, to the rotor, a physical quantity sensor (61, 62) for detecting a physical quantity of the rotor; and a second step of, after the attachment of the physical quantity sensor in the first step, assembling a circuit module (153) in a state of being aligned with the rotor in the axial direction and being rotatable integrally with the rotor, said circuit module including a sensor signal processing unit (A1) for transmitting a physical quantity signal detected by the physical quantity sensor to the outside of the rotor. In the second step, a signal line (63) extending in the axial direction from the physical quantity sensor is connected to the sensor signal processing unit on the circuit module side.

Description

Method for manufacturing a rotating electrical machine Cross-reference to related applications

[0001] This application is based on Japanese Application No. 2024-198088 filed on November 13, 2024, the contents of which are incorporated herein by reference.

[0002] The disclosure in this specification relates to a method for manufacturing a rotating electrical machine.

[0003] The rotating electrical machine includes a stator having a stator winding and a rotor disposed opposite the stator. As the stator winding is energized, the rotating magnetic flux of the stator and the field magnetic flux on the rotor side interlink, and the rotor rotates integrally with the rotation axis. In this rotating electrical machine, a technique has been proposed in which the temperature is detected by a temperature sensor on the rotor side and the temperature detection signal is transmitted to the stator side (see Patent Document 1).

[0004] German Patent Application Publication No. 102020204446

[0005] When transmitting the temperature detection signal of the temperature sensor from the rotor side to the stator side, it is conceivable that a circuit configuration for signal transmission is arranged outside the axial direction of the rotor. In this case, there is a concern that restrictions may occur regarding the attachment of the temperature sensor to the rotor. Also, in the case of a brushless field winding type rotor, an electrical configuration for flowing a field current through the field winding by electromagnetic induction is required. Therefore, there is a concern that the restrictions regarding the attachment of the temperature sensor to the rotor will increase. From these circumstances, it is considered that there is room for technical improvement in the configuration of the rotor.

[0006] An object of the present disclosure is to provide a method for manufacturing a rotating electrical machine that can realize a suitable sensor structure in the rotor.

[0007] This disclosure relates to a method for manufacturing a rotating electric machine comprising: a stator unit including a stator having stator windings and a housing for housing the stator; and a rotor arranged radially opposite to the stator and capable of rotating integrally with a rotation shaft, the method comprising: a first step of attaching a physical quantity sensor to the rotor for detecting a physical quantity related to the rotor; and a second step of assembling a circuit module, after the attachment of the physical quantity sensor in the first step, a circuit module including a sensor signal processing unit that transmits a physical quantity signal detected by the physical quantity sensor to the outside of the rotor, in a manner that is aligned axially with the rotor and capable of rotating integrally with the rotor, wherein in the second step, a signal line extending axially from the physical quantity sensor is connected to the sensor signal processing unit on the circuit module side.

[0008] In a rotating electric machine, a physical quantity sensor is attached to the rotor. Furthermore, a circuit module including a sensor signal processing unit, which enables the transmission of the physical quantity signal detected by the physical quantity sensor to the outside of the rotor, is assembled in a manner aligned axially with the rotor and capable of rotating integrally with it. In this case, there are concerns that the narrow space between the axial end of the rotor and the circuit module may impose constraints on the attachment of the physical quantity sensor to the rotor.

[0009] In this regard, according to the above manufacturing method, the physical quantity sensor is attached to the rotor before the circuit module is assembled (i.e., the physical quantity sensor is pre-attached to the rotor). In this case, there are fewer constraints on the attachment of the physical quantity sensor to the rotor, and the physical quantity sensor can be attached to the rotor in a desirable position or by a desirable method. Furthermore, by extending a signal line axially from the physical quantity sensor when attaching it, the signal line extending from the physical quantity sensor can be suitably connected to the sensor signal processing unit when the circuit module is assembled later. As a result, a suitable sensor structure can be realized in the rotor.

[0010] The above-mentioned and other purposes, features, and benefits of this disclosure will be further clarified by the following detailed description with reference to the attached drawings. The drawings are as follows: Figure 1 shows the general configuration of the rotating electric machine system; Figure 2 shows the inverter and its peripheral configuration; Figure 3 shows a cross-sectional view of the rotor and stator; Figure 4 shows the electrical circuit including each winding of the field winding; Figure 5 is a circuit diagram showing the electrical configuration of the stator side and rotor side in the rotating electric machine; Figure 6 is a longitudinal cross-sectional view showing the configuration of the rotating electric machine; Figure 7 is an exploded cross-sectional view showing the rotating electric machine disassembled into a stator unit and a rotor assembly; Figure 8 is an exploded view of the rotor assembly; Figure 9 is a circuit diagram showing the electrical configuration of the rotor assembly; Figure 10 is a flowchart showing the processing procedure for abnormality detection; Figure 11 shows the manufacturing procedure of the rotor assembly; Figure 12 is a longitudinal cross-sectional view showing the configuration of the rotating electric machine; Figure 13 is a circuit diagram showing the electrical configuration of the rotor assembly; Figure 14 shows the manufacturing procedure of the rotor assembly; Figure 15 is a rotation Figure 16 is a vertical cross-sectional view showing the configuration of a power switch, Figure 17 is a diagram showing the electrical configuration of the rotor assembly, Figure 18 is a vertical cross-sectional view showing the configuration of a rotating electric machine, Figure 19 is a circuit diagram showing the electrical configuration of the rotor assembly, Figure 20 is a vertical cross-sectional view of the rotor assembly, Figure 21 is a diagram showing the manufacturing procedure of the rotor assembly, Figure 22 is a vertical cross-sectional view of the rotor assembly, Figure 23 is a circuit diagram showing the electrical configuration of the rotor assembly, Figure 24 is a vertical cross-sectional view showing the configuration of a rotating electric machine, Figure 25 is a circuit diagram showing the electrical configuration of the rotor assembly, Figure 26 is a vertical cross-sectional view showing the configuration of a rotating electric machine, Figure 27 is a circuit diagram showing the electrical configuration of the rotor assembly, Figure 28 is a vertical cross-sectional view showing the configuration of a rotating electric machine, Figure 29 is a cross-sectional view of the rotor, and Figure 30 is a diagram showing a configuration in which a current sensor is provided on the rotor.

[0011] Hereinafter, embodiments of the rotating electric machine described herein will be explained with reference to the drawings. The rotating electric machine is used, for example, as a power source for electric vehicles such as electric cars and hybrid cars. In each embodiment, functionally and / or structurally corresponding parts and / or related parts may be given the same reference numerals. For corresponding parts and / or related parts, refer to the description of other embodiments.

[0012] (First Embodiment) First, a rotating electric machine system including a rotating electric machine 10 and a control unit will be described using Figure 1. This system comprises a rotating electric machine 10, a battery 100 which is a DC power source, an inverter 110, and a control device 120. The rotating electric machine 10 is a self-excited wound-field type synchronous machine. For example, the rotating electric machine 10, the inverter 110, and the control device 120 may be configured as an electromechanical integrated drive unit, or the rotating electric machine 10, the inverter 110, and the control device 120 may each be configured as separate components.

[0013] The rotating electric machine 10 comprises a housing 11 and a stator 20 and rotor 30 housed within the housing 11. The rotating electric machine 10 of this embodiment is an inner rotor type rotating electric machine in which the rotor 30 is arranged radially inward of the stator 20. The stator 20 comprises a stator core 21 and stator windings 22. The stator windings 22 are, for example, three-phase windings and have U-phase, V-phase, and W-phase windings. The phase windings of each phase are arranged so as to be offset from each other by 120° in electrical angle.

[0014] The rotor 30 comprises a rotor core 31 and field windings 32. A rotating shaft 12 is assembled into the central hole of the rotor core 31. The rotating shaft 12 is rotatably supported in the housing 11 by bearings 13 and 14.

[0015] As shown in Figure 2, the inverter 110 includes a series connection of U, V, and W phase upper arm switches SUp, SVp, and SWp, and U, V, and W phase lower arm switches SUn, SVn, and SWn. In each phase, the first ends of the U, V, and W phase windings 23U, 23V, and 23W are connected to the connection points between the upper arm switches SUp, SVp, and SWp and the lower arm switches SUn, SVn, and SWn. The second ends of the U, V, and W phase windings 23U, 23V, and 23W are connected at the neutral point. In other words, in this embodiment, the stator winding 22 is star-connected. However, the stator winding 22 may be delta-connected. In this embodiment, each switch SUp to SWn is, for example, an IGBT. A freewheeling diode is connected in antiparallel to each switch SUp to SWn.

[0016] The collectors of the upper arm switches SUp, SVp, and SWp for each phase are connected to the positive terminals of the battery 100. The emitters of the lower arm switches SUn, SVn, and SWn for each phase are connected to the negative terminals of the battery 100. A smoothing capacitor 111 is connected in parallel to the battery 100.

[0017] Next, the stator 20 and rotor 30 will be described using Figure 3.

[0018] The stator 20 and rotor 30 are both arranged coaxially with the rotating shaft 12. In the following description, the direction in which the rotating shaft 12 extends is referred to as the axial direction, the direction extending radially from the center of the rotating shaft 12 is referred to as the radial direction, and the direction extending circumferentially with respect to the rotating shaft 12 is referred to as the circumferential direction.

[0019] The stator core 21 is made of laminated steel plates made of soft magnetic material and has an annular back yoke 24 and a plurality of teeth 25 that protrude radially inward from the back yoke 24. A plurality of slots 26 are formed between adjacent teeth 25, arranged in the circumferential direction. The stator windings 22 are formed by housing the phase windings of each phase in a predetermined order in each of these slots 26. For example, a segment coil structure using a plurality of conductor segments may be adopted in the stator 20. However, the structure of the stator windings 22 is arbitrary.

[0020] The rotor core 31 is made of a soft magnetic material, for example, laminated steel plates. The rotor core 31 has a cylindrical portion 33 and a plurality of main pole portions 34 that protrude radially outward from the cylindrical portion 33. Field windings 32 are wound around each main pole portion 34 by concentrated winding. In this embodiment, eight main pole portions 34 are provided at equal intervals in the circumferential direction.

[0021] The field winding 32 comprises a first winding section 41 and a second winding section 42. The first winding section 41 is wound radially outward around each main pole section 34, and the second winding section 42 is wound radially inward from the first winding section 41. The first winding sections 41 wound around each main pole section 34 are connected in series in the order of the circumferential arrangement of the main pole sections 34, and similarly, the second winding sections 42 are connected in series in the order of the circumferential arrangement of the main pole sections 34. Furthermore, the series connections of the first winding sections 41 and the series connections of the second winding sections 42 are connected to each other.

