CN111512523B

CN111512523B - Rotating electrical machine and method for manufacturing rotating electrical machine

Info

Publication number: CN111512523B
Application number: CN201880083917.9A
Authority: CN
Inventors: 高桥裕树
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 2017-12-28
Filing date: 2018-12-27
Publication date: 2022-07-19
Anticipated expiration: 2038-12-27
Also published as: CN111512523A; JP7010204B2; JP2019122250A

Abstract

The rotating electrical machine (400) includes a field element (410) and an armature (420). The armature winding (421) has lead portions (423) that are arranged at predetermined intervals in the circumferential direction at positions facing the field element (410). The base member (422) and the armature winding (421) are covered with a resin member (1001) in a state where the armature winding is wound around the base member (422), thereby constituting an armature (420). In a resin member (1001), a plurality of gates (1002) into which resin flows at the time of resin molding of the resin member (1001) are provided at equal intervals in the circumferential direction at the same positions in the axial direction and the radial direction.

Description

Rotating electrical machine and method for manufacturing rotating electrical machine

Citation of related applications

The present application is based on japanese patent application No. 2017-255060 applied on 12/28/2017 and japanese patent application No. 2018-240700 applied on 12/25/2018, the contents of which are incorporated herein by reference.

Technical Field

The present invention relates to a rotating electrical machine and a method of manufacturing the rotating electrical machine.

Background

Conventionally, as described in, for example, patent document 1, there is known a rotating electric machine applied to home appliances, industrial machines, game machines, agricultural machines, and automobiles. Generally, a stator winding is configured such that winding housing portions defined by pole teeth, so-called slots, are formed in a stator core (i.e., a core), and conductive wires such as copper wires and aluminum wires are housed in the slots. On the other hand, a slot-less motor in which pole teeth of a stator are removed has also been proposed (for example, patent document 1).

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 6-70522

Disclosure of Invention

In the above-described slot-less motor, in order to fix the stator winding to the stator core, resin molding (resin molding) is generally performed so as to cover the entire stator winding and the stator core.

Generally, the shape (coil shape) of a stator winding formed by winding the stator winding around a stator core is relatively complicated. When the stator winding having the complicated winding shape is accommodated in a mold and resin is caused to flow in, there is a high possibility that the resin is difficult to uniformly flow in. In addition, if the unevenness is present, partial curing may occur before the entire stator winding is covered (i.e., during filling), which may cause cracking or cracking of the resin.

The main object of the present invention is to provide a rotating electrical machine and a method for manufacturing the rotating electrical machine, which can uniformly flow resin into the rotating electrical machine during resin molding.

According to a first aspect for solving the above-described technical problem, a rotating electrical machine includes: an exciting element having a magnet portion including a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature including a multi-phase armature winding and a base member to which the armature winding is fixed, wherein either one of the field element and the armature is a rotor, the armature winding includes a lead portion arranged at a position facing the field element at a predetermined interval in a circumferential direction, the base member and the armature winding are covered with a resin member in a state in which the armature winding is wound around the base member, and the resin member includes a plurality of gates into which a resin flows at the time of resin molding of the resin member, the plurality of gates being arranged at equal intervals in the circumferential direction at the same positions in an axial direction and a radial direction.

A plurality of gates into which resin flows at the time of resin molding are provided at the same positions in the axial direction and the radial direction at equal intervals in the circumferential direction. Since the resin is provided at the same position in the axial direction and the radial direction, the resin can be made to flow in the axial direction and the radial direction at the time of flowing in the resin from the gate. Thus, the time required for the resin to reach the opposite side of the gate can be made the same regardless of the path, and the resin flowing in through an arbitrary path can be prevented from reaching the opposite side of the gate first and being solidified.

Further, since the gates are provided at equal intervals in the circumferential direction, the resin can be uniformly flowed in the circumferential direction. This can prevent the resin flowing from one gate from reaching an intermediate point between gates adjacent in the circumferential direction before the other gate and from being solidified. Therefore, cracking and cracking of the resin can be suppressed in the resin member.

