Wound-field rotary electric machine

Abstract

In this rotary electric machine, a stator holding part (41) holds a stator. A rotor (60) has a rotor core (61) and field windings (70) wound around the rotor core, and rotates integrally with a rotating shaft (32). A circuit module (106) is provided outside the rotor in the axial direction so as to be capable of rotating integrally with the rotor, and includes a plurality of electronic components connected to the field windings. The stator holding part is provided with a cooling liquid supply part (161) in a position outside the rotor in the axial direction that supplies a cooling liquid in a direction toward the field winding side in the axial direction. In the circuit module, the plurality of electronic components are arranged in positions surrounding the rotating shaft, and the cooling liquid supplied from the cooling liquid supply part is guided in the circuit module to a position overlapping the plurality of electronic components in the axial direction or to a position radially inward of the plurality of electronic components.

Description

Wound-field type rotating electrical machine Cross-reference to related applications

[0001] This application is based on Japanese Application No. 2025-002702 filed on January 8, 2025, the contents of which are incorporated herein by reference.

[0002] The disclosure in this specification relates to a wound-field type rotating electrical machine.

[0003] In a wound-field type rotating electrical machine, the rotor includes a rotor core having a plurality of main pole portions (magnetic salient pole portions) arranged in the circumferential direction, and a field winding wound around the main pole portions. Also, a configuration is known in which a circuit module including a capacitor and a diode as electronic components is provided at a position outside the rotor in the axial direction (see Patent Document 1). In the circuit module, components such as capacitors are held by component holders. 3]

[0004] Japanese Unexamined Patent Application Publication No. 2020-124100

[0005] In the circuit module, electronic components such as capacitors generate heat when energized. Therefore, it is desirable to properly cool the circuit module.

[0006] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a wound-field type rotating electrical machine capable of properly cooling the electronic components of the circuit module.

[0007] The rotating electric machine of the present disclosure is a wound-field rotating electric machine comprising: a stator having stator windings; a stator holding part for holding the stator; a rotor having a rotor core and field windings wound around the rotor core, and rotating integrally with a rotating shaft, wherein the rotor is provided on the axially outward side and has a circuit module including a plurality of electronic components connected to the field windings; the stator holding part is provided with a coolant supply unit that supplies coolant in an axial direction toward the side of the field windings, at a position on the axially outward side of the rotor; the plurality of electronic components are arranged in a row in the circuit module at a position surrounding the rotating shaft; and the coolant supplied from the coolant supply unit is guided to a position in the circuit module that overlaps with the plurality of electronic components in the axial direction, or a position radially inward from the plurality of electronic components.

[0008] In a wound-field rotating electric machine, a configuration that includes a circuit module containing electronic components connected to the field winding requires cooling of the electronic components that generate heat when the field winding is energized. Furthermore, in the circuit module, multiple electronic components are arranged in a line surrounding the rotating shaft. In such a rotating electric machine, the coolant supplied from the coolant supply unit of the stator holding section is guided to a position that overlaps with the multiple electronic components in the axial direction, or to a position radially inward from the multiple electronic components. This allows the coolant to be supplied over a wide area from the coolant supply unit to the circuit module by the rotational centrifugal force during rotor rotation. As a result, the electronic components of the circuit module can be properly cooled.

[0009] The above-mentioned and other purposes, features and advantages of this disclosure will be further clarified by the following detailed description with reference to the attached drawings. These drawings include: Figure 1, an overall diagram of the control system of a rotating electric machine; Figure 2, a diagram showing the inverter and its surrounding configuration; Figure 3, a cross-sectional view of the rotor and stator; Figure 4, a diagram showing the electrical circuitry of the rotor; Figure 5, a perspective view showing the overall configuration of the rotor; Figure 6, a perspective view showing the rotor with the covering and coil end cover removed; Figure 7, an exploded perspective view of the rotor; Figure 8, a longitudinal cross-sectional view of the rotor; Figure 9, a perspective view of the busbar module; Figure 10, a diagram showing the internal configuration of the busbar module; Figure 11, a perspective view of the circuit module; Figure 12, a schematic diagram showing the cooling system of the rotating electric machine; Figure 13, a perspective view of the coil end cover seen from the outside; Figure 14, a perspective view of the coil end cover seen from the inside; and Figure 15, a diagram showing the coil end cover from the inside. Figure 16 is a vertical cross-sectional view showing the coil end cover attached to the rotor coil end side of the field winding; Figure 17 is a plan view of the circuit module as seen from the field winding side; Figure 18 is a cross-sectional view taken along line 18-18 of Figure 17; Figure 19 is an exploded perspective view of the circuit module; Figure 20 is a perspective view showing the three busbars assembled to the component holder; Figure 21 is a diagram showing the arrangement of each electronic component in the circuit module; Figure 22 is a diagram showing another configuration regarding the coolant flow path in the coil end cover; Figure 23 is a diagram showing another configuration regarding the coolant flow path in the coil end cover; Figure 24 is a diagram showing another configuration of the circuit module; and Figure 25 is a diagram for explaining the coolant flow path in the rotor in another example.

[0010] Hereinafter, embodiments of the wound-field 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.

[0011] First, a rotating electric machine system including a rotating electric machine 40 and a control unit will be described using Figure 1. This system comprises a DC power supply 10, an inverter 20, a control device 30, and a rotating electric machine 40. The rotating electric machine 40 is a self-excited wound-field synchronous machine. For example, the rotating electric machine 40, inverter 20, and control device 30 may be configured as an electromechanical integrated drive unit, or the rotating electric machine 40, inverter 20, and control device 30 may each be configured as separate components.

[0012] The rotating electric machine 40 comprises a housing 41 and a stator 50 and rotor 60 housed within the housing 41. The rotating electric machine 40 of this embodiment is an inner rotor type rotating electric machine in which the rotor 60 is arranged radially inward of the stator 50. The housing 41 corresponds to a stator holding part that holds the stator 50. The stator 50 comprises a stator core 51 and stator windings 52. The stator windings 52 are, for example, three-phase windings and have U, V, and W phase windings 52U, 52V, and 52W. The phase windings of each phase are arranged so as to be offset from each other by 120° in electrical angle.

[0013] The rotor 60 comprises a rotor core 61 and field windings 70. A rotating shaft 32 is assembled into the central hole of the rotor core 61. The rotating shaft 32 is rotatably supported in the housing 41 by bearings 42 and 43.

[0014] As shown in Figure 2, the inverter 20 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 52U, 52V, and 52W 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 52U, 52V, and 52W are connected at the neutral point. In other words, in this embodiment, the stator winding 52 is star-connected. However, the stator winding 52 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.

[0015] The collectors of the upper arm switches SUp, SVp, and SWp for each phase are connected to the positive terminals of the DC power supply 10. The emitters of the lower arm switches SUn, SVn, and SWn for each phase are connected to the negative terminals of the DC power supply 10. A smoothing capacitor 11 is connected in parallel to the DC power supply 10.

[0016] Next, the stator 50 and rotor 60 will be explained using Figure 3.

[0017] The stator 50 and rotor 60 are both arranged coaxially with the rotating shaft 32. In the following description, the direction in which the rotating shaft 32 extends is referred to as the axial direction, the direction extending radially from the center of the rotating shaft 32 is referred to as the radial direction, and the direction extending circumferentially with respect to the rotating shaft 32 is referred to as the circumferential direction.

[0018] The stator core 51 is made of laminated steel plates made of soft magnetic material and has an annular back yoke 51a and a plurality of teeth 51b that protrude radially inward from the back yoke 51a. A plurality of slots 54 are formed between adjacent teeth 51b, arranged in the circumferential direction. The stator windings 52 are formed by housing the phase windings of each phase in a predetermined order in each of these slots 54. For example, a segment coil structure using a plurality of conductor segments may be adopted in the stator 50. However, the structure of the stator windings 52 is arbitrary.

[0019] The rotor core 61 is made of a soft magnetic material, for example, laminated steel plates. The rotor core 61 has a cylindrical portion 61a and a plurality of main pole portions 62 that protrude radially outward from the cylindrical portion 61a. Field windings 70 are wound around the main pole portions 62 by concentrated winding. In this embodiment, eight main pole portions 62 are provided at equal intervals in the circumferential direction.