[0022] In each main pole portion 34, the winding directions of the first winding portion 41 and the second winding portion 42 are the same. Furthermore, among circumferentially adjacent main pole portions 34, the winding directions of the winding portions 41 and 42 wound around one main pole portion 34 are opposite to those of the winding portions 41 and 42 wound around the other main pole portion 34. Therefore, when the field winding 32 is energized, the magnetization directions of circumferentially adjacent main pole portions 34 are opposite to each other. In the rotor 30, multiple magnetic poles (field poles) aligned in the circumferential direction are formed by each main pole portion 34 in the rotor core 31 and the field winding 32 wound around each main pole portion 34. In this embodiment, the number of turns in the second winding portion 42 is greater than the number of turns in the first winding portion 41.

[0023] Figure 4 shows an electrical circuit in the rotor 30 that includes the winding sections 41 and 42 of the field winding 32. The first winding section 41 and the second winding section 42 are connected in series by the connection of terminal A of the first winding section 41 and terminal C of the second winding section 42 to each other. In addition, a diode 51 is connected in series between terminal B of the first winding section 41 and terminal D of the second winding section 42, and a resonant capacitor 52 is connected in parallel with the diode 51. The diode 51 is provided to allow current IL1 to flow in the first winding section 41 with the forward direction from terminal B to terminal A, and current IL2 to flow in the second winding section 42 with the forward direction from terminal C to terminal D.

[0024] Furthermore, the ends of a diode 53 are connected to terminals C and D of the second winding section 42, and a resonant capacitor 54 is connected in parallel with the diode 53. The diode 53 is provided in the second winding section 42 to allow current IL2 to flow with the forward direction from terminal C to terminal D.

[0025] Returning to the explanation of Figure 2, the control device 120 is an electronic control unit (ECC) mainly composed of a microcontroller 121. The microcontroller 121 is equipped with a CPU (Central Processing Unit). The functions provided by the microcontroller 121 can be provided by software recorded in a physical memory device and the computer that executes it, by software only, by hardware only, or by a combination thereof. For example, if the microcontroller 121 is provided by an electronic circuit which is hardware, it can be provided by a digital circuit including a large number of logic circuits, or by an analog circuit. For example, the microcontroller 121 executes a program stored in a non-transitory tangible storage medium which serves as its own storage unit. The program includes a program for the control processing of the rotating electric machine 10. The method corresponding to the program is executed by executing a set of instructions that constitute the program. The storage unit is, for example, a non-volatile memory. The program stored in the storage unit can be updated via a communication network such as the Internet, for example, OTA (Over The Air).

[0026] The control device 120 generates drive signals to turn on and off each switch SUp to SWn that constitute the inverter 110. Specifically, the control device 120 generates drive signals to turn on and off each switch SUp to SWn in order to convert the DC power output from the battery 100 into AC power and supply it to the U, V, and W phase windings 23U, 23V, and 23W, and outputs the generated drive signals to the gates of each switch SUp to SWn. As a result, the upper arm switch and the lower arm switch are turned on alternately in each phase, with a dead time in between.

[0027] The control device 120 switches switches SUp to SWn on and off to allow a combined current of a fundamental wave current and a high-frequency current (specifically, a high-frequency excitation current) with a frequency higher than the fundamental wave current to flow through each phase winding 23U, 23V, and 23W of the stator winding 22. The fundamental wave current is the current that primarily generates torque in the rotating electric machine 10. The high-frequency current is the current that primarily excites the first winding section 41 and the second winding section 42 that constitute the field winding 32, thereby inducing a field current in the field winding 32. The phase currents flowing through each phase winding 23U, 23V, and 23W are shifted by 120° in electrical angle.

[0028] The high-frequency current flowing through the stator winding 22 may be a harmonic current whose fluctuating frequency is N times the frequency of the fundamental wave current (where N is an integer greater than or equal to 2), or it may be a current whose fluctuating frequency is outside of N times the frequency of the fundamental wave current.

[0029] When a high-frequency current flows through the stator winding 22, a voltage is induced in each winding portion 41, 42 of the field winding 32, and a field current flows. The induced voltages in each winding portion 41, 42 are, for example, in the same phase. The currents IL1, IL2 flowing through each winding portion 41, 42 include the frequency components of the high-frequency current.

[0030] In the electrical circuit shown in Figure 4, when the stator winding 22 is energized, the windings 41 and 42 of the field winding 32 are energized, and current flows through a closed circuit (circulation path) including the first winding 41 and the second winding 42. Furthermore, when the voltage across the second winding 42 exceeds the forward voltage of the diode 53, a current IL2 greater than the current IL1 flowing through the first winding 41 flows through the second winding 42 in the closed circuit including the second winding 42 and the diode 53. The flow of current through the closed circuit including the second winding 42 and the diode 53 increases the DC component of the field current. This increases the DC component of the magnetic flux of the rotor 30, thereby increasing the torque of the rotating electric machine 10.

[0031] In the rotating electric machine 10 of this embodiment, a physical quantity sensor is provided on the rotor 30 to detect physical quantities related to the rotor 30, and the detection signal from the physical quantity sensor is wirelessly transmitted from the rotor 30 to the stator 20. The details are described below. Figure 5 is a circuit diagram showing the electrical configuration of the stator 20 and rotor 30 sides in the rotating electric machine 10.

[0032] In the rotating electric machine 10, when the stator winding 22 is energized, a field current flows through the field winding 32 due to electromagnetic induction between the stator winding 22 and the first winding portion 41 of the field winding 32. The configuration of the inverter 110 on the stator 20 side and the configuration of the resonant circuit on the rotor 30 side are as previously described (see Figures 2 and 4).

[0033] On the rotor 30 side, there is a current sensor 61 for detecting the current flowing through the second winding section 42 and a temperature sensor 62 for detecting the temperature of the second winding section 42. The current sensor 61 and the temperature sensor 62 correspond to "physical quantity sensors". The current sensor 61 and the temperature sensor 62 are each connected to a signal processing circuit 71. The signal processing circuit 71 has an A / D converter 72 that converts the analog detection signals detected by the current sensor 61 and the temperature sensor 62 into digital values, and a control unit 73 consisting of a microcontroller or the like. The control unit 73 is an electronic control device consisting of a microcontroller and various memories.

[0034] The field winding 32 may have a configuration for voltage detection. Specifically, the signal processing circuit 71 acquires the potential difference generated across the second winding section 42 when the field winding 32 is energized, and converts this potential difference into a voltage detection value. Instead of acquiring the potential difference across the second winding section 42, it is also possible to acquire the potential difference across the first winding section 41.

[0035] The detected values, which are detected by each sensor 61 and 62 and A / D converted by the signal processing circuit 71, can be transmitted to the stator 20 side by the communication transformer 80. The communication transformer 80 has a primary coil 81 provided on the stator 20 side and a secondary coil 82 provided on the rotor 30 side. In the communication transformer 80, a power signal consisting of an AC signal of a predetermined frequency (e.g., 1 MHz) and a sensor detection signal from the rotor 30 side are transmitted between the primary coil 81 and the secondary coil 82. The communication transformer 80 is a communication coil that enables short-range wireless communication with a maximum communication distance of several meters.

[0036] On the secondary side of the communication transformer 80, i.e., the rotor 30 side, there is a power receiving circuit 74 connected to both ends of the secondary coil 82, and a modulation circuit 76 connected to one end of the secondary coil 82 via a resistor 75. A signal processing circuit 71 is connected to the power receiving circuit 74. In addition, a smoothing capacitor 77 is provided between the pair of electrical paths connecting the secondary coil 82 and the power receiving circuit 74, and a smoothing capacitor 78 is provided between the pair of electrical paths connecting the power receiving circuit 74 and the signal processing circuit 71.

[0037] The power receiving circuit 74 has a rectifier circuit that converts AC signals into DC signals. The power receiving circuit 74 converts the power received from the stator 20 side into a DC voltage and drives the signal processing circuit 71 with that DC voltage.

[0038] The modulation circuit 76 modulates the digital signals output from the signal processing circuit 71, namely the digital signal of the current detection value from the current sensor 61 and the digital signal of the temperature detection value from the temperature sensor 62, into harmonic signals for transmission by the secondary coil 82 and outputs them. As a result, voltage signals corresponding to the current detection value and temperature detection value are superimposed on the AC voltage flowing through the secondary coil 82.

[0039] The control unit 73 of the signal processing circuit 71 determines the timing for transmitting the current detection value and temperature detection value of the current sensor 61 in a time series, and sequentially transmits these sensor detection signals, which are the current detection value and temperature detection value, from the secondary coil 82.

[0040] A circuit including a signal processing circuit 71, a power receiving circuit 74, a modulation circuit 76, etc. is the "sensor signal processing unit A1". By operating the sensor signal processing unit A1, the detection signals detected by the sensors 61 and 62 are transmitted outside the rotor. Also, a circuit that resonates the field current flowing through the field winding 32 with the energization of the stator winding 22 is the "field current processing unit A2".

[0041] On the primary side of the communication transformer 80, that is, on the stator 20 side, a power transmission circuit 91 connected to both ends of the primary coil 81 and a demodulation circuit 92 also connected to both ends of the primary coil 81 are provided. Also, a resonance capacitor 93 is provided in the electrical path between the primary coil 81 and the power transmission circuit 91, and a resonance capacitor 94 is provided in the electrical path between the primary coil 81 and the demodulation circuit 92. A control device 120 is connected to the demodulation circuit 92.

[0042] The power transmission circuit 91 transmits the power for driving each circuit of the sensor signal processing system on the rotor 30 side. The power transmission circuit 91 applies an AC voltage of a predetermined frequency (for example, 1 MHz) to the primary coil 81. The power transmission circuit 91 may be, for example, a circuit that generates an AC signal using the power supplied from the battery 100.

[0043] The demodulation circuit 92 demodulates the sensor detection signal in the AC signal flowing through the primary coil 81 into a digital signal and outputs it to the control device 120. The control device 120 calculates the energization current (field current) of the field winding 32 in the rotor 30 and the temperature of the field winding 32 based on the digital signal input from the demodulation circuit 92.