According to a second aspect, in the first aspect, the armature winding is wound in a constant pattern in the circumferential direction, and the gate is provided for each of the patterns in the circumferential direction.

The size of the armature winding to die gap may vary depending on the manner in which the armature winding is wound. When the gap size is large, the inflow speed of the resin is slow due to the pressure as compared with the case where the gap size is small, and as a result, there is a fear that the resin cannot uniformly flow in.

Therefore, the armature winding is wound in a constant pattern in the circumferential direction. This makes it possible to make the shape of the coil constant for each pattern, and to make the shape of the path through which the resin flows uniform. Therefore, by providing the gate for each pattern, the resin can be easily and uniformly flowed in.

According to a third aspect, in the first or second aspect, the lead portion includes: a coil side portion opposed to the magnet portion in a radial direction; and a coil edge arranged on an outer side of the magnet portion in the axial direction, wherein the armature winding is provided with a predetermined uneven pattern which is uneven in the axial direction by the coil edge repeatedly arranged in the circumferential direction, and the gate is provided for each of the uneven pattern in the circumferential direction.

A predetermined concavo-convex pattern which is concavo-convex in the axial direction is repeatedly provided in the circumferential direction by the coil edge. Therefore, the size of the gap from the edge end of the coil to the die in the axial direction is different. Further, when the gap size is large, the inflow speed of the resin becomes slower due to the pressure relationship as compared with the case where the gap size is small, and as a result, there is a fear that the resin cannot flow in uniformly.

Therefore, a gate is provided for each concave-convex pattern. Since the shape of the path through which the resin flows is made the same for each uneven pattern, the resin can easily flow uniformly by providing the gate in this manner.

According to a fourth aspect, in the third aspect, the resin member is formed along the uneven pattern of the coil side end so that a thickness dimension of the resin member covering the coil side end is constant.

The resin member is formed along the concave-convex pattern of the coil side end in such a manner that the thickness dimension of the resin member covering the coil side end is constant. This makes it possible to make the size of the path constant in the circumferential direction, thereby allowing the resin to flow in uniformly.

According to a fifth aspect, in any one of the first to fourth aspects, the wire guide portion includes: a coil side portion opposed to the magnet portion in a radial direction; and a coil edge end disposed outside the magnet portion in the axial direction, the coil edge end being bent toward the base member in the radial direction to engage with an end portion of the base member in the axial direction, wherein the gate is provided at least one of both end portions of the resin member in the axial direction.

Thereby, the resin member can be formed so as to apply a pressure in the axial direction that presses the coil edge end toward the base member. Therefore, the armature winding can be desirably fixed to the base member.

According to a sixth aspect, in any one of the first to third aspects, in the resin member, the gate is provided on the magnet portion side in a radial direction.

The armature winding can be pressed toward the base member by the resin and fixed at the time of resin molding. This makes it possible to reduce and equalize the air gap between the armature winding and the magnet portion.

According to a seventh aspect, in any one of the first to sixth aspects, the gate is provided on the opposite side of the magnet portion in a radial direction in the resin member.

Thereby, the resin layer is easily formed between the armature winding and the base member. Therefore, the armature winding can be insulated from the base member desirably.

According to an eighth aspect, in the seventh aspect, the lead portion includes: a coil side portion opposed to the magnet portion in a radial direction; and a coil edge end disposed outside the magnet portion in the axial direction, the coil edge end being bent toward the base member in the radial direction to engage with an end portion of the base member in the axial direction, wherein the gate is provided between the coil edge end and the coil side portion in the axial direction in the resin member.

Thus, the resin layer is easily formed between the coil edge and the base member. Therefore, the coil edge end can be insulated from the base member desirably.

According to a ninth aspect, in any one aspect of the first to eighth aspects, the armature is configured to be divided into a plurality of members in a circumferential direction.