[0020] The field winding 70 comprises a first winding section 71 and a second winding section 72. The first winding section 71 is wound radially outward around each main pole section 62, and the second winding section 72 is wound radially inward from the first winding section 71. The first winding sections 71 wound around each main pole section 62 are connected in series in the circumferential order of the main pole section 62, and similarly, the second winding sections 72 are connected in series in the circumferential order of the main pole section 62. Furthermore, the series connections of the first winding sections 71 and the series connections of the second winding sections 72 are connected to each other.

[0021] In each main pole portion 62, the winding directions of the first winding portion 71 and the second winding portion 72 are the same. Furthermore, among circumferentially adjacent main pole portions 62, the winding directions of the winding portions 71 and 72 wound around one main pole portion 62 are opposite to those of the winding portions 71 and 72 wound around the other main pole portion 62. Therefore, when the field winding 70 is energized, the magnetization directions of circumferentially adjacent main pole portions 62 are opposite to each other. In the rotor 60, multiple magnetic poles (field poles) arranged in the circumferential direction are formed by each main pole portion 62 in the rotor core 61 and the field winding 70 wound around each main pole portion 62. In this embodiment, the number of turns in the second winding portion 72 is greater than the number of turns in the first winding portion 71.

[0022] Figure 4 shows an electrical circuit in the rotor 60 that includes the winding sections 71 and 72 of the field winding 70. The first winding section 71 and the second winding section 72 are connected in series by the connection of terminal B of the first winding section 71 and terminal C of the second winding section 72 to each other. In addition, a diode 81 is connected in series between terminal A of the first winding section 71 and terminal D of the second winding section 72, and a capacitor 82 is connected in parallel with the diode 81. The diode 81 is provided to allow current IL1 to flow in the first winding section 71 with the forward direction from terminal A to terminal B, and current IL2 to flow in the second winding section 72 with the forward direction from terminal C to terminal D.

[0023] Furthermore, the ends of the diode 83 are connected to terminals C and D of the second winding section 72, and a capacitor 84 is connected in parallel to the diode 83. The diode 83 is provided in the second winding section 72 to allow current IL2 to flow with the forward direction from terminal C to terminal D.

[0024] Returning to the explanation of Figure 2, the control device 30 is an electronic control unit (ECC) mainly composed of a microcontroller 31. The microcontroller 31 is equipped with a CPU (Central Processing Unit). The functions provided by the microcontroller 31 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, when the microcontroller 31 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 31 executes a program stored in a non-transitory tangible storage medium which serves as its own memory. The program includes a program for the control processing of the rotating electric machine 40. The method corresponding to the program is executed by executing a set of instructions that constitute the program. The memory is, for example, a non-volatile memory. The program stored in the memory can be updated via a communication network such as the Internet, for example, OTA (Over The Air).

[0025] The control device 30 generates drive signals to turn on and off each switch SUp to SWn that constitute the inverter 20. Specifically, the control device 30 generates drive signals to turn on and off each switch SUp to SWn in order to convert the DC power output from the DC power supply 10 into AC power and supply it to the U, V, and W phase windings 52U, 52V, and 52W, 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.

[0026] The control device 30 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 52U, 52V, and 52W of the stator winding 52. The fundamental wave current is the current that primarily generates torque in the rotating electric machine 40. The high-frequency current is the current that primarily excites each winding section 71 and 72 that constitute the field winding 70, thereby inducing a field current in the field winding 70. The phase currents flowing through each phase winding 52U, 52V, and 52W are shifted by 120° in electrical angle.

[0027] The high-frequency current flowing through the stator winding 52 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.

[0028] When a high-frequency current flows through the stator winding 52, a voltage is induced in each winding section 71, 72 of the field winding 70, causing a field current to flow. The induced voltages in each winding section 71, 72 are, for example, in the same phase. The currents IL1, IL2 flowing through each winding section 71, 72 include the frequency components of the high-frequency current.

[0029] In the electrical circuit shown in Figure 4, when the stator winding 52 is energized, the windings 71 and 72 of the field winding 70 are energized, and current flows through a closed circuit (circulation path) including the first winding 71 and the second winding 72. Furthermore, when the voltage across the second winding 72 exceeds the forward voltage of the diode 83, a current IL2 greater than the current IL1 flowing through the first winding 71 flows through the second winding 72 in the closed circuit including the second winding 72 and the diode 83. The flow of current through the closed circuit including the second winding 72 and the diode 83 increases the DC component of the field current. This increases the DC component of the magnetic flux of the rotor 60, thereby increasing the torque of the rotating electric machine 40.

[0030] Next, the configuration of the rotor 60 will be described in more detail. Figure 5 is a perspective view showing the overall configuration of the rotor 60, and Figure 6 is a perspective view showing the rotor 60 with the outer peripheral covering portion 102 and coil end covers 103 and 104 that cover the rotor main portion 101 removed. Figure 7 is an exploded perspective view of the rotor 60, and Figure 8 is a longitudinal cross-sectional view of the rotor 60.

[0031] The rotor 60 is broadly composed of a rotor main section 101, a cylindrical outer peripheral covering section 102 provided to surround the outer circumference of the rotor main section 101, coil end covers 103 and 104 attached to one axial end and the other end of the rotor main section 101, and a busbar module 105 and a circuit module 106 provided on one of the axial sides of the rotor main section 101. The rotor main section 101 comprises a rotor core 61 and field windings 70, and a rotating shaft 32 is assembled in the central hole of the rotor core 61. The field windings 70 consist of a plurality of winding units 110 arranged in a circumferential direction.

[0032] The busbar module 105 and the circuit module 106 are fixed to the rotating shaft 32 with the rotating shaft 32 inserted through their respective hollow portions. As a result, the busbar module 105 and the circuit module 106 are positioned axially opposite to the coil ends of the field winding 70. The outer peripheral covering portion 102 is constructed by using, for example, a string-like material called yarn, and winding the yarn multiple times around the outer circumference of a plurality of winding units 110 assembled on the rotor core 61.

[0033] The rotor main section 101 has a plurality of winding units 110 provided for each magnetic pole of the rotor 60. Each winding unit 110 is formed in an annular shape with its longitudinal direction in the axial direction, and is assembled to the rotor core 61 with the main pole section 62 of the rotor core 61 inserted through its hollow portion.

[0034] As shown in Figure 7, the winding unit 110 is composed of two coil modules 111 and 112 that are radially outer and radially inner when mounted on the main pole portion 62. The radially outer first coil module 111 corresponds to the first winding portion 71, and the radially inner second coil module 112 corresponds to the second winding portion 72. The first coil module 111 has two wire ends 113 drawn out in the axial direction, and the second coil module 112 has two wire ends 114 drawn out in the axial direction. In each winding unit 110 arranged in the circumferential direction, multiple first coil modules 111 are connected in series by connecting each wire end 113 to each other, and multiple second coil modules 112 are connected in series by connecting each wire end 114 to each other.

[0035] Next, the busbar module 105 and the circuit module 106 will be described. Figure 9 is a perspective view of the busbar module 105, and Figure 10 is a diagram showing the internal configuration of the busbar module 105.

[0036] As shown in Figures 9 and 10, the busbar module 105 has a main body 131 made of a resin molded body, and a central hole 132 is provided in the center of the main body. A highly rigid cylindrical member 133 made of, for example, metal is assembled into the central hole 132. The busbar module 105 is assembled to the rotating shaft 32 with the rotating shaft 32 inserted through the inner circumference of the cylindrical member 133.

[0037] The main body 131 has a plurality of busbars 134 embedded in it for electrically connecting each coil module 111, 112 for each magnetic pole. In the main body 131, each busbar 134 is arranged to extend circumferentially around the central hole 132, and both longitudinal ends of each are radially extending arm portions 134a. The arm portions 134a protrude radially outward from the outer circumferential surface of the main body 131, and their tip portions are bent in the axial direction.

[0038] The busbars 134 of the busbar module 105 include: seven busbars 134 that connect the first coil modules 111 for 8 magnetic poles in series, and seven busbars 134 that connect the second coil modules 112 for 8 magnetic poles in series. The arm portion 134a of each of these busbars 134 is connected one by one to the wire ends 113, 114 of each coil module 111, 112. In addition, the busbars 134 include busbars 134 that form the ends of the series connection of the first coil modules 111 for 8 magnetic poles, and busbars 134 that form the ends of the series connection of the second coil modules 112 for 8 magnetic poles.