[0044] Next, based on the above electrical configuration of FIG. 5, the detailed configuration of the rotating electrical machine 10 will be described again. FIG. 6 is a longitudinal sectional view showing the configuration of the rotating electrical machine 10 of the present embodiment. FIG. 7 is an exploded sectional view showing the rotating electrical machine 10 disassembled into a stator unit SU and a rotor assembly 150. FIG. 8 is an exploded view of the rotor assembly 150. Here, first, the configuration of the rotor assembly 150 will be described.

[0045] The rotor assembly 150 is roughly divided into a rotor module 151 integrated with the rotating shaft 12, a coil end cover 152 attached to one axial end side of the rotor module 151, and a circuit module 153 arranged axially with the rotor module 151 while sandwiching the coil end cover 152 therebetween. The secondary coil 82 of the communication transformer 80 is integrally provided in the circuit module 153.

[0046] The rotor module 151 has a configuration including a rotor 30 that includes a rotor core 31 and a field winding 32, and further includes a temperature sensor 62. The temperature sensor 62 has a thermistor which is a temperature detection element. The temperature sensor 62 may be fixed, for example, to the coil end of the field winding 32. The temperature sensor 62 may be attached to, for example, the second winding portion 42. However, the temperature sensor 62 may be attached to the first winding portion 41, or may be attached to both the first winding portion 41 and the second winding portion 42 respectively.

[0047] The temperature sensor 62 can be fixed to the field winding 32 by any method such as welding, brazing, fixing with an adhesive, fixing with a fastener such as a snap fit or a screw, or assembling into the gap between the conductor wires of the winding coil end. A signal line 63 extending in the axial direction is connected to the temperature sensor 62.

[0048] Also, a conductor end portion 64 which is an end portion of the conductor wire in the field winding 32 is drawn out in the axial direction. In the field winding 32, both ends of the first winding portion 41 and both ends of the second winding portion 42 may be drawn out in the axial direction as the conductor end portions 64.

[0049] The coil end cover 152 has a disk-shaped end plate portion 161 extending radially from the rotating shaft 12, and an annular portion 162 extending axially from the outer peripheral portion of the end plate portion 161 and surrounding the rotor end from the radially outer side. The end plate portion 161 has a central hole 163 penetrating in the plate thickness direction at the radially central portion. The coil end cover 152 is assembled to the rotor coil end with the rotating shaft 12 inserted through the central hole 163 of the end plate portion 161.

[0050] The end plate portion 161 is provided with a through hole 161a through which a signal wire 63 extending from the temperature sensor 62 is inserted. The end plate portion 161 is also provided with a through hole 161b through which the conductor end 64 of the field winding 32 is inserted.

[0051] The coil end cover 152 is preferably fixed to the rotating shaft 12 at its end plate portion 161. However, the coil end cover 152 may also be fixed to the rotor 30 at its annular portion 162. In this case, the annular portion 162 is preferably fixed to at least one of the rotor core 31 and the field winding 32. The coil end cover 152 is preferably made of a non-magnetic material, such as aluminum. The coil end cover 152 may also be made of an insulating material such as synthetic resin.

[0052] The circuit module 153 has a sensor signal processing unit A1 and a field current processing unit A2. More specifically, the circuit module 153 has a substrate 171 on which various electrical components 172 constituting the sensor signal processing unit A1 and the field current processing unit A2, as well as the secondary coil 82 of the communication transformer 80, are mounted. The various electrical components 172 include the signal processing circuit 71, the power receiving circuit 74, the modulation circuit 76, etc., which are components of the sensor signal processing unit A1, as well as diodes 51, 53 and resonant capacitors 52, 54, which are components of the field current processing unit A2. The various electrical components 172 are preferably arranged circumferentially on the substrate 171 so as to surround the radial center (rotation axis 12).

[0053] The secondary coil 82 is, for example, a planar printed coil placed on the substrate 171. It is preferable that various electrical components 172 are mounted on one side of the substrate 171 (the bottom side in the figure), and the secondary coil 82 is mounted on the other side (the top side in the figure).

[0054] The circuit module 153 also includes a current sensor 61 for detecting the current flowing through the field winding 32. The current sensor 61 is either a resistance-detection type or a magnetic field-detection type current sensor. The current sensor 61 is preferably mounted on the circuit board 171. The current sensor 61 is provided on an electrical path connected to the wire end 64 of the field winding 32.

[0055] Then, the substrate 171, various electrical components 172, and various wirings are resin-sealed by the resin sealing part 173 to form a roughly disc-shaped resin-sealed unit. A through hole is provided in the center of the resin-sealed unit, and a press-fit ring 174 is assembled into the through hole. The circuit module 153 is fixed to the rotating shaft 12 by the press-fit ring 174 being press-fitted onto the rotating shaft 12. The outer diameter of the circuit module 153 is preferably the same as the inner diameter of the coil end cover 152 (annular part 162), or smaller than the inner diameter of the coil end cover 152.

[0056] The circuit module 153 may be configured, for example, by housing various electrical components in a resin case that serves as a component holder. Furthermore, the method for fixing the circuit module 153 to the rotating shaft 12 does not have to be press-fitting. For example, the circuit module 153 may be fixed to the rotating shaft 12 by heat scribing or adhesive bonding. Alternatively, the circuit module 153 may be fixed to the rotating shaft 12 by spline coupling.

[0057] The circuit module 153 is positioned on top of the end plate portion 161 of the coil end cover 152. In this case, the circuit module 153 may be fixed to the coil end cover 152. Alternatively, the circuit module 153 may be configured not to be fixed to the rotating shaft 12, but to be fixed to the coil end cover 152.

[0058] The circuit module 153 is located axially outward from the coil end of the field winding 32 and is aligned axially with the rotor 30.

[0059] Figure 9 shows the electrical configuration of the rotor assembly 150. In the rotating electric machine 10 shown in Figure 6, the electrical configuration shown in Figure 9, excluding the winding sections 41 and 42 of the field winding 32, is included in the circuit module 153.

[0060] On the other hand, as shown in Figures 6 and 7, the housing 11 has a cylindrical peripheral wall portion 11a and end plate portions 11b and 11c provided at both ends of the peripheral wall portion 11a, respectively. For example, it is preferable that the end plate portions 11c are separable. The stator 20 is housed inside the housing 11, fixed to the peripheral wall portion 11a of the housing 11. The stator 20 and the housing 11 are an integrated unit, and in the following description, this integrated unit including the stator 20 and the housing 11 will be referred to as the stator unit SU. Bearings 13 and 14 that support the rotating shaft 12 are provided at each end plate portion 11b and 11c.

[0061] In the stator unit SU, the end plate portion 11b is provided with a resolver 181 as a rotation sensor at a position surrounding the rotation shaft 12, and a coil module 182 including the primary coil 81 of the communication transformer 80 is provided at a position facing the circuit module 153 of the rotor assembly 150.

[0062] The coil module 182 has a circuit board 183 on which the primary coil 81 of the communication transformer 80 is mounted. The primary coil 81 is a planar printed coil, similar to the secondary coil 82 of the circuit module 153. The primary coil 81 is mounted on the side of the circuit board 183 that faces the circuit module 153 of the rotor assembly 150 (the lower side in the figure).

[0063] As shown in Figure 6, when the rotor assembly 150 is assembled to the stator unit SU, the primary coil 81 and secondary coil 82 of the communication transformer 80 face each other in the axial direction at a predetermined distance apart. The primary coil 81 and secondary coil 82 are arranged in an annular shape so as to surround the rotation axis 12.

[0064] In the rotating electric machine 10, the field winding 32 of the rotor 30 is energized when the stator winding 22 is energized, and a field current flows through the field winding 32. As a result, each main pole portion 34 of the rotor 30 becomes either a north pole or a south pole. The rotating electric machine 10 then rotates due to the stator magnetic flux and the rotor magnetic flux.

[0065] When the rotating electric machine 10 is driven, the field current is detected by the current sensor 61 in the rotor assembly 150. In addition, the temperature of the field winding 32 rises as energy is supplied, and this temperature is detected by the temperature sensor 62. The detected values ​​from the current sensor 61 and the temperature sensor 62 are appropriately transmitted to the stator 20 side by the sensor signal processing unit A1 and the secondary coil 82 of the circuit module 153.

[0066] The control device 120 on the stator 20 side adjusts the harmonic signals superimposed on the energizing current of the stator winding 22 while understanding the state of the rotor 30 based on the current detection values ​​and temperature detection values ​​received from the rotor 30 side. This ensures that the field current of the rotor 30 is properly controlled.

[0067] Furthermore, in the sensor signal processing unit A1, the control unit 73 of the signal processing circuit 71 may have a function to determine abnormalities in the rotor 30 based on the temperature detected by the temperature sensor 62 (abnormality determination unit). Specifically, the control unit 73 determines whether the temperature of the field winding 32 detected by the temperature sensor 62 is above a predetermined temperature threshold TH, and if the temperature of the field winding 32 is above the temperature threshold TH, it determines that a temperature abnormality has occurred, that is, that the temperature of the rotor 30 has risen excessively. The temperature abnormality information of the rotor 30 is transmitted to the stator 20 side as appropriate by the sensor signal processing unit A1 and the secondary coil 82 of the circuit module 153, similar to the sensor detection signal.

[0068] If temperature anomaly information is received from the rotor 30, the control device 120 adjusts the harmonic signal superimposed on the energizing current of the stator winding 22 in order to limit the field current flowing through the field winding 32.

[0069] Furthermore, the control unit 73 may perform an abnormality determination of the rotor 30 based on the temperature detected by the temperature sensor 62 and the current detected by the current sensor 61. The procedure for this abnormality determination is shown in the flowchart of Figure 10. This process is preferably performed by the control unit 73 at a predetermined interval.

[0070] In Figure 10, step S11 acquires the detection values ​​of each sensor 61 and 62. In step S12, the temperature threshold TH is set based on the current detection value. At this time, assuming that the temperature of the field winding 32 will be higher as the field current increases, the temperature threshold TH is set to a higher temperature as the current detection value increases.

[0071] Subsequently, in step S13, it is determined whether the detected temperature value is equal to or greater than the temperature threshold TH. If the temperature of the field winding 32 is equal to or greater than the temperature threshold TH, the process proceeds to step S14, where it is determined that a temperature anomaly has occurred. In step S15, the temperature anomaly information of the rotor 30 is transmitted to the stator 20.