This enables resin molding by division. Therefore, the mold can be easily manufactured according to the shape of the armature winding. That is, a mold in which resin flows uniformly is easily manufactured.

According to a tenth aspect, in any one of the first to ninth aspects, the magnet portion is configured such that the direction of the magnetization easy axis is more parallel to the d axis at the magnetic pole center, i.e., the d axis side than the q axis side, which is the magnetic pole boundary.

According to an eleventh aspect, in any one of the first to tenth aspects, the magnet portion has an intrinsic coercive force of 400[ kA/m ] or more and a residual magnetic flux density of 1.0[ T ] or more.

According to a twelfth aspect, in any one of the first to eleventh aspects, a thickness dimension of the wire portion in a radial direction is smaller than a width dimension of the one magnetic pole in a circumferential direction corresponding to one.

According to a thirteenth aspect, in any one of the first to twelfth aspects, the armature is configured such that an inter-wire member is provided between the respective wire portions in the circumferential direction, and the inter-wire member is made of a magnetic material or a non-magnetic material that satisfies a relationship of Wt × Bs ≦ Wm × Br when a circumferential width of the inter-wire member of one magnetic pole is Wt, a saturation magnetic flux density of the inter-wire member is Bs, a circumferential width of the magnet portion of one magnetic pole is Wm, and a residual magnetic flux density of the magnet portion is Br, or such that no inter-wire member is provided between the respective wire portions in the circumferential direction.

According to a fourteenth aspect, in any one of the first to thirteenth aspects, each of the lead wires constituting the lead wire portion is a wire assembly of: bundling a plurality of wires and having a resistance value between the bundled wires greater than a resistance value of the wires themselves

According to a fifteenth aspect, a method of manufacturing a rotary electric machine includes: a field element having a magnet portion including a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature having a multi-phase armature winding and a base member to which the armature winding is fixed, wherein either one of the field element and the armature is a rotor, and the method for manufacturing a rotating electrical machine includes: winding the armature winding around the base member so that a lead portion is formed at a position facing the field element and is arranged at a predetermined interval in a circumferential direction; a step of housing the base member and the armature winding in a mold in a state where the armature winding is wound around the base member; and a step of molding the resin member so that the resin flows into the mold through gates provided in a plurality at equal intervals in the circumferential direction at the same positions in the axial direction and the radial direction of the resin member and covers the base member and the armature winding.

Further, since the gates are provided at equal intervals in the circumferential direction, the resin can be uniformly flowed in the circumferential direction. This can prevent the resin flowing from any one gate from reaching an intermediate point between gates adjacent in the circumferential direction and being solidified. This can suppress cracking or cracking of the resin.

Drawings

The above objects, other objects, features and advantages of the present invention will become more apparent with reference to the accompanying drawings and the following detailed description. The drawings are as follows.

Fig. 1 is a longitudinal sectional perspective view of a rotating electric machine.

Fig. 2 is a longitudinal sectional view of the rotating electric machine.

Fig. 3 is a sectional view taken along line III-III of fig. 2.

Fig. 4 is an enlarged cross-sectional view of a portion of fig. 3.

Fig. 5 is an exploded view of the rotary electric machine.

Fig. 6 is an exploded view of the inverter unit.

Fig. 7 is a torque line graph showing a relationship between the ampere-turns of the stator winding and the torque density.

Fig. 8 is a cross-sectional view of the rotor and stator.

Fig. 9 is an enlarged view of a part of fig. 8.

Fig. 10 is a cross-sectional view of the stator.

Fig. 11 is a longitudinal sectional view of the stator.

Fig. 12 is a perspective view of the stator winding.

Fig. 13 is a perspective view showing the structure of the lead.

Fig. 14 is a schematic diagram showing the structure of the wire rod.

Fig. 15 is a diagram showing the form of each conductive line of the n-th layer.

Fig. 16 is a side view showing each conductive line of the nth layer and the (n + 1) th layer.

Fig. 17 is a diagram showing a relationship between an electrical angle and