[0039] Figure 11 is a perspective view showing the configuration of the circuit module 106. Figure 11 shows the configuration of the circuit module 106 as viewed from the field winding 70 side (the rotor main part 101 side) in the axial direction.

[0040] The circuit module 106 includes a component holder 141 for holding multiple electronic components and a cup-shaped case 151 for housing the component holder 141. The component holder 141 is made of a resin molded body and has a central hole 142 in its center. A highly rigid cylindrical member 143, made of, for example, metal, is assembled into the central hole 142. The component holder 141 is assembled to the rotating shaft 32 with the rotating shaft 32 inserted through the inner circumference of the cylindrical member 143.

[0041] The component holder 141 has a plurality of component housing sections 144 that house the electronic components that constitute the electrical circuit described in Figure 4. The component housing sections 144 are partitioned by partition walls 145. Multiple component housing sections 144 are provided in a circumferential direction. As a result, the component holder 141 holds electronic components such as diodes 81, 83 and capacitors 82, 84, surrounding the central hole 142. A plurality of busbars 146 are connected to each of these electronic components. The electronic components are electrically connected to the field winding 70 via the busbars 146. The connection between each electronic component and the busbars 146 constitutes the electrical circuit shown in Figure 4 in the circuit module 106.

[0042] The case 151 has a disc-shaped base plate 152 and an annular peripheral wall portion 153 provided at the outer edge portion of the base plate 152 (see FIG. 8). The case 151 is formed of, for example, an aluminum material (aluminum or an aluminum alloy). The axial end face of the base plate 152 on the side of the counter field winding (the side opposite to the main rotor portion 101) is a flat surface and is provided so as to extend in a plane perpendicular to the axial direction (see FIG. 6). A central hole 154 is provided at the center of the base plate 152. The peripheral wall portion 153 is provided so as to surround the radially outer side of the component holder 141 (see FIG. 8).

[0043] As shown in FIG. 8, in the rotor 60, the circuit module 106 is arranged in such a direction that the opening side of the cup-shaped case 151 faces the field winding 70 side. That is, the circuit module 106 is provided with electronic components (for example, capacitors 82 and 84) on the field winding 70 side with the base plate 152 of the case 151 interposed therebetween, and is attached to the rotor 60 such that the counter field winding side faces the coil end cover 103.

[0044] In the component holder 141, it is preferable that the component housing portion 144 is filled with resin. By filling with resin, each electronic component is held in a state of being buried in the resin. Thereby, even when a radial force or a circumferential force is generated in each electronic component during the rotation of the rotor 60, displacement of each electronic component is suppressed.

[0045] As shown in FIGS. 7 and 8, in the rotor 60, one of the coil end covers 103 and 104 on both axial sides houses the bus bar module 105 and the circuit module 106 inside the cover on one axial side and is provided in a state of covering the rotor coil end of the field winding 70. The other coil end cover 104 is provided on the other axial end side in a state of covering the rotor coil end of the field winding 70. The coil end covers 103 and 104 are preferably non-magnetic bodies, for example, formed of an aluminum material. The coil end covers 103 and 104 may be made of synthetic resin.

[0046] In the rotating electric machine 40 of the present embodiment, the circuit module 106 is cooled by a coolant inside the housing 41. Hereinafter, the configuration related to the cooling of the circuit module 106 will be described.

[0047] FIG. 12 is a diagram schematically showing the cooling system of the rotating electric machine 40. In FIG. 12, as described above, the stator 50 is provided on the radially outer side of the rotor 60, and the rotor 60 and the stator 50 are housed inside the housing 41. Here, the cooling structure on the circuit module 106 side of the rotating electric machine 40 is shown. In the field winding 70 of the rotor 60, the portion axially outside the rotor core 61 is the rotor coil end RE. Further, in the stator winding 52, the portion axially outside the stator core 51 is the stator coil end SE. The stator coil end SE is arranged on the radially outer side of the rotor coil end RE.

[0048] In the rotor 60 and the stator 50, the axial lengths of the rotor core 61 and the stator core 51 are the same, and the coil side portions overlapping the respective cores 61 and 51 in the radial direction in the field winding 70 and the stator winding 52 are in the same axial range.

[0049] In the rotating electric machine 40, a coolant supply portion 161 for supplying a coolant toward the rotor 60 is provided at a position axially outside the rotor 60 in the housing 41. The coolant is a liquid refrigerant such as, for example, cooling water or cooling oil. The housing 41 has a cylindrical peripheral wall portion 41a and an end plate portion 41b provided at the axial end of the peripheral wall portion 41a, and the coolant supply portion 161 is provided on the end plate portion 41b. That is, the coolant supply portion 161 is integrally provided on the end plate portion 41b of the housing 41 as a supply passage for flowing the coolant. The coolant supply portion 161 may include a coolant pipe extending from the end plate portion 41b toward the rotor 60 side.

[0050] In Figure 12, assuming that the rotating electric machine 40 is installed with the rotating shaft 32 facing horizontally, the cooling liquid supply unit 161 is provided at a position above the rotating shaft 32 on the end plate portion 41b of the housing 41. However, it is also possible to provide multiple cooling liquid supply units 161 in the circumferential direction surrounding the rotating shaft 32.

[0051] The coolant supply unit 161 takes in coolant from outside the rotating electric machine 40 and supplies the coolant in an axial direction toward the rotor 60. The housing 41 is also provided with an outlet 163 as a coolant discharge unit for discharging the coolant.

[0052] The coolant supply system that supplies coolant to the rotating electric machine 40 has a circulation passage 171 for circulating the coolant, and also has a circulation pump 172 and a heat dissipation unit 173 provided in the circulation passage 171. The circulation pump 172 is, for example, an electric pump. The heat dissipation unit 173 is, for example, a radiator that releases the heat of the coolant to the atmosphere. The coolant flows through the circulation passage 171 when the circulation pump 172 is driven.

[0053] When the rotating electric machine 40 is driven, coolant flowing in from the circulation passage 171 is supplied from the coolant supply unit 161 to the coil end cover 103 of the rotor 60. The coolant penetrates the coil end cover 103 axially and flows inside the cover. The circuit module 106 inside the coil end cover 103 is cooled by this coolant.

[0054] The cooling structure using the coil end cover 103 will be described in more detail below.

[0055] Figure 13 is a perspective view of the coil end cover 103 as seen from the outside of the cover, and Figure 14 is a perspective view of the coil end cover 103 as seen from the inside of the cover. Figure 15 is a longitudinal cross-sectional view showing the coil end cover 103 attached to the rotor coil end RE side of the field winding 70. In the following description, the capacitors and diodes of the circuit module 106 will be collectively referred to as electronic components PA.

[0056] The coil end cover 103 has an end plate portion 181 which is fixed to the rotating shaft 32, and an annular portion 182 which extends axially from the outer circumference of the end plate portion 181 and surrounds the rotor coil end RE from the radially outside. The end plate portion 181 extends radially while fixed to the rotating shaft 32, and a central hole 183 is provided in the radial center portion which penetrates in the thickness direction. The coil end cover 103 is fixed to the rotating shaft 32 by press-fitting the end plate portion 181 or by screw fastening, etc., with the rotating shaft 32 inserted through the central hole 183 of the end plate portion 181.

[0057] The annular portion 182 is formed in two stages in the axial direction and has a small-diameter portion 184 with a relatively small outer diameter and a large-diameter portion 185 with a relatively large outer diameter. The inside of the small-diameter portion 184 is a module housing portion for housing the circuit module 106, and the inside of the large-diameter portion 185 is a coil end housing portion for housing the rotor coil end RE. The large-diameter portion 185 may be assembled to the axial end of the winding unit 110 (first coil module 111).

[0058] The end plate portion 181 is provided with an annular recess 186 surrounding the central hole 183, and a plurality of inlets 187 are provided in the recess 186 at predetermined intervals in the circumferential direction. The inlets 187 are provided as a plurality of elongated holes that surround the central hole 183 and extend in the circumferential direction, at a position set back from the axial end face of the coil end cover 103 (the outer surface of the end plate portion 181). The recess 186 and the inlets 187 correspond to through-holes that penetrate the end plate portion 181 in the axial direction.

[0059] On the rotor core side of the end plate portion 181, the circuit module 106 is positioned while being housed in the small diameter portion 184. In this case, the end plate portion 181 and the circuit module 106 face each other with a gap in the axial direction. Therefore, when coolant flows into the inside of the coil end cover 103, the coolant flows through the gap space between the end plate portion 181 and the circuit module 106, and the circuit module 106 is cooled by the coolant.