[0072] The control unit 73 may have a function to determine abnormalities in the field current based on the current detection value of the current sensor 61. Specifically, the control unit 73 determines whether the current detection value from the current sensor 61 is above a predetermined current threshold, and if the current detection value is above the current threshold, it determines that a current abnormality has occurred, that is, that an excessive current is flowing in the field winding 32. The current abnormality information of the rotor 30 is appropriately transmitted to the stator 20 side by the sensor signal processing unit A1 and the secondary coil 82 of the circuit module 153, similar to the sensor detection signal.

[0073] Furthermore, it is also possible to determine an anomaly based on the voltage detection value of the field winding 32. In this case, it is determined whether the voltage detection value is above a predetermined voltage threshold, and if the voltage detection value is above the voltage threshold, it is determined that a voltage anomaly has occurred. In step S12 of Figure 10, it is also possible to set a temperature threshold TH based on the voltage detection value. In this case, assuming that the temperature of the field winding 32 will be higher the voltage across both ends of the field winding 32 is higher, the temperature threshold TH is set to a higher temperature as the voltage detection value increases.

[0074] Next, we will explain the manufacturing method of the rotating electric machine 10. First, we will explain the manufacturing procedure of the rotor assembly 150 using Figure 11.

[0075] Here, the initial state is as shown in Figure 11(a), in which the rotor 30, comprising the rotor core 31 and the field winding 32, is assembled to the rotating shaft 12. In this state, the conductor end 64 of the field winding 32 is pulled out in the axial direction.

[0076] Then, as shown in Figure 11(b), the temperature sensor 62 is attached to the rotor 30 (first step). This forms a rotor module 151 including the rotor 30 and the temperature sensor 62. At this time, the temperature sensor 62 is fixed to the coil end of the field winding 32 by welding, welding, fixing with adhesive, fixing with fasteners such as snap-fits or screws, or assembly into the gap between the conductors of the winding coil end. In addition, a signal line 63 is connected to the temperature sensor 62, and the signal line 63 is led out in the axial direction.

[0077] Alternatively, the rotor 30 may be assembled to the rotating shaft 12 after the temperature sensor 62 has been attached to the rotor 30.

[0078] Subsequently, as shown in Figure 11(c), the coil end cover 152 is attached to the rotor coil end. At this time, the signal wire 63 is inserted through the through hole 161a of the end plate portion 161, and the conductor end 64 of the field winding 32 is inserted through the through hole 161b of the end plate portion 161. As a result, the signal wire 63 and the conductor end 64 are pulled out in the axial direction on the side of the coil end cover 152 opposite the rotor.

[0079] Subsequently, as shown in Figure 11(d), the circuit module 153 is assembled in a position aligned axially with the rotor module 151, with the coil end cover 152 sandwiched between it and the rotor module 151 (second step). This makes the circuit module 153 capable of rotating integrally with the rotor 30. The circuit module 153 is fixed to the rotating shaft 12 by press-fitting the press-fit ring 174 onto the rotating shaft 12.

[0080] In the process shown in Figure 11(d), the signal line 63 extending from the temperature sensor 62 is electrically connected to the sensor signal processing unit A1 of the circuit module 153, and the wire end 64 of the field winding 32 is electrically connected to the field current processing unit A2 of the circuit module 153. For example, terminals for electrically connecting the signal line 63 of the temperature sensor 62 and the wire end 64 of the field winding 32 may be provided on the outer surface of the circuit module 153, and the signal line 63 and the wire end 64 may be connected to these terminals. This completes the rotor assembly 150.

[0081] The connection of the signal line 63 and the wire end 64 to the sensor signal processing unit A1 and the field current processing unit A2 may be performed on the side of the circuit module 153 opposite the rotor (the upper side in the figure) of the substrate 171. In this case, the signal line 63 and the wire end 64 should be guided through the substrate 171 to the side opposite the rotor before being electrically connected to the sensor signal processing unit A1 and the field current processing unit A2. In the circuit module 153, the substrate 171 may be left exposed on the side opposite the rotor before the connection of the signal line 63 and the wire end 64, and after the connection of the signal line 63 and the wire end 64, the connection portions of the signal line 63 and the wire end 64 may be covered by resin filling or by attaching a cover.

[0082] It is preferable to bring the axial end face of the circuit module 153 into close contact with the coil end cover 152. In this case, an intermediate member made of adhesive or sealing material is interposed between the circuit module 153 and the coil end cover 152, and the circuit module 153 and the coil end cover 152 are brought into close contact with each other by the intermediate member. This prevents foreign matter from entering the cover through the through holes 161a and 161b of the coil end cover 152.

[0083] After the rotor assembly 150 is completed, it is assembled to the stator unit SU (see Figure 7). This assembly positions the rotor 30 radially opposite the stator 20. In the stator unit SU, the primary coil 81 of the communication transformer 80 is fixed to the housing 11, and the secondary coil 82 of the rotor assembly 150 is positioned axially opposite the primary coil 81 on the stator unit SU side. Finally, the end plate portion 11c is assembled to the open end of the housing 11, completing the rotating electric machine 10 shown in Figure 6.

[0084] According to the embodiment described in detail above, the following excellent effects can be obtained.

[0085] In the rotating electric machine 10, a temperature sensor 62 is attached to the rotor 30. Furthermore, a circuit module 153 is assembled, which includes a sensor signal processing unit A1 that is aligned axially with the rotor 30 and capable of rotating integrally with the rotor 30, and which enables the detection signal detected by the temperature sensor 62 to be transmitted to the outside of the rotor. In this case, there is a concern that the narrow space between the axial end of the rotor 30 and the circuit module 153 may restrict the attachment of the temperature sensor 62 to the rotor 30.

[0086] In this regard, in the above manufacturing method, the temperature sensor 62 is attached to the rotor 30 before the circuit module 153 is assembled (i.e., the temperature sensor 62 is pre-attached to the rotor 30). In this case, there are fewer constraints on the attachment of the temperature sensor 62 to the rotor 30, and the temperature sensor 62 can be attached to the rotor 30 in a desirable position or by a desirable method. Furthermore, by extending the signal line 63 axially from the temperature sensor 62 when attaching the temperature sensor 62, the signal line 63 extending from the temperature sensor 62 can be suitably connected to the sensor signal processing unit A1 when the circuit module 153 is assembled later. As a result, a suitable sensor structure can be realized in the rotor 30.

[0087] The following configuration can be adopted as an alternative configuration for the self-excited wound-field type rotating electric machine 10.

[0088] (Modification 1 of the First Embodiment) In the rotating electric machine 10 shown in Figure 12, the difference from the rotating electric machine 10 in Figure 6 is that in the rotor assembly 150, the circuit module 153 is composed of two circuit modules 153_1 and 153_2. The circuit modules 153_1 and 153_2 are arranged side by side in the axial direction with a coil end cover 152 interposed at an intermediate position in the axial direction. In other words, the circuit modules 153_1 and 153_2 are spaced apart from each other with the coil end cover 152 acting as an intermediate plate in between. Hereinafter, of these circuit modules 153_1 and 153_2, the side closer to the rotor 30 in the axial direction will be referred to as the first circuit module 153_1, and the side further from the rotor 30 will be referred to as the second circuit module 153_2.

[0089] As shown in Figure 13, the first circuit module 153_1 includes a field current processing unit A2 consisting of diodes 51, 53 and resonant capacitors 52, 54, etc. The second circuit module 153_2 includes a sensor signal processing unit A1 consisting of a signal processing circuit 71, a power receiving circuit 74, a modulation circuit 76, etc., and a secondary coil 82 of a communication transformer 80. The current sensor 61 is preferably included in the first circuit module 153_1.

[0090] Circuit module 153_1 is preferably configured in the same way as in Figure 8, with electrical components constituting the field current processing unit A2 mounted on a substrate and these components sealed in resin. Similarly, circuit module 153_2 is preferably configured in the same way, with electrical components constituting the sensor signal processing unit A1 mounted on a substrate and these components sealed in resin. Each circuit module 153_1 and 153_2 is fixed to the rotating shaft 12 by press-fitting a press-fit ring or the like.

[0091] However, in the rotating electric machine 10 shown in Figure 12, the divisions of each circuit module 153_1 and 153_2 may differ from those shown in Figure 13. For example, the first circuit module 153_1 may include a sensor signal processing unit A1 and a field current processing unit A2, and the second circuit module 153_2 may include the secondary coil 82 of the communication transformer 80.

[0092] In the rotating electric machine 10 shown in Figure 12, the rotor assembly 150 may not have a coil end cover 152. For example, either circuit module 153_1 or 153_2 may have a component holder made of resin material, and various electrical components may be held in that component holder. In this case, the component holder corresponds to an "intermediate plate".

[0093] Next, the manufacturing procedure for the rotor assembly 150 of the rotating electric machine 10 shown in Figure 12 will be explained using Figure 14. In Figure 14(a), the temperature sensor 62 is already attached to the rotor 30.

[0094] Then, as shown in Figure 14(b), the first circuit module 153_1 is assembled in a position aligned with the rotor 30 in the axial direction. In this step, the wire ends 64 of the field winding 32 extending from the rotor 30 side are electrically connected to the field current processing unit A2 of the first circuit module 153_1. In addition, the signal line 63 extending from the temperature sensor 62 is routed through the first circuit module 153_1 in the axial direction and brought out to the side of the first circuit module 153_1 that is not connected to the rotor.

[0095] The first circuit module 153_1 includes a current sensor 61, to which a signal line 66 that outputs a current detection signal is connected. The signal line 66 is routed out in the axial direction toward the side opposite the rotor.

[0096] Subsequently, as shown in Figure 14(c), the coil end cover 152 is attached so as to cover the rotor coil end and the first circuit module 153_1. At this time, the signal wire 63 is inserted through the through hole 161a of the end plate portion 161, and the signal wire 66 is inserted through the through hole 161b of the end plate portion 161. As a result, the signal wire 63 and the signal wire 66 are pulled out in the axial direction on the side of the coil end cover 152 opposite the rotor.

[0097] Subsequently, as shown in Figure 14(d), the second circuit module 153_2 is assembled. This assembles the secondary coil 82 to the side of the coil end cover 152 that is not on the rotor side. In this step, the signal line 63 extending from the temperature sensor 62 and the signal line 66 that outputs the current detection signal from the current sensor 61 are electrically connected to the sensor signal processing unit of the second circuit module 153_2. This completes the rotor assembly 150.

[0098] After the rotor assembly 150 is completed, it is assembled to the stator unit SU as described above. As a result, the rotor 30 is positioned radially opposite to the stator 20, and the secondary coil 82 of the rotor assembly 150 is positioned axially opposite to the primary coil 81 on the stator unit SU side.