[0060] Figure 16 shows the positional relationship between the inlet 187 and the electronic components PA of the circuit module 106 in the coil end cover 103. The inlet 187 is provided on the end plate portion 181 at a position that overlaps with each electronic component PA in the axial direction. In other words, the radial position of each inlet 187 is at a position that overlaps with each electronic component PA in the axial direction. Therefore, when the rotor 60 rotates, the cooling water that flows into the inside of the cover from the inlet 187 first reaches each electronic component PA, and then diffuses radially outward due to centrifugal force, cooling the circuit module 106 over a wide area. It is preferable that the inlet 187 be provided at a position radially inward from the radial center position (1 / 2 position radially) of each electronic component PA. Alternatively, the inlet 187 may be provided at a position radially inward from each electronic component PA.

[0061] Furthermore, as shown in Figures 14 and 15, an expanded chamber 188 is provided on the inside of the cover of the end plate portion 181, radially outward from the inlet 187 and at a position that overlaps with each electronic component PA in the axial direction, and is expanded toward the side away from the circuit module 106 in the axial direction. In this case, a gap space is provided between the end plate portion 181 and the circuit module 106 through which coolant can flow, and a portion of this gap space is expanded in the axial direction to form the expanded chamber 188. The expanded chamber 188 can store a larger amount of coolant than other parts between the end plate portion 181 and the circuit module 106.

[0062] Furthermore, the annular portion 182 (more specifically, the small-diameter portion 184) of the coil end cover 103 faces the radially outer peripheral portion of the circuit module 106, and the space between the annular portion 182 and the peripheral portion of the circuit module 106 forms the downstream coolant passage on the inside of the cover. In this case, on the inside of the coil end cover 103, the space between the end plate portion 181 of the coil end cover 103 and the axial end face of the circuit module 106 becomes the first flow path Y1, and the space between the annular portion 182 of the coil end cover 103 and the peripheral portion of the circuit module 106 becomes the second flow path Y2 (see Figure 15). The coolant flows along the outer surface of the circuit module 106 through these respective flow paths Y1 and Y2.

[0063] Inside the coil end cover 103, the coolant that has passed through the second flow path Y2 inside the small diameter portion 184 flows axially inside the large diameter portion 185. Then it is discharged to the outside of the cover through the discharge hole 189 provided in the large diameter portion 185 of the coil end cover 103. Inside the large diameter portion 185, the rotor coil end RE is cooled by the coolant.

[0064] Figure 15 shows the flow of coolant when the rotating electric machine 40 is driven. When coolant is supplied axially from the coolant supply unit 161 to the coil end cover 103, the inlet 187 of the coil end cover 103 guides the coolant along the path R. At this time, the coolant is guided by the inlet 187 to a position that overlaps with each electronic component PA in the axial direction. If the inlet 187 is located radially inward from the position shown in the figure, the coolant will be guided to a position radially inward from each electronic component PA of the circuit module 106.

[0065] Subsequently, the coolant flows radially through the first channel Y1 and axially through the second channel Y2 due to the centrifugal force generated by the rotation of the rotor 60. As a result, the coolant spreads over a wide area in both the radial and axial directions along the circuit module 106, efficiently cooling the circuit module 106. At this time, the coolant flowing through the first channel Y1 is temporarily stored in the expansion chamber 188. Therefore, effective heat exchange takes place in the expansion chamber 188, promoting the cooling of the electronic component PA. After that, the coolant is used to cool the rotor coil end RE and then discharged outside the coil end cover 103.

[0066] In the configuration shown in Figure 15, the end plate portion 181 of the coil end cover 103 has an annular recess 186 on the axial end face on the anti-field winding side (the upper end face in the figure), and an annular expansion chamber 188 on the axial end face on the field winding side (the lower end face in the figure). Both the recess 186 and the expansion chamber 188 are provided in an annular shape around the axis of rotation. The expansion chamber 188 is an annular recess with a larger diameter than the recess 186. The recess 186 and the expansion chamber 188 are connected to each other by an inlet 187. In this embodiment, the recess 186 corresponds to the "first recess," and the expansion chamber 188 corresponds to the "second recess." The inlet 187 corresponds to the "connecting portion."

[0067] According to the above configuration, when the rotor rotates, the coolant is temporarily stored at the inlet side of the axial end face of the end plate portion 181 on the anti-field winding side (i.e., the coolant inlet side) by the annular recess 186. Also, at the axial end face on the field winding side, the coolant is temporarily stored near the electronic component PA by the annular expansion chamber 188. At this time, since the expansion chamber 188 has a larger diameter than the recess 186, the coolant is stored in two stages during the flow process. As a result, the coolant flows properly into the cover and the electronic component PA is properly cooled.

[0068] As shown in Figure 12, the stator coil end SE of the stator winding 52 is located radially outward from the rotor coil end RE of the rotor 60. Therefore, when coolant is discharged from the discharge hole 189 provided in the annular portion 182 of the coil end cover 103, the stator coil end SE is cooled by the coolant.

[0069] When coolant flows through a first flow path Y1 between the coil end cover 103 and the axial end face of the circuit module 106, and a second flow path Y2 between the coil end cover 103 and the outer periphery of the circuit module 106, if the flow of coolant in the second flow path Y2 is obstructed, for example, the flowability of the coolant in the first flow path Y1 deteriorates, and the cooling performance of the electronic components PA decreases. Therefore, in this embodiment, as shown in Figures 13 to 15, the end plate portion 181 of the coil end cover 103 is configured to have a plurality of intermediate discharge holes 191 at predetermined intervals in the circumferential direction at a position radially outward from the plurality of electronic components PA. The intermediate discharge holes 191 are through holes that penetrate the end plate portion 181 in the axial direction, allowing coolant to be discharged axially from the end plate portion 181 of the coil end cover 103. The intermediate discharge holes 191 are provided at a position radially outward from the expansion chamber 188.

[0070] The intermediate discharge holes 191 are provided at predetermined intervals in the circumferential direction on a virtual circle centered on the axis of rotation in the end plate portion 181. As shown in Figure 16, it is preferable that the intermediate discharge holes 191 be provided in the end plate portion 181 at a position where at least a portion is radially outward from the multiple electronic components PA. As shown in Figure 15, the intermediate discharge holes 191 are provided at a position opposite in the axial direction to the second flow path Y2 between the annular portion 182 of the coil end cover 103 and the outer periphery of the circuit module 106. In particular, it is preferable that the intermediate discharge holes 191 be provided radially inward from the outer periphery of the circuit module 106, in other words, radially inward from the second flow path Y2.

[0071] The multiple intermediate discharge holes 191 do not all have to be open. In other words, some of the multiple intermediate discharge holes 191 may be closed, and only some of the intermediate discharge holes 191 may be open.

[0072] Even if the flow of coolant is obstructed in the second flow path Y2 within the coil end cover 103, the coolant flows out from the intermediate discharge hole 191, allowing the coolant to continuously flow in from the inlet 187. This enables continuous cooling of the circuit module 106.

[0073] In this embodiment, the multiple intermediate discharge holes 191 function as a balance adjustment unit that adjusts the circumferential weight balance of the rotor 60 by closing (filling) any of them. Specifically, if the center of gravity of the rotor 60 is misaligned with respect to the axis of rotation, a sealing member can be fixed to one of the multiple intermediate discharge holes 191 to suppress the misalignment of the center of gravity.

[0074] Here, the configuration of the circuit module 106 will be described in more detail. Figure 17 is a plan view of the circuit module 106 as seen from the field winding 70 side in the axial direction, and Figure 18 is a cross-sectional view taken along line 18-18 of Figure 17. Figure 19 is an exploded perspective view of the circuit module 106. The front side of Figure 17 and the lower side of Figure 18 are the field winding 70 side (rotor main section 101 side). Note that the circuit module 106 shown in Figures 17 to 19 has the same configuration as the one described in Figure 11.

[0075] In the circuit module 106, the case 151 has a disc-shaped base plate 152 as described above, and an annular peripheral wall portion 153 provided on the outer edge of the base plate 152. The base plate 152 is provided with a housing recess 155 for housing a portion of the electronic components PA (diodes 81, 83 and capacitors 82, 84) on the component placement surface of both axial sides. The housing recess 155 is provided at multiple locations (four locations in this embodiment) on the base plate 152 where the capacitors 82, 84 are placed.

[0076] In the component holder 141, the component housing section 144 is partitioned by partition walls 145, and is capable of holding electronic components PA at least in the circumferential direction. Each component housing section 144 penetrates in the axial direction. Each electronic component PA is housed in the component housing section 144 in contact with the base plate 152 of the case 151. In this case, the electronic components PA, namely diodes 81, 83 and capacitors 82, 84, have different axial thickness dimensions (height dimensions), but all electronic components PA are positioned in the component housing section 144 close to the base plate 152. As described above, the base plate 152 is provided with housing recesses 155, and the capacitors 82, 84 are housed within the component housing sections 144 that penetrate in the axial direction, with their ends on the base plate 152 side housed within the housing recesses 155 (see Figure 18).

[0077] The electronic components PA, namely diodes 81 and 83 and capacitors 82 and 84, each have a roughly rectangular shape with two opposing wide surfaces, and are arranged so that the wide surfaces of each electronic component PA face the base plate 152. In this case, the base plate 152 is provided with housing recesses 155 at the locations where the capacitors 82 and 84 are to be placed, and the capacitors 82 and 84 are arranged so that their wide surfaces fit into the housing recesses 155.

[0078] In the circuit module 106, each electronic component PA is housed in the component holder 141, ensuring proper positioning of each electronic component PA within the case 151 and suppressing unintended misalignment of each electronic component PA. Furthermore, because parts of the capacitors 82 and 84 are embedded in the housing recess 155 of the base plate 152, the capacitors 82 and 84 act as anchors, suppressing the undesirable behavior of the component holder 141 rotating circumferentially relative to the case 151.

[0079] The component housing section 144 includes a component housing section 144A for housing diodes 81 and 83, and a component housing section 144B for housing capacitors 82 and 84. Each of these component housing sections 144A and 144B is sized according to the dimensions of the diodes 81 and 83 and the capacitors 82 and 84, respectively. The component housing section 144A for diodes has a partition wall 145 that can hold the diodes 81 and 83 in the circumferential direction, and a partition section 147 that separates the circumferential wall 153 of the case 151 from the diodes 81 and 83 in the radial direction. In contrast, the component housing section 144B for capacitors has a partition wall 145 that can hold the capacitors 82 and 84 in the circumferential direction, but does not have a partition section that separates the circumferential wall 153 from the capacitors 82 and 84 in the radial direction.

[0080] The difference between component housings 144A and 144B lies in the difference in size between the diodes 81 and 83 and the capacitors 82 and 84. Since the diodes 81 and 83 are smaller in plan view (size of the wide surface shown in Figure 17) than the capacitors 82 and 84, they are positioned offset inward from the outer circumference of the component holder 141. For this reason, a partition 147 is provided on the radially outer side of the component housing 144A for the diodes.

[0081] On the other hand, the component housing section 144B for the capacitors does not have a radially outer partition, and the radially outermost position of the capacitors 82 and 84 is approximately the same as the outer circumference of the component holder 141. In this case, the capacitors 82 and 84 can contact the peripheral wall 153 of the case 151 in the radial direction. Therefore, heat dissipation from the capacitors 82 and 84 to the case 151 is improved.

[0082] The circuit module 106 has three busbars 146. Figure 20 is a perspective view showing the three busbars 146 assembled in the component holder 141. Here, the three busbars 146 are referred to as busbars 146_1, 146_2, and 146_3. Of the busbars 146_1 to 146_3, busbar 146_1 is a wiring member that connects diode 81 and capacitor 82 to terminal A of the first winding section 71 in Figure 4. Busbar 146_2 is a wiring member that connects diode 83 and capacitor 84 to terminal B of the first winding section 71 and terminal C of the second winding section 72. Busbar 146_3 is a wiring member that connects diodes 81 and 83 and capacitors 82 and 84 to terminal D of the second winding section 72.

[0083] Each busbar 146 has a base portion 146a extending in the circumferential direction, and a first connecting portion 146b and a second connecting portion 146c extending axially from the base portion 146a. The first connecting portion 146b is the portion connected to each electronic component PA, and the second connecting portion 146c is the portion connected to the coil-side busbar (specifically, the busbar 134 extending from the busbar module 105) extending from the field winding 70 side. The first connecting portion 146b corresponds to the "component connection portion".

[0084] The component holder 141 is provided with a busbar housing section 148 for housing the busbar 146, located radially inward of the component housing sections 144 arranged in the circumferential direction. The busbar housing section 148 is provided in an annular shape radially outward of the boss section 149, which is the radial center. The boss section 149 has a polygonal shape (hexagonal in this embodiment) with the same number of sides as the number of electronic components PA arranged in the circumferential direction in the circuit module 106. The base portion 146a of the busbar 146 has a straight portion for each side of the boss section 149 that faces each electronic component PA, and these straight portions are connected to the electronic components PA via the first connection portion 146b.

[0085] Each busbar 146 is housed in the busbar housing 148 with its first connection portion 146b connected to the connection terminal of each electronic component PA by welding, adhesive, or the like. Figure 18 shows the state in which the connection terminal 84a of the capacitor 84 is connected to the first connection portion 146b of the busbar 146_2.

[0086] When each busbar 146 is housed in the busbar housing portion 148 of the component holder 141, each busbar 146 is positioned radially inward of a plurality of electronic components PA arranged in the circumferential direction. More specifically, the base portion 146a of each busbar 146 is positioned (within the thickness range) between the two wide surfaces of each electronic component PA in the axial direction, and the first connecting portion 146b is provided so as not to protrude from the component holder 141 in the axial direction. In this case, each busbar 146 is connected to the electronic components PA within the same plane on which the plurality of electronic components PA are arranged. Therefore, compared to a configuration in which, for example, the busbars 146 are positioned to overlap the plurality of electronic components PA in the axial direction, it is possible to reduce the axial length of the circuit module 106. In addition, because the busbars 146 do not protrude from the component holder 141, interference between the busbars 146 and other components is suppressed.

[0087] Furthermore, as shown in Figure 19, the base plate 152 is provided with a plurality of through holes 156 that penetrate in the thickness direction (axial direction). The through holes 156 open to the axial end face of the base plate 152 on the side of the anti-field winding. The second connecting portion 146c, which extends axially in each busbar 146, is inserted through the through holes 156. The through holes 156 serve as connection spaces for connecting the second connecting portion 146c of each busbar 146 to the busbar 134 of the busbar module 105 (busbars connected to both ends of each winding portion 71, 72 in Figure 4) by welding or the like.

[0088] In this case, when the circuit module 106 is assembled to the assembly including the rotating shaft 32, rotor core 61, and field winding 70, the second connection portion 146c of each busbar 146 in the circuit module 106 and the busbar 134 of the busbar module 105 are inserted through the through hole 156 of the base plate 152. In this state, welding (connection) work is performed between the busbar 146 of the circuit module 106 and the busbar 134 of the busbar module 105 from the side of the anti-field winding of the circuit module 106.

[0089] As shown in Figure 17, in the circuit module 106, diodes and capacitors are arranged at point-symmetrical positions on both sides of the axis AX within a virtual plane perpendicular to the axial direction of the rotation axis 32. In other words, the component holder 141 of the circuit module 106 is configured so that identical electronic components PA are arranged at symmetrical positions on both sides of the axis AX. This ensures that the weight balance of the circuit module 106 is maintained in the circumferential direction. In a broader sense, it is preferable that multiple electronic components PA be arranged at point-symmetrical positions on both sides of the axis AX within a virtual plane perpendicular to the axial direction of the rotation axis 32.

[0090] Furthermore, in the circuit module 106, the multiple electronic components PA arranged in the circumferential direction are positioned such that the center of gravity of each electronic component PA lies on a virtual circle centered on the axis AX of the rotation axis 32. In Figure 19, the virtual circle CR, shown by the dashed line, is a circle that passes through the center of gravity of each electronic component PA. In this case, the distance between the center of gravity AX of each electronic component PA and the axis AX of the rotation axis 32 is equal.