[0099] (Modification 2 of the First Embodiment) In the rotating electric machine 10 shown in Figure 15, the difference from the previously described rotating electric machine 10 is that on the coil end cover 152 of the rotor assembly 150, a signal processing module 191 including a sensor signal processing unit A1 and a current processing module 192 including a field current processing unit A2 are provided on the rotor 30 side of the axial side. In other words, the signal processing module 191 and the current processing module 192 are separate components and are arranged side by side in the axial direction. In this example, the signal processing module 191 and the current processing module 192 correspond to "circuit modules". In addition, a coil module 193 including the secondary coil 82 of the communication transformer 80 is provided on the side of the coil end cover 152 opposite the rotor.

[0100] The current processing module 192 is equipped with a temperature sensor 194 that detects the temperature of the field current processing unit A2, more specifically, the temperatures of the diodes 51 and 53. As a result, the rotor assembly 150 of the rotating electric machine 10 has two temperature sensors: a temperature sensor 62 (first temperature sensor) that detects the temperature of the field winding 32, and a temperature sensor 194 (second temperature sensor) that detects the temperature of the field current processing unit A2. The temperature sensor 194 may also detect the temperatures of the resonant capacitors 52 and 54.

[0101] The control unit 73 of the signal processing circuit 71 may perform an abnormality determination of the rotor 30 based on the temperature detection values ​​of each temperature sensor 62, 194 (abnormality determination unit). Specifically, the control unit 73 determines whether the temperature of the field winding 32 detected by the temperature sensor 62 is above a predetermined temperature threshold TH1, and if the temperature of the field winding 32 is above the temperature threshold TH1, it determines that a temperature abnormality has occurred in the field winding 32. The control unit 73 also determines whether the diode temperature detected by the temperature sensor 194 is above a predetermined temperature threshold TH2, and if the diode temperature is above the temperature threshold TH2, it determines that a temperature abnormality has occurred in the field current processing unit A2. The temperature abnormality information of the rotor 30 is transmitted to the stator 20 side by the secondary coil 82 of the coil module 193 as appropriate, similar to the sensor detection signal.

[0102] As explained in Figure 10, it is also possible to set the temperature thresholds TH1 and TH2 variably based on the current detected value of the current sensor 61. In this case, the larger the current detected value, the higher the temperature thresholds TH1 and TH2 are set to. It is also possible to set the temperature thresholds TH1 and TH2 based on the voltage detected value of the field winding 32. In this case, the larger the voltage detected value, the higher the temperature thresholds TH1 and TH2 are set to.

[0103] As shown in Figures 6 and 12 above, it is also possible to configure the system to include a temperature sensor 194 for detecting the temperature of the field current processing unit A2, in addition to the temperature sensor 62 for detecting the temperature of the field winding 32.

[0104] Figure 16 shows the circuit divisions included in the signal processing module 191 and the circuit divisions included in the current processing module 192 in the electrical configuration of the rotor assembly 150.

[0105] Next, the manufacturing procedure for the rotor assembly 150 of the rotating electric machine 10 shown in Figure 15 will be explained using Figure 17. In Figure 17(a), the temperature sensor 62 is already attached to the rotor 30.

[0106] Then, as shown in Figure 17(b), the signal processing module 191 and the current processing module 192 are assembled in a position aligned with the rotor 30 in the axial direction. These modules 191 and 192 are fixed to the rotating shaft 12 by press-fitting or the like. In this process, the signal line 63 extending from the temperature sensor 62 is electrically connected to the sensor signal processing unit A1 of the signal processing module 191. Also, the wire end 64 of the field winding 32 is electrically connected to the field current processing unit A2 of the current processing module 192. The temperature sensor 194 provided in the current processing module 192 is electrically connected to the sensor signal processing unit A1 of the signal processing module 191 by the signal line 195.

[0107] Subsequently, as shown in Figure 17(c), a coil end cover 152 is attached so as to cover the rotor coil end, the signal processing module 191, and the current processing module 192. At this time, the signal lines 196 extending from each module 191 and 192 are brought out to the side opposite the rotor.

[0108] Subsequently, as shown in Figure 17(d), the coil module 193 is assembled to the side of the coil end cover 152 opposite the rotor on the axial side. In this step, the secondary coil 82 is electrically connected to the signal line 196. This completes the rotor assembly 150.

[0109] After the rotor assembly 150 is completed, it is assembled to the stator unit SU as described above. As a result, the rotor 30 is positioned radially opposite to the stator 20, and the secondary coil 82 of the rotor assembly 150 is positioned axially opposite to the primary coil 81 on the stator unit SU side.

[0110] In the rotor assembly 150 of the rotating electric machine 10 shown in Figure 15, the signal processing module 191, current processing module 192, and coil module 193 are arranged such that the coil module 193 is positioned on the side opposite the rotor of the coil end cover 152 and opposite the coil module 182 on the stator side. However, the arrangement of the signal processing module 191 and current processing module 192 may be arbitrarily changed. For example, on the rotor side of the coil end cover 152, the signal processing module 191 may be positioned on the side farther from the rotor 30 and the current processing module 192 on the side closer to the rotor 30, contrary to Figure 15. It is also possible to configure the signal processing module 191 and current processing module 192 to be positioned on the rotor 30 side of the axial side of the coil end cover 152, and the other on the side opposite the rotor.

[0111] (Modification 3 of the First Embodiment) In the rotating electric machine 10 shown in Figure 18, the configuration of the signal transmission means for transmitting signals from the rotor assembly 150 to the stator unit SU is different from that of the rotating electric machine 10 in Figure 6. In this example, the first winding portion 41 of the field winding 32 is used to transmit signals from the rotor 30 to the stator 20. Therefore, in the rotor assembly 150 of this example, the circuit module 153 fixed to the rotating shaft 12 includes a sensor signal processing unit A1 and a field current processing unit A2, but does not include the secondary coil 82 of the communication transformer 80.

[0112] In the electrical configuration of the rotor assembly 150 shown in Figure 19, power receiving circuits 74 are connected to both ends of the first winding section 41. A modulation circuit 76 is also connected to one end of the first winding section 41 via a resistor 75. The control unit 73 superimposes the sensor detection signal, which has been processed by the sensor signal processing unit A1, onto the current flowing through the first winding section 41. As a result, the sensor detection signal is transmitted from the first winding section 41 to the stator winding 22.

[0113] The manufacturing procedure for the rotor assembly 150 in the rotating electric machine 10 shown in Figure 18 is generally the same as the manufacturing procedure shown in Figure 11, so a detailed explanation is omitted here.

[0114] The configuration in this example aims to reduce the size of the rotating electric machine 10 by shortening its axial dimension (shaft length). Furthermore, the configuration in this example aims to suppress the complexity of the configuration associated with the addition of a wireless transmission function to the rotating electric machine 10. Specifically, proportionally, in the configuration shown in Figure 6, for example, a coil module 182 containing the primary coil 81 of the communication transformer 80 is provided in the stator unit SU at a position aligned axially with the rotor assembly 150, resulting in a longer shaft length for the rotating electric machine 10. Additionally, the inclusion of the communication transformer 80 raises concerns about increased configuration complexity, a higher number of parts, and higher costs.

[0115] In contrast, in the configuration of this example, the field winding 32 of the rotor 30 and the stator winding 22 also serve as signal transmission means, and the communication transformer 80 is omitted. For example, in the configuration of Figure 6, the resolver 181 and the coil module 182 are stacked on the end plate portion 11b of the housing 11 in the stator unit SU, but the coil module 182 can be omitted. This shortens the shaft length of the rotating electric machine 10 and, consequently, makes the rotating electric machine 10 smaller. In short, the rotating electric machine 10 of this example is able to properly transmit sensor detection signals wirelessly from the rotor side to the stator side while suppressing an increase in size. Furthermore, by omitting the communication transformer 80, the configuration can be simplified, the number of parts can be reduced, and costs can be reduced.

[0116] In a rotating electric machine 10 that does not have a communication transformer 80, the circuit module 153 may be configured to be located on the rotor 30 side of the axial side of the coil end cover 152, as shown in Figure 20. In other words, in the rotating electric machine 10 of Figure 20, since the circuit module 153 of the rotor assembly 150 does not have a communication coil, the circuit module 153 is configured to be located inside the coil end cover 152 (i.e., between the end plate portion 161 of the coil end cover 152 and the rotor 30).

[0117] Figure 21 shows the manufacturing procedure for the rotor assembly 150 of the rotating electric machine 10 shown in Figure 20. In the manufacturing procedure shown in Figure 21, the assembly order of the coil end cover 152 and the circuit module 153 is reversed compared to the manufacturing procedure shown in Figure 11 (the manufacturing procedure for the rotor assembly 150 of the rotating electric machine 10 in Figure 6).

[0118] In other words, after the temperature sensor 62 is attached to the rotor 30 (Figures 21(a), (b)), the circuit module 153 is assembled in a position aligned axially with the rotor module 151, as shown in Figure 21(c). At this time, the signal line 63 of the temperature sensor 62 is electrically connected to the sensor signal processing unit A1 of the circuit module 153, and the wire end 64 of the field winding 32 is electrically connected to the field current processing unit A2 of the circuit module 153.

[0119] Subsequently, as shown in Figure 21(d), the coil end cover 152 is attached so as to cover the axial end of the rotor 30 and the circuit module 153. In this configuration, it is not necessary to bring out the signal wire 63 and the wire end 64 on the side of the coil end cover 152 opposite the rotor, and the through holes 161a and 161b of the end plate portion 161 can be omitted.

[0120] (Modification 4 of the First Embodiment) As shown in Figure 22, the rotor module 151 may be configured such that the temperature sensor 62 is positioned at the axial intermediate position of the rotor core 31. In this case, the rotor core 31 has a housing portion open on both axial sides between a plurality of main pole portions 34 arranged in the circumferential direction, and the field winding 32 is wound around this housing portion (see Figure 3). The temperature sensor 62 is then mounted inside the housing portion of the rotor core 31. For example, the temperature sensor 62 is mounted between the radially inner second winding portion 42 and the radially outer first winding portion 41 of the field winding 32. The temperature sensor 62 is attached to the field winding 32 by welding, bonding, brazing, etc.

[0121] Furthermore, field windings 32 are wound around each main pole portion 34 of the rotor core 31 by concentrated winding, and a temperature sensor 62 may be attached between the concentrated winding coils of each pole that are arranged in the circumferential direction.