[0091] Furthermore, the multiple electronic components PA include electronic components PA whose wide surfaces, which are the opposing surfaces facing the base plate 152, have different dimensions. The size of the wide surface is defined by the linear dimensions of the length and width in a plan view of the electronic component PA. For example, diodes 81 and 83 have smaller length and width dimensions than capacitors 82 and 84. In the circuit module 106, electronic components PA with smaller wide surfaces (diodes 81 and 83) are positioned so that their radially outer portions are located radially inward compared to electronic components PA with larger wide surfaces (capacitors 82 and 84). In this case, since interference between adjacent electronic components PA in the circumferential direction is less likely to occur with electronic components PA with smaller wide surfaces, it is possible to position them closer to the radial center.

[0092] In addition, unlike the configuration in Figure 17, it is also possible to configure the circuit module 106 such that the electronic components PA (diodes 81, 83) with smaller wide surfaces are positioned radially inward compared to the electronic components PA (capacitors 82, 84) with larger wide surfaces.

[0093] As shown in Figure 21, in the circuit module 106, the multiple electronic components PA (diodes 81, 83 and capacitors 82, 84) may be arranged in positions that are symmetrical on both sides of a straight line passing through the axis AX in a virtual plane perpendicular to the axial direction of the rotation axis 32. Specifically, each electronic component PA may be arranged in positions that are symmetrical on both sides of a straight line L1. Alternatively, each electronic component PA may be arranged in positions that are symmetrical on both sides of a straight line L2.

[0094] According to the embodiment described in detail above, the following excellent effects can be obtained.

[0095] In the rotating electric machine 40, the coolant supplied from the coolant supply unit 161 of the housing 41 is guided to a position that overlaps with multiple electronic components PA in the axial direction, or to a position that is radially inward from the multiple electronic components PA. As a result, when the rotor 60 rotates, the rotational centrifugal force allows the coolant to be supplied over a wide area from the coolant supply unit 161 to the circuit module 106. Consequently, the electronic components PA of the circuit module 106 can be properly cooled.

[0096] The coolant supplied from the coolant supply unit 161 is guided to the inside of the coil end cover 103 through the inlet 187 (through-hole) and then circulated radially outward through the gap space between the end plate portion 181 and the circuit module 106. In this configuration, the entire axial end face of the circuit module 106 can be effectively cooled.

[0097] In the coil end cover 103, an expansion chamber 188 is provided at the end plate portion 181, in a position that overlaps with the electronic component PA in the axial direction, and is extended away from the circuit module 106 in the axial direction. In this case, a larger amount of coolant is stored in the expansion chamber 188 than in other parts, which allows for proper cooling of the electronic component PA.

[0098] In the end plate portion 181, an annular recess 186 (first recess) is provided on the axial end face on the anti-field winding side, and an annular expansion chamber 188 (second recess) with a larger diameter than the recess 186 is provided on the axial end face on the field winding side, and these recesses are connected by an inlet 187. This configuration allows for proper flow of coolant into the cover and proper cooling of the electronic component PA.

[0099] The coil end cover 103 is configured to circulate coolant through a first flow path Y1 between it and the axial end face of the circuit module 106, and a second flow path Y2 between it and the outer periphery of the circuit module 106. This makes it possible to improve the cooling performance of the circuit module 106.

[0100] In the end plate portion 181 of the coil end cover 103, an intermediate discharge hole 191 is provided that penetrates axially at a position radially outward from the multiple electronic components PA. This configuration suppresses the inconvenience of reduced coolant flow in the first channel Y1 due to stagnation of coolant flow in the second channel Y2 inside the coil end cover 103, which in turn reduces the cooling performance of the electronic components PA.

[0101] Multiple intermediate discharge holes 191 provided in the end plate portion 181 of the coil end cover 103 are configured to function as a balance adjustment section for adjusting the rotational balance. In this configuration, the intermediate discharge holes 191 of the coil end cover 103 can achieve both the function of releasing the coolant to the outside of the cover to suppress a decrease in the flowability of the coolant, and the function of adjusting the weight balance of the rotor 60.

[0102] The circuit module 106 is configured such that multiple electronic components are arranged on the side of the base plate 152, which extends in a direction perpendicular to the axial direction, on the side facing the field winding 70 (the side facing the rotor main section 101). As a result, in the circuit module 106, the heat generated by each electronic component is released through the base plate 152 to the side opposite to the field winding 70. Therefore, excessive temperature rise of the electronic components can be appropriately suppressed.

[0103] In the circuit module 106, a cup-shaped case 151 opens towards the field winding 70, and multiple electronic components are arranged radially inward on the peripheral wall portion 153 of the case 151. In this configuration, even if centrifugal force acts on the electronic components due to the rotation of the rotor 60, the peripheral wall portion 153 of the case 151 can suppress the radially outward movement of the electronic components.

[0104] The component holder 141 of the circuit module 106 is provided with a component housing section 144, and the electronic components are arranged in a circumferential direction, and the electronic components are held in place at least in the circumferential direction. This allows for proper positioning of the electronic components within the case 151. Furthermore, the position of the electrical components can be properly maintained even when the rotation of the rotor 60 is accelerating or decelerating.

[0105] In the component holder 141, the component housing section 144 penetrates axially, and the electronic components are housed within the component housing section 144 while in contact with the base plate 152. As a result, the electronic components are properly held in the component holder 141 while heat is suitably dissipated through the base plate 152 of the case 151.

[0106] The base plate 152 of the case 151 is configured to have a housing recess 155 on the component placement surface on both axial sides where electronic components are arranged, which accommodates a portion of the electronic components. This restricts the movement of electronic components arranged on the component placement surface of the base plate 152, thereby suppressing problems such as the component holder 141 rotating in the circumferential direction. In addition, the area in which the base plate 152 and the electronic components face each other increases, improving heat dissipation.

[0107] The component holder 141 has partition walls 145 in the component housing section 144 that allow electronic components to be held in the circumferential direction, but does not have partitions that separate the peripheral wall 153 of the case 151 from the electronic components (capacitors) in the radial direction. As a result, the capacitor can contact the peripheral wall 153 of the case 151 in the radial direction, improving heat dissipation from the capacitor to the case 151. Furthermore, this configuration allows for a reduction in the radial dimensions of the circuit module 106.

[0108] The component holder 141 has a busbar housing section 148 for housing a busbar 146 located radially inward of a component housing section 144 that houses multiple electronic components. In this case, since the busbar 146 is positioned radially inward of the multiple electronic components arranged to surround the rotating shaft 32 in the component holder 141 (i.e., busbar connection is possible within the same plane as the multiple electronic components), the axial length of the circuit module 106 can be reduced compared to, for example, a configuration in which the busbar 146 is positioned to overlap the multiple electronic components in the axial direction, thereby contributing to the miniaturization of the rotating electric machine 40.

[0109] In the circuit module 106, multiple electronic components have two opposing wide surfaces, and the electronic components are arranged so that the wide surfaces face the base plate 152. This configuration increases the heat dissipation area from the electronic components to the case 151, thereby improving heat dissipation performance. Furthermore, the base portion 146a of the busbar 146 is positioned between the two wide surfaces of the electronic components in the axial direction (within the thickness range of the electronic components), and the first connection portion 146b (component connection portion) is provided so as not to protrude from the component holder 141 in the axial direction. This prevents the busbar 146 from interfering with other components.

[0110] In the circuit module 106, capacitors and diodes are arranged at point-symmetrical positions on either side of the axis within a virtual plane perpendicular to the axial direction of the rotation axis 32. This configuration ensures circumferential weight balance in the circuit module 106 and equalizes centrifugal force in the circumferential direction.

[0111] In the circuit module 106, multiple electronic components are arranged in positions that are point-symmetrical on both sides of the axis within a virtual plane perpendicular to the axial direction of the rotation axis 32, or in positions that are line-symmetrical on both sides of a straight line passing through the axis. This ensures that the circumferential weight balance of the circuit module 106 is achieved, and the centrifugal force is equalized in the circumferential direction.

[0112] In the circuit module 106, electronic components with smaller wide surfaces are arranged such that their radially outer portions or their center of gravity are located radially inward compared to electronic components with larger wide surfaces. In this configuration, the electronic components in the circuit module 106 are positioned as radially inward as possible, thereby suppressing the effects of centrifugal force during rotor rotation.

[0113] (Other Embodiments) The above embodiments may be modified as follows, for example.

[0114] - The configuration of the through-hole in the end plate portion 181 of the coil end cover 103 may be changed as shown in Figure 22. As shown in Figure 22, the end plate portion 181 is provided on the anti-field winding side with an inflow passage 201 that opens to the axial end face and extends radially. The inflow passage 201 consists of a recess 186 that opens to the axial end face and a radial passage 202 that extends radially from the recess 186. The radial passage 202 is provided at multiple locations in the circumferential direction. An expansion chamber 188 is also provided so as to be connected to the radial passage 202. In this configuration, the inflow passage 201 corresponds to the upstream portion of the through-hole, and the expansion chamber 188 corresponds to the downstream portion of the through-hole. The radial passage 202 also corresponds to a "connecting portion" that connects the recess 186 (first recess) and the expansion chamber 188 (second recess).

[0115] According to the above configuration, the coolant flows radially outward through the inflow passage 201 at the end plate portion 181 of the coil end cover 103. The coolant is then temporarily stored in the radially outward region of the expansion chamber 188, and then flows downstream through the gap between the coil end cover 103 and the circuit module 106 (flow paths Y1, Y2). Here, the radial passage 202 is provided in a direction that extends radially, so that the coolant can be suitably guided into the expansion chamber 188 even when the rotor 60 is rotating at high speed. As a result, the coolant can be suitably introduced into the expansion chamber 188 when the rotor is rotating, and the cooling performance of the electronic component PA can be improved.

[0116] As shown in Figure 23, a protrusion 203 may be provided on the surface of the circuit module 106 facing the end plate portion 181. The protrusion 203 should have a height that allows it to fit into the expansion chamber 188 of the end plate portion 181. The protrusion 203 may be an annular shape extending in the circumferential direction or a plurality of fragmentary arc shapes in a plan view from the axial direction, or a plurality of fins extending radially. This promotes heat exchange between the coolant and the circuit module 106 within the expansion chamber 188.

[0117] Figure 24 is a plan view of the circuit module 106 as seen from the anti-field winding side in the axial direction. As shown in Figure 24, the case 151 of the circuit module 106 is provided with a plurality of protrusions 211 on the outer surface of the peripheral wall portion 153. The protrusions 211 are elongated and extend radially outward from the peripheral wall portion 153. The protrusions 211 are provided so that their longitudinal direction extends axially or obliquely to the axial direction. In this case, coolant is guided along the protrusions 211 on the radially outer side of the circuit module 106. Furthermore, the protrusions 211 in the circuit module 106 can increase the strength of the case 151.

[0118] Furthermore, the protruding portion 211 ensures a predetermined gap between the annular portion 182 of the coil end cover 103 and the outer circumference of the circuit module 106 along the entire radially outer circumference of the circuit module 106. As a result, the second flow path Y2 can be provided evenly in the circumferential direction on the outer circumference of the circuit module 106. In other words, if the circuit module 106 is biased radially in either direction inside the cover, there is a concern that the second flow path Y2 may be locally compressed, but this inconvenience can be suppressed. This allows for proper cooling of the circuit module 106.

[0119] As shown in Figure 24, the circuit module 106 may be configured to have a plurality of fins 212 extending radially outward from the axial end face on the anti-field winding side. This allows for efficient heat exchange with the coolant in the case 151.

[0120] Furthermore, the fins 212 can suppress the localized collapse of the gap (first flow path Y1) between the coil end cover 103 and the axial end face of the circuit module 106 on the anti-field winding side. This allows for proper cooling of the circuit module 106.

[0121] In the above embodiment, the circuit module 106 has a case 151 having a disc-shaped base plate 152 and an annular peripheral wall portion 153, but this can be changed. The case 151 may not have a peripheral wall portion 153, and a plurality of electronic components PA may be arranged on the side of the axial surface of the base plate 152 that faces the field winding 70. Each electronic component PA may be fixed to the base plate 152 with an adhesive or the like.

[0122] The circuit module 106 may be configured without a component holder 141. In this case, it is preferable that the case 151 has projections on the winding field side for positioning each electronic component PA.

[0123] As shown in Figure 25, it is also possible to have a configuration in the rotor 60 that does not have a coil end cover 103. In this configuration, when coolant is supplied axially from the coolant supply unit 161, the coolant is guided to a position on the axial end face of the circuit module 106 that overlaps with each electronic component PA in the axial direction, or to a position that is radially inward from each electronic component PA. Then, the coolant flows radially in the flow path Y11 due to the centrifugal force generated as the rotor 60 rotates. As a result, the coolant spreads over a wide area along the circuit module 106, and the circuit module 106 is cooled efficiently.

[0124] - The number of electronic components PA installed in the circuit module 106 can be changed. In this case, it is preferable that each of the multiple electronic components PA in the circuit module 106 includes two or more diodes and capacitors.

[0125] The field winding 70 is not limited to a configuration comprising a first winding section 71 and a second winding section 72. For example, the field winding 70 may be configured such that each winding section for each main pole section 62 is connected in series without being divided into first and second winding sections 71 and 72, and diodes are connected to both ends of the field winding 70, or diodes and capacitors are connected in parallel.

[0126] - In the stator 50, the stator core may be a stator core without teeth.

[0127] The rotating electric machine is not limited to those used as vehicle-mounted main engines; for example, it may also be a rotating electric machine used as an ISG (Integrated Starter Generator), which is both an electric motor and a generator.

[0128] 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.

[0129] 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.

[0130] According to the embodiments described above, the following characteristic configurations can be extracted for the rotor 60 equipped with the circuit module 106.

[0131] [Feature 1] A rotor (60) comprising: a rotor core (61) fixed to a rotating shaft (32); a field winding (70) wound around the rotor core; and a circuit module (106) including a plurality of electronic components connected to the field winding, wherein the circuit module is provided on the axial side of the field winding, and the circuit module has a base plate (152) extending in a direction perpendicular to the axial direction, and the plurality of electronic components are arranged on the side of the base plate facing the field winding.

[0132] The rotor's circuit module is configured such that multiple electronic components are arranged on the field winding side of the axial direction on a base plate extending in a direction perpendicular to the axial direction. This allows heat generated by each electronic component in the circuit module to be released through the base plate to the side opposite the field winding. Therefore, excessive temperature rise of the electronic components can be appropriately suppressed.

[0133] For example, Japanese Patent Publication No. 5724843 describes a rotating electric machine comprising an end plate provided to cover the coil ends of a coil at the axial end of a rotor, and a diode fixed to the axial outer surface of a mounting plate connected to the coil and provided to rotate with the rotor, wherein a heat insulating layer is provided between the end plate covering the rotor coil and the mounting plate.

[0134] However, in the rotating electric machine described in the above-mentioned publication, the diode is fixed to the axially outer surface of a mounting plate that rotates with the rotor. Therefore, the heat generated by the diode is released to the coil end side of the coil via the mounting plate. In the configuration of this embodiment, unlike the technology described in the above-mentioned publication, the heat generated by each electronic component in the circuit module is released to the opposite side of the field winding via the base plate. Therefore, compared to the configuration described in the above-mentioned document, excessive temperature rise of the electronic components can be appropriately suppressed.