[0122] A signal line 197 extending axially within the rotor core 31 is connected to a temperature sensor 62 positioned in the middle of the rotor core 31. A signal line 63 extending axially from the rotor coil end is connected to this signal line 197. The signal line 63 is then connected to the sensor signal processing unit A1 of the circuit module 153. Note that signal lines 63 and 197 may be a single continuous signal line.

[0123] In the rotor 30, it is considered that the highest temperature occurs at the axial midpoint of the rotor core 31 when the field winding 32 is energized. Therefore, with the above configuration in which the temperature sensor 62 is positioned at the axial midpoint of the rotor core 31, the temperature of the field winding 32 can be properly detected.

[0124] During the manufacturing of the rotor assembly 150, in the first step, which is the process of attaching the sensor to the rotor 30, the temperature sensor 62 is attached to a position within the housing of the rotor core 31. At this time, the rotor 30 is in a state where accessories such as the circuit module 153 are not assembled, and the temperature sensor 62 can be attached easily and appropriately by any method such as welding or bonding.

[0125] Below, we will describe another embodiment in which some parts of the configuration of the first embodiment have been modified, focusing on the differences from the first embodiment.

[0126] (Second Embodiment) In this embodiment, a separately excited wound-field type rotating electric machine 10A will be described. In this embodiment, the rotating electric machine 10A differs from the rotating electric machine 10 in Figure 6 in that a power transformer 210 is used to excite the field winding 32 on the rotor 30 side.

[0127] Figure 23 is a circuit diagram showing the electrical configuration of the stator 20 and rotor 30 sides in the rotating electric machine 10A. The power transformer 210 has a primary coil 211 and a secondary coil 212.

[0128] In the rotating electric machine 10A, the primary coil 211 of the power transformer 210 is provided on the stator 20 side. An inverter 220 is connected to the primary coil 211, and a battery 100 is connected to the inverter 220.

[0129] The inverter 220 is a power converter consisting of a full-bridge circuit and comprises a first series circuit including an upper arm switch 221 and a lower arm switch 222, and a second series circuit including an upper arm switch 223 and a lower arm switch 224. Each of the switches 221 to 224 is a semiconductor switching element, such as an N-channel MOSFET. Switches 221 and 222 are turned on and off by a drive circuit 225, and switches 223 and 224 are turned on and off by a drive circuit 226.

[0130] The control device 120 performs switching control of the inverter 220. Switching control of the inverter 220 applies a high-frequency AC voltage to the primary coil 211. This causes a high-frequency current to flow through the primary coil 211, generating a magnetic field for power transmission in the primary coil 211.

[0131] Furthermore, a secondary coil 212 of the power transformer 210 is provided on the rotor 30 side. A rectifier circuit 230 is connected to the secondary coil 212. The rectifier circuit 230 consists of a diode bridge circuit and includes a first series circuit including a pair of diodes 231 and 232, and a second series circuit including a pair of diodes 233 and 234. In this embodiment, the rectifier circuit 230 corresponds to the "field current processing unit A2".

[0132] A magnetic field is generated in the primary coil 211 of the power transformer 210, and when this magnetic field links with the secondary coil 212, a high-frequency current flows in the secondary coil 212, fluctuating at the frequency of the high-frequency current flowing through the primary coil 211. The high-frequency current flowing through the secondary coil 212 is converted to DC by the rectifier circuit 230 and then supplied to the field winding 32. As a result, a field current flows through the field winding 32.

[0133] As previously described, when the rotor is rotating, the current detection signal from the current sensor 61 and the temperature detection signal from the temperature sensor 62 are wirelessly transmitted from the rotor 30 to the stator 20 by the communication transformer 80.

[0134] Figure 24 is a cross-sectional view showing the configuration of the rotating electric machine 10A of this embodiment. In the rotating electric machine 10A, the rotor assembly 150 is broadly composed of a rotor module 151 integrated with the rotating shaft 12, a coil end cover 152 attached to one axial end of the rotor module 151, and a circuit module 153A that is aligned axially with the rotor module 151 with the coil end cover 152 sandwiched between them. The circuit module 153A has a sensor signal processing unit A1 and a field current processing unit A2. The circuit module 153A also integrally provides a secondary coil 82 of a communication transformer 80 and a secondary coil 212 of a power transformer 210. These secondary coils 82 and 212 are preferably planar printed coils arranged on a substrate 171.

[0135] On the other hand, in the stator unit SU, a coil module 182A is provided at a position axially opposite to the circuit module 153A, which includes the primary coil 81 of the communication transformer 80 and the primary coil 211 of the power transformer 210. These primary coils 81 and 211 are preferably planar printed coils arranged on the substrate 183.

[0136] On the rotor 30 side, a secondary coil 212 for power and a secondary coil 82 for communication are arranged in an annular double configuration, inside and out, surrounding the rotation axis 12. For example, the secondary coil 212 for power may be arranged radially outward, and the secondary coil 82 for communication may be arranged radially inward. However, the reverse may also be the case. On the other hand, on the stator 20 side, a primary coil 211 for power is arranged axially opposite to the secondary coil 212 for power, and a primary coil 81 for communication is arranged axially opposite to the secondary coil 82 for communication.

[0137] In the rotating electric machine 10A shown in Figure 24, the manufacturing procedure for the rotor assembly 150 is generally the same as that shown in Figure 11, so a detailed explanation is omitted here. Briefly, when the rotor module 151 is formed, the temperature sensor 62 is attached to the rotor 30 (Figure 11(b)), and then the coil end cover 152 is attached to the rotor coil end (Figure 11(c)). After that, the circuit module 153A is assembled in a position aligned axially with the rotor module 151, with the coil end cover 152 sandwiched between it and the rotor module 151 (Figure 11(d)).

[0138] After the rotor assembly 150 is completed, it is assembled onto the stator unit SU to produce the rotating electric machine 10A shown in Figure 24. The assembly of the rotor assembly 150 onto the stator unit SU causes the primary coil 81 and secondary coil 82 of the communication transformer 80 to face each other in the axial direction, and the primary coil 211 and secondary coil 212 of the power transformer 210 to face each other in the axial direction.

[0139] (Modification of the second embodiment) In the rotating electric machine 10A shown in Figure 24, the communication transformer 80 may be omitted, and a power transformer 210 may be used to transmit signals from the rotor 30 to the stator 20. In this case, the circuit module 153A has the secondary coil 212 of the power transformer 210, but does not have the secondary coil 82 of the communication transformer 80. On the other hand, in the stator unit SU, the coil module 182A has the primary coil 211 of the power transformer 210, but does not have the primary coil 81 of the communication transformer 80.

[0140] Figure 25 shows the electrical configuration of the rotor assembly 150 when a signal is transmitted from the rotor 30 side using a power transformer 210. In Figure 25, a power receiving circuit 74 is connected to both ends of the secondary coil 212 of the power transformer 210. A modulation circuit 76 is also connected to one end of the secondary coil 212 via a resistor 75. The control unit 73 superimposes the sensor detection signal, which has been processed by the sensor signal processing unit A1, onto the current flowing through the secondary coil 212. As a result, the sensor detection signal is transmitted from the secondary coil 212 on the rotor 30 side to the primary coil 211 on the stator 20 side.

[0141] Figure 26 is a cross-sectional view showing the configuration of the rotating electric machine 10A in which the communication transformer 80 is omitted. In the rotating electric machine 10A shown in Figure 26, the difference from the configuration in Figure 24 is that the circuit module 153A does not have the secondary coil 82 of the communication transformer 80, but does have the secondary coil 212 of the power transformer 210. Also, in the stator unit SU, the coil module 182A does not have the primary coil 81 of the communication transformer 80, but does have the primary coil 211 of the power transformer 210.

[0142] In this example configuration, the components related to the communication transformer 80 can be omitted in the rotor-side circuit module 153A and the stator-side coil module 182A. This simplifies the configuration, reduces the number of components, and lowers costs.

[0143] In the externally excited wound-field type rotating electric machine 10A, the configuration of the circuit module 153A can be changed, similar to the self-excited wound-field type rotating electric machine 10.

[0144] For example, as shown in Figure 12, the circuit module 153A may be divided into two circuit modules arranged in the axial direction. The circuit module closer to the rotor 30 may include the field current processing unit A2, and the circuit module further away from the rotor 30 may include the sensor signal processing unit A1 and secondary coils 82, 212. Alternatively, the circuit module closer to the rotor 30 may include the sensor signal processing unit A1 and the field current processing unit A2, and the circuit module further away from the rotor 30 may include the secondary coils 82, 212.

[0145] Furthermore, as shown in Figure 15, it is also possible to configure the coil end cover 152 to have a signal processing module 191 including a sensor signal processing unit A1 and a current processing module 192 including a field current processing unit A2 on the rotor 30 side of the axial side. As previously described, in the rotor assembly 150, assuming that the coil module is positioned on the side opposite the rotor of the coil end cover 152 and facing the coil module 182 on the stator side, it is also possible to arbitrarily change the arrangement of the signal processing module 191 and the current processing module 192, while assuming that the coil module is positioned on the side opposite the rotor of the coil end cover 152 and facing the coil module 182 on the stator side, it is also possible to arbitrarily change the arrangement of the signal processing module 191 and the current processing module 192.

[0146] (Third Embodiment) In this embodiment, a permanent magnet type rotating electric machine 10B will be described. In the rotating electric machine 10B of this embodiment, the rotor assembly 150 is configured to generate field magnetic flux using permanent magnets.

[0147] Figure 27 is a circuit diagram showing the electrical configuration of the stator 20 and rotor 30 sides in the rotating electric machine 10B. The temperature sensor 62 detects the temperature of the permanent magnet in the rotor module 151.

[0148] In the rotating electric machine 10B, the stator 20 side is provided with the primary coil 81 of the communication transformer 80, and a power transmission circuit 91, a demodulation circuit 92, and a control device 120 connected to both ends of the primary coil 81, as described above.

[0149] Furthermore, the rotor 30 is provided with a power receiving circuit 74, a modulation circuit 76, and a signal processing circuit 71 connected to the secondary coil 82 of the communication transformer 80. A temperature sensor 62 is connected to the signal processing circuit 71. In this example configuration, for example, of the sensor signal processing unit A1 and field current processing unit A2 shown in Figure 5, only the sensor signal processing unit A1 is provided.

[0150] When the rotating electric machine 10B is in operation, the temperature detection signal from the temperature sensor 62 is wirelessly transmitted from the rotor 30 to the stator 20 by the communication transformer 80.

[0151] Figure 28 is a cross-sectional view showing the configuration of the rotating electric machine 10B of this embodiment. Figure 29 is a cross-sectional view of the rotor 30. Figure 29 shows the configuration for one pole.

[0152] In the rotating electric machine 10B, the rotor assembly 150 is broadly composed of a rotor module 151 integrated with the rotating shaft 12, a coil end cover 152 attached to one axial end of the rotor module 151, and a circuit module 153B that is aligned axially with the rotor module 151 with the coil end cover 152 sandwiched between them. The circuit module 153B has a sensor signal processing unit A1. The circuit module 153B also has a secondary coil 82 of a communication transformer 80 integrated into it.

[0153] In the rotor module 151, the rotor 30 has a rotor core 251 and a plurality of permanent magnets 252 assembled to the rotor core 251. The rotor 30 is, for example, an embedded magnet type rotor, and the permanent magnets 252 are housed in magnet housing holes 253 formed in the rotor core 251. Multiple magnet housing holes 253 are provided for each magnetic pole, and the portion of the magnet housing hole 253 in which no permanent magnets 252 are housed acts as a flux barrier. The magnet housing holes 253 correspond to the housing portions in the rotor core 251 that are open on both axial sides.

[0154] A temperature sensor 62 is provided in the magnet housing hole 253 in a position that it is in contact with the permanent magnet 252. The temperature sensor 62 is attached to the permanent magnet 252 by welding, bonding, brazing, or the like.

[0155] However, the rotor 30 may be a surface magnet type rotor. In this case, a plurality of permanent magnets 252 are arranged in a row on the radially outer circumferential surface of the rotor core 251, and a temperature sensor 62 is preferably attached between adjacent magnets in the circumferential direction, or between the rotor core 251 and the permanent magnets 252.

[0156] A signal line 254 extending axially within the magnet housing hole 253 is connected to a temperature sensor 62 located in the magnet housing hole 253 of the rotor core 251. A signal line 63 extending axially from the rotor coil end is connected to this signal line 254. The signal line 63 is then connected to the sensor signal processing unit A1 of the circuit module 153B. Note that signal lines 63 and 254 may be a single continuous signal line.

[0157] In the rotor 30, it is considered that the position in the axial middle of the rotor core 251 becomes the hottest when the rotating electric machine 10B is in operation. Therefore, with the above configuration in which the temperature sensor 62 is positioned in the axial middle of the rotor core 251, the temperature of the permanent magnet 252 can be properly detected.

[0158] In the rotating electric machine 10B shown in Figure 28, the manufacturing procedure for the rotor assembly 150 is generally the same as that shown in Figure 11, so a detailed explanation is omitted here. Briefly, when the rotor module 151 is formed, the temperature sensor 62 is attached to the permanent magnet 252 of the rotor 30 (Figure 11(b)), and then the coil end cover 152 is attached to the rotor coil end (Figure 11(c)). After that, the circuit module 153B is assembled in a position aligned axially with the rotor module 151, with the coil end cover 152 sandwiched between it and the rotor module 151 (Figure 11(d)).

[0159] After the rotor assembly 150 is completed, it is assembled onto the stator unit SU to produce the rotating electric machine 10B shown in Figure 28. The assembly of the rotor assembly 150 onto the stator unit SU causes the primary coil 81 and secondary coil 82 of the communication transformer 80 to face each other in the axial direction, and the primary coil 211 and secondary coil 212 of the power transformer 210 to face each other in the axial direction.

[0160] (Other Embodiments) The above embodiments may be modified as follows, for example.

[0161] In the above embodiment, the current sensor 61 is provided on the circuit module 153 in the rotor assembly 150, but this can be changed to a configuration where the current sensor 61 is provided on the rotor 30. A specific configuration will be explained using Figure 30.

[0162] In Figure 30, field windings 32 are wound around each main pole portion 34 of the rotor core 31 in the rotor 30, and the winding portions (concentrated winding coils) of adjacent magnetic poles in the circumferential direction are connected to each other by connecting portions 35. The current sensor 61 is provided on the connecting portion 35. A signal line 36 is connected to the current sensor 61, and the signal line 36 is electrically connected to a circuit module 153 (not shown). In this case, during the manufacturing of the rotor assembly 150, in the first step, which is the sensor attachment process to the rotor 30, the temperature sensor 62 is attached to the rotor 30 as described above, and the current sensor 61 is attached to the connecting portion 35 of the field winding 32 of the rotor 30.

[0163] In the above embodiment, a temperature sensor 62 is attached to the rotor 30 as a physical quantity sensor, but the configuration is not limited to this. For example, the physical quantity sensor may detect physical quantities such as pressure (atmospheric pressure), humidity, magnetic force, load, etc., around the rotor. Alternatively, the physical quantity sensor may detect torque, vibration, and rotational acceleration generated when the rotating shaft 12 rotates.

[0164] In the above embodiment, as shown in Figure 5, the sensor detection signal is converted from an analog signal to a digital signal and then wirelessly transmitted from the rotor 30 to the stator 20. However, this can be changed to a configuration in which the sensor detection signal is wirelessly transmitted from the rotor 30 to the stator 20 as an analog signal.

[0165] The field winding 32 is not limited to a configuration comprising a first winding section 41 and a second winding section 42. For example, the field winding 32 may be wound as a single winding section (concentrated winding coil) without dividing it into first and second winding sections 41 and 42 for each main pole section 34. In this case, it is preferable to connect diodes to both ends of the field winding 32, or to connect diodes and capacitors in parallel.

[0166] - In the stator 20, the stator core may be a teethless stator core without teeth.

[0167] The rotating electric machine 10 is not limited to a rotating electric machine used as a vehicle-mounted main engine, but may also be a rotating electric machine used as an ISG (Integrated Starter Generator), which is a motor and generator.

[0168] The mobile body on which the rotating electric machine system is mounted is not limited to a vehicle; for example, it may be an aircraft or a ship. Furthermore, the rotating electric machine system is not limited to a system mounted on a mobile body; it may be a stationary system.

[0169] In the above embodiment, a communication transformer 80 or magnetic induction via a field winding 32 is used as a means of wireless communication from the rotor 30 to the stator 20. However, other means of communication can also be used. For example, communication conforming to any communication standard established by IEEE, ISO, and IEC can be used. Specifically, for example, Wi-Fi®, Bluetooth®, ZigBee®, RFID (Radio Frequency Identification), or DSRC (Dedicated Short Range Communication) can be used as a narrow-range wireless communication.

[0170] According to the embodiments described above, the following characteristic configurations can be extracted as a rotating electric machine.

[0171] [Feature 1] A rotating electric machine (10) comprising: a stator unit (SU) including a stator (20) having stator windings (22) and a housing (11) housing the stator; a rotor (30) arranged radially opposite to the stator and capable of rotating integrally with a rotating shaft (12), wherein the rotor is provided as a rotor module (151) to which physical quantity sensors (61, 62) for detecting physical quantities related to the rotor are attached; a circuit module (153) including a sensor signal processing unit (A1) for processing physical quantity signals detected by the physical quantity sensors is arranged at a position aligned with the rotor in the axial direction, capable of rotating integrally with the rotor; the physical quantity sensors on the rotor module side and the sensor signal processing unit on the circuit module side are electrically connected by a signal line (63) extending in the axial direction; and the physical quantity signals processed by the sensor signal processing unit can be transmitted to the outside of the rotor.

[0172] In rotating electric machines, it is conceivable that physical quantity sensors, such as temperature, be installed on the rotor, which rotates relative to the stator. In this case, a technology is needed to properly transmit the physical quantity signals detected by the physical quantity sensors to the outside of the rotor.

[0173] In the rotating electric machine with the above configuration, the rotor is provided as a rotor module to which a physical quantity sensor is assembled, and a circuit module including a sensor signal processing unit that processes the physical quantity signal detected by the physical quantity sensor is arranged in a manner that allows it to rotate integrally with the rotor module. The rotor module and the circuit module are arranged side by side in the axial direction, and the physical quantity sensor and the sensor signal processing unit are electrically connected by a signal line extending in the axial direction. With this configuration, the physical quantity signal detected by the physical quantity sensor in the rotor module can be suitably transmitted to the outside of the rotor.

[0174] [Feature 2] The rotating electric machine according to Feature 1, further comprising a communication transformer (80) that transmits a physical quantity signal processed by the sensor signal processing unit, wherein the primary coil (81) of the communication transformer is provided on the stator unit side, and the secondary coil (82) of the communication transformer is provided on the rotor side, wherein on the rotor side, the secondary coil is arranged in an annular shape so as to surround the rotation axis, and on the stator unit side, the primary coil is arranged facing the secondary coil in the axial direction. A rotating electric machine with this configuration is shown, for example, in Figures 6, 24, 28, etc.

[0175] [Feature 3] The rotor has a field winding (32) that generates a field flux, and a field current flows through the field winding due to the generation of induced power when the stator unit is energized, the circuit module has a first circuit module (153_1) and a second circuit module (153_2), the first circuit module and the second circuit module are sandwiched axially by an intermediate plate (152) made of a non-magnetic material, the first circuit module is on the rotor module side and the second circuit module is on the opposite side of the rotor module, the field current processing unit (A2) provided for resonance or rectification of the field current flowing through the field winding when the stator unit is energized is included in the first circuit module, the secondary coil is included in the second circuit module, and the sensor signal processing unit is included in either the first circuit module or the second circuit module, as described in Feature 2. A rotating electric machine with this configuration is shown, for example, in Figures 12 and 13.

[0176] [Feature 4] The rotor has a field winding (32) that generates a field flux, and a field current flows through the field winding due to the generation of induced power when the stator unit is energized, the circuit module has a signal processing module (191) including the sensor signal processing unit, and a current processing module (192) including a field current processing unit (A2) provided for resonance or rectification of the field current flowing through the field winding when the stator unit is energized, an intermediate plate (152) made of a non-magnetic material is provided on the axially outer side of the rotor module, the signal processing module, the current processing module and the secondary coil are arranged so as to sandwich the intermediate plate in the axial direction, with the signal processing module and the current processing module on the rotor module side and the secondary coil on the opposite side of the rotor module, as described in Feature 2. A rotating electric machine with this configuration is shown, for example, in Figures 15 and 16.

[0177] [Feature 5] The rotating electric machine according to Feature 3 or 4, wherein the physical quantity sensor is a temperature sensor for detecting the temperature of the rotor, and the temperature sensor comprises a first temperature sensor (62) for detecting the temperature of the field winding and a second temperature sensor (194) for detecting the temperature of the electrical components of the field current processing unit. A rotating electric machine with this configuration is shown, for example, in Figure 15.