[0135] [Feature 2] The rotor according to Feature 1, wherein the circuit module comprises a case (151) having a base plate and a peripheral wall portion (153) that extends axially from the base plate toward the field winding and is annular in shape, and the plurality of electronic components are arranged radially inward of the peripheral wall portion in the case. [Feature 3] The rotor according to Feature 2, wherein the circuit module comprises the case and a component holder (141) provided in the case for holding the plurality of electronic components, and the component holder has a component housing portion (144) that houses the electronic components arranged in a circumferential direction and in a state that can hold the electronic components at least in the circumferential direction. [Feature 4] The rotor according to Feature 3, wherein the component housing portion penetrates the component holder axially, and the electronic components are housed in the component housing portion in contact with the base plate. [Feature 5] The rotor according to Feature 4, wherein the base plate is provided with a housing recess (155) for housing a part of the electronic component on the component placement surface on both axial sides of the base plate. [Feature 6] The rotor according to any one of Features 3 to 5, wherein the component housing portion of the component holder has a partition wall (145) that can hold the electronic component in the circumferential direction, but does not have a partition portion that separates the circumferential wall portion of the case from the electronic component in the radial direction. [Feature 7] The rotor according to any one of Features 3 to 5, wherein the electronic component is electrically connected to the side of the field winding via a busbar (146), and the component holder has a busbar housing portion (148) for housing the busbar on the radially inner side of the component housing portion that houses the plurality of electronic components.[Feature 8] The rotor according to Feature 7, wherein the plurality of electronic components each have two opposing wide surfaces, and the wide surfaces are arranged in a direction facing the base plate of the case, and the busbar is arranged radially inward of the plurality of electronic components arranged in the circumferential direction, and has a base portion (146a) extending in the circumferential direction, and a component connection portion (146b) extending axially from the base portion and connected to each of the electronic components, the base portion is positioned in the axial direction between the two wide surfaces of the electronic components, and the component connection portion is provided so as not to protrude from the component holder in the axial direction. [Feature 9] The rotor according to any one of Features 3 to 5, wherein in the circuit module, the plurality of electronic components each include two or more diodes (81, 83) and capacitors (82, 84), and the diodes and capacitors are arranged point-symmetrically on both sides of the axis in a virtual plane perpendicular to the axial direction of the rotation axis. [Feature 10] The rotor according to any one of Features 3 to 5, wherein in the circuit module, the plurality of electronic components are arranged at positions that are point-symmetric with respect to the axis on both sides of the axis in a virtual plane perpendicular to the axial direction of the rotation axis, or at positions that are line-symmetric with respect to a straight line passing through the axis. [Feature 11] The rotor according to any one of Features 3 to 5, wherein the plurality of electronic components have two opposing wide surfaces, the wide surfaces are arranged in a direction facing the base plate of the case, and the wide surfaces are of different sizes, wherein in the circuit module, the electronic component with the smaller wide surface is arranged such that the position of its radially outer portion or its center of gravity is radially inward compared to the electronic component with the larger wide surface.

Claims

1. A wound-field rotating electric machine (40) comprising: a stator (50) having stator windings (52); a stator holding part (41) that holds the stator; a rotor (60) having a rotor core (61) and field windings (70) wound around the rotor core, and rotating integrally with a rotating shaft (32), wherein the rotor has a circuit module (106) provided on the axially outward side and including a plurality of electronic components connected to the field windings; the stator holding part is provided with a coolant supply part (161) that supplies coolant in an axial direction toward the side of the field windings; the plurality of electronic components are arranged in a line in the circuit module at positions surrounding the rotating shaft; and the coolant supplied from the coolant supply part is guided to a position in the circuit module that overlaps with the plurality of electronic components in the axial direction, or a position radially inward from the plurality of electronic components.

2. The rotor has a coil end cover (103) that covers the coil ends of the field winding that are axially outward from the rotor core, the coil end cover has an end plate portion (181) fixed to the rotating shaft and extending radially, and an annular portion (182) extending axially from the outer circumference of the end plate portion and surrounding the coil ends of the field winding from the radially outward, the end plate portion has a through portion that penetrates in the axial direction, the coolant supplied from the coolant supply portion is guided through the through portion to a position that overlaps with the plurality of electronic components in the axial direction, or to a position that is radially inward from the plurality of electronic components, and then flows radially outward from the gap space between the end plate portion and the circuit module, the wound-field rotating electric machine according to claim 1.

3. The end plate portion is provided with an expanded chamber (188) that extends axially away from the circuit module, at a position radially outward from the coolant inlet (187) in the through-hole and overlapping with the electronic component in the axial direction, the wound-field type rotating electric machine according to claim 2.

4. The end plate portion is provided with an inflow passage (201) that opens to the axial end face on the side of the anti-field winding and extends radially, as the upstream portion of the through-hole, and an expansion chamber (188) that expands toward the side away from the circuit module in the axial direction and leads to the inflow passage, as the downstream portion of the through-hole.

5. The end plate portion is provided with an annular first recess (186) on the axial end face on the side of the anti-field winding, centered on the rotation axis, and a second recess (188) is provided on the axial end face on the side of the field winding, which is annular around the rotation axis and has a larger diameter than the first recess, and the through portion is formed by the first recess, the second recess and connecting portions (187, 202) connecting the respective recesses, as described in claim 2.

6. The wound-field rotating electric machine according to any one of claims 2 to 5, wherein the annular portion of the coil end cover faces the radially outer outer portion of the circuit module, and the space between the annular portion and the outer portion of the circuit module is a coolant passage downstream of the coolant passage between the end plate portion and the circuit module.

7. The end plate portion is provided with an intermediate discharge hole (191) that penetrates axially and allows for the discharge of coolant, located radially outward from the plurality of electronic components, as described in claim 6.

8. The end plate portion is provided with a plurality of intermediate discharge holes at predetermined intervals in the circumferential direction on a virtual circle centered on the rotation axis, and the plurality of intermediate discharge holes function as a balance adjustment unit that adjusts the circumferential balance of the rotor by filling any one of them, as described in claim 7.

9. The wound-field rotating electric machine according to claim 6, wherein the circuit module comprises a component holder (141) for holding the electronic component and a case (151) for housing the component holder, the case having an annular peripheral wall portion (153) provided on the radially outer side of the case, the electronic component being housed radially inside the peripheral wall portion, and a protruding portion (211) extending axially or obliquely with respect to the axial direction is provided on the outer surface of the peripheral wall portion.

10. The wound-field rotating electric machine according to claim 1, wherein the circuit module has a base plate (152) extending in a direction perpendicular to the axial direction, and the plurality of electronic components are arranged on the side of the field winding among the axial surfaces on both sides of the base plate.

11. The wound-field rotating electric machine according to claim 10, wherein the circuit module comprises a case (151) having a base plate and a peripheral wall portion (153) that extends axially from the base plate toward the field winding and is annular in shape, and the plurality of electronic components are arranged radially inward of the peripheral wall portion in the case.

12. The wound-field rotating electric machine according to claim 11, wherein the circuit module comprises the case and a component holder (141) provided within the case for holding the plurality of electronic components, and the component holder has a component housing section (144) for housing the electronic components in a manner that allows the electronic components to be arranged in a circumferential direction and to be held in at least the circumferential direction.

13. The wound-field type rotating electric machine according to claim 12, wherein the component holder has a component housing portion that penetrates in the axial direction, and the electronic component is housed in the component housing portion in contact with the base plate.

14. The winding field type rotating electric machine according to claim 13, wherein the base plate is provided with a housing recess (155) for housing a part of the electronic components on the component arrangement surface among the axial surfaces on both sides.

15. The wound-field rotating electric machine according to any one of claims 12 to 14, wherein the component holder has a partition wall (145) that can hold the electronic component in the circumferential direction, but does not have a partition that separates the circumferential wall of the case from the electronic component in the radial direction.

16. The wound-field rotating electric machine according to any one of claims 12 to 14, wherein the electronic component is electrically connected to the field winding side via a busbar (146), and the component holder has a busbar housing portion (148) for housing the busbar on the radially inward side of the component housing portion for housing the plurality of electronic components.

17. The wound-field rotating electric machine according to claim 16, wherein the plurality of electronic components have two opposing wide surfaces, and the wide surfaces are arranged in a direction facing the base plate of the case, and the busbar is arranged radially inward of the plurality of electronic components arranged in the circumferential direction, and has a base portion (146a) extending in the circumferential direction, and a component connection portion (146b) extending axially from the base portion and connected to each of the electronic components, the base portion is positioned in the axial direction between the two wide surfaces of the electronic components, and the component connection portion is provided so as not to protrude from the component holder in the axial direction.

18. The wound-field rotating electric machine according to any one of claims 12 to 14, wherein in the circuit module, each of the plurality of electronic components includes two or more diodes (81, 83) and capacitors (82, 84), and the diodes and capacitors are arranged at point-symmetric positions on both sides of the axis in a virtual plane perpendicular to the axial direction of the rotation axis.

19. The wound-field rotating electric machine according to any one of claims 12 to 14, wherein in the circuit module, the plurality of electronic components are arranged at positions that are point-symmetric with respect to the axis on both sides of the axis in a virtual plane perpendicular to the axial direction of the rotation axis, or at positions that are line-symmetric with respect to a straight line passing through the axis on both sides.

20. The wound-field rotating electric machine according to any one of claims 12 to 14, wherein the plurality of electronic components have two opposing wide surfaces, and the wide surfaces are arranged in a direction facing the base plate of the case, and the electronic components include components of different sizes, wherein in the circuit module, the electronic components with smaller wide surfaces are arranged such that the position of the radially outer portion or the center of gravity is radially inward compared to the electronic components with larger wide surfaces.

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