[0178] [Feature 6] The rotating electric machine according to Feature 1, wherein the physical quantity sensor is a temperature sensor (62) that detects the temperature of the rotor, and the circuit module has an abnormality determination unit that determines an abnormality of the rotor based on the temperature signal detected by the temperature sensor. A rotating electric machine with this configuration is shown in Figure 10, for example.

[0179] [Feature 7] The rotor has a field winding (32) that generates field flux, and is configured such that a field current flows through the field winding due to the generation of induced power when the stator unit is energized, and includes a power transformer (210) having a primary power coil (211) and a secondary power coil (212), which generates the induced power in the secondary power coil on the rotor side when the primary power coil on the stator unit side is energized, causing a field current to flow through the field winding, and a communication transformer (80) having a primary communication coil (81) and a secondary communication coil (82), which enables the transmission of a physical quantity signal processed by the sensor signal processing unit from the secondary communication coil on the rotor side to the primary communication coil on the stator unit side. The rotating electric machine according to Feature 1, wherein on the rotor side, the power secondary coil and the communication secondary coil are arranged in an annular double arrangement, inner and outer, surrounding the rotation axis, while on the stator unit side, the power primary coil is arranged axially opposite to the power secondary coil, and the communication primary coil is arranged axially opposite to the communication secondary coil. The rotating electric machine with this configuration is a separately excited wound-field type rotating electric machine 10A. Its configuration is shown, for example, in Figure 24.

[0180] [Feature 8] The rotor has a field winding (32) that generates field flux, and is a rotating electric machine that induces a field current in the field winding by passing a harmonic current through the stator winding, and transmits the physical quantity signal, which has been signal-processed by the sensor signal processing unit, to the stator winding by superimposing the current flowing through the field winding, as described in Feature 1. The rotating electric machine with this configuration is a rotating electric machine 10 that has a self-excited winding field structure and uses the field winding 32 as a means of communication. Its configuration is shown, for example, in Figures 18 and 19.

[0181] [Feature 9] The rotor has a field winding (32) that generates field flux, and a field current flows through the field winding due to the generation of induced power when the stator unit is energized. The rotor has a primary power coil (211) and a secondary power coil (212), and a power transformer (210) is provided that generates the induced power in the secondary power coil on the rotor side when the primary power coil on the stator unit side is energized, causing a field current to flow through the field winding. The physical quantity signal processed by the sensor signal processing unit is superimposed on the energizing current flowing through the secondary power coil, thereby transmitting the physical quantity signal to the primary power coil side, as described in Feature 1. The rotating electric machine with this configuration is a rotating electric machine 10A that has an externally excited wound field structure and uses a power coil as a means of communication. Its configuration is shown, for example, in Figures 25 and 26.

[0182] [Feature 10] The rotating electric machine according to Feature 1, wherein the rotor has a rotor core (31, 251) fixed to the rotating shaft, and a plurality of field windings (32) or permanent magnets (252) housed in a plurality of housings open on both sides of the axial direction in the rotor core, the physical quantity sensor is a temperature sensor (62) for detecting the temperature of the rotor, and the temperature sensor is positioned within the housing of the rotor core. A rotating electric machine with this configuration is shown, for example, in Figures 22 and 28.

[0183] [Feature 11] A rotating electric machine (10) comprising: a stator unit (SU) including a stator (20) having stator windings (22) and a housing (11) housing the stator; a rotor (30) arranged radially opposite to the stator and capable of rotating integrally with a rotating shaft (12); the rotor having field windings (32) that generate field flux, and a field current flowing through the field windings due to electromagnetic induction between the stator unit and the rotor; the rotor is provided as a rotor module (151) to which physical quantity sensors (61, 62) for detecting physical quantities related to the rotor are assembled; a circuit module (153) including a sensor signal processing unit (63) for processing physical quantity signals detected by the physical quantity sensors is arranged at a position aligned with the rotor in the axial direction, capable of rotating integrally with the rotor; the physical quantity sensors on the rotor module side and the sensor signal processing unit on the circuit module side are electrically connected by a signal line (63) extending in the axial direction. A rotating electric machine that, on the rotor side, superimposes a physical quantity signal processed by the sensor signal processing unit onto the current flowing through the field winding, thereby wirelessly transmitting the physical quantity signal to the stator unit.

[0184] This disclosure is described in accordance with the embodiments, but it is understood that this disclosure is not limited to such embodiments or structures. This disclosure also includes various modifications and variations within the equivalence. In addition, various combinations and forms, as well as other combinations and forms that include only one, more, or fewer of those elements, fall within the scope and concept of this disclosure.

Claims

1. A method for manufacturing a rotating electric machine (10), comprising: a stator unit (SU) including a stator (20) having stator windings (22) and a housing (11) for housing the stator; and a rotor (30) arranged radially opposite to the stator and capable of rotating integrally with a rotating shaft (12), the method comprising: a first step of attaching physical quantity sensors (61, 62) for detecting physical quantities related to the rotor to the rotor; and a second step of assembling a circuit module (153) including a sensor signal processing unit (A1) for transmitting physical quantity signals detected by the physical quantity sensors to the outside of the rotor, after the attachment of the physical quantity sensors in the first step, in a manner aligned axially with the rotor and capable of rotating integrally with the rotor, wherein in the second step, a signal line (63) extending axially from the physical quantity sensor is connected to the sensor signal processing unit on the circuit module side.

2. The method for manufacturing a rotating electric machine according to claim 1, comprising the step of attaching a coil end cover (152) that covers the coil end of the rotor after the physical quantity sensor has been attached in the first step, and during the attachment, the signal wire being pulled out in the axial direction through a through hole (161a) of the coil end cover, wherein in the second step, after the coil end cover has been attached, the signal wire is connected to the sensor signal processing unit.

3. The method for manufacturing a rotating electric machine according to claim 1, comprising: a communication transformer (80) that enables wireless transmission of the physical quantity signal from the sensor signal processing unit on the rotor side to the stator unit side, a primary coil (81) of the communication transformer attached to the stator unit side, and a secondary coil (82) of the communication transformer attached to the rotor side, the circuit module including the secondary coil, the method for manufacturing a rotating electric machine according to claim 1, wherein in the second step the circuit module including the secondary coil is assembled in a position aligned with the rotor in the axial direction, and thereafter the rotor assembly (150) including the rotating shaft, the rotor and the circuit module is assembled to the stator unit with the primary coil fixed to the housing, and the secondary coil is positioned opposite the primary coil.

4. The method for manufacturing a rotating electric machine according to claim 3, wherein the second step includes: after the installation of the physical quantity sensor in the first step, assembling the circuit module in a position aligned with the rotor in the axial direction and connecting the signal line to the sensor signal processing unit; then, attaching a coil end cover (152) so as to cover the coil end of the rotor and the circuit module; and then, assembling the secondary coil on the side opposite the rotor from the axial side of the coil end cover.

5. The method for manufacturing a rotating electric machine according to any one of claims 1 to 4, wherein the rotor has a rotor core (31, 251) fixed to the rotating shaft and a plurality of field windings (32) or permanent magnets (252) housed in a plurality of housings open on both sides of the axial direction in the rotor core, the physical quantity sensor is a temperature sensor (62) for detecting the temperature of the rotor, and in the first step, the temperature sensor is mounted in a position within the housing of the rotor core.

6. The rotor has a field winding (32) that generates field flux, and is configured such that a field current flows through the field winding due to the generation of induced power when the stator unit is energized, the rotating electric machine comprises a power transformer (210) having a primary power coil (211) and a secondary power coil (212), which generates the induced power in the secondary power coil on the rotor side when the primary power coil on the stator unit side is energized, causing a field current to flow through the field winding, and a communication transformer (80) having a primary communication coil (81) and a secondary communication coil (82), which enables wireless transmission of a physical quantity signal processed by the sensor signal processing unit from the secondary communication coil on the rotor side to the primary communication coil on the stator unit side, and the circuit module includes the secondary power coil and the secondary communication coil, The method for manufacturing a rotating electric machine according to claim 1, wherein in the second step, the circuit module including the power secondary coil and the communication secondary coil is assembled in a position aligned with the rotor in the axial direction, and thereafter, the rotor assembly (150) including the rotating shaft, the rotor and the circuit module is assembled to the stator unit in which the power primary coil and the communication primary coil are fixed to the housing, and the power secondary coil and the communication secondary coil are positioned opposite the power primary coil and the communication primary coil, respectively.

7. The rotor has a field winding (32) that generates a field flux, and a field current flows through the field winding due to the generation of induced power when the stator unit is energized, and the circuit module has a signal processing module (191) including the sensor signal processing module, and a current processing module (192) including a field current processing module (A2) provided for resonance or rectification of the field current that flows through the field winding when the stator unit is energized, and in the second step, after the physical quantity sensor is installed in the first step, the signal processing module and the current processing module are assembled in a position aligned with the rotor in the axial direction, the method for manufacturing a rotating electric machine according to claim 1.

8. The method for manufacturing a rotating electric machine according to claim 1, wherein the rotor has a field winding (32) that generates a field flux, and a field current is induced in the field winding by passing a harmonic current through the stator winding, the circuit module transmits the physical quantity signal processed by the sensor signal processing unit to the stator winding by superimposing the physical quantity signal onto the current flowing through the field winding, and in the second step, the circuit module is assembled in such a state that it is aligned with the rotor in the axial direction and can rotate integrally with the rotor.

9. The rotor has a field winding (32) that generates field flux, and is configured such that a field current flows through the field winding due to the generation of induced power when the stator unit is energized, the rotating electric machine has a primary power coil (211) and a secondary power coil (212), and is equipped with a power transformer (210) that generates the induced power in the secondary power coil on the rotor side when the primary power coil on the stator unit side is energized, causing a field current to flow through the field winding, the circuit module includes the secondary power coil, and is capable of transmitting the physical quantity signal, which has been signal-processed by the sensor signal processing unit, to the primary power coil side by superimposing the current flowing through the secondary power coil, the circuit module including the secondary power coil is assembled in a position aligned with the rotor in the axial direction, The method for manufacturing a rotating electric machine according to claim 1, wherein the rotor assembly (150), including the rotating shaft, the rotor, and the circuit module, is then assembled to the stator unit with the primary power coil fixed in place, and the secondary power coil is positioned opposite the primary power coil.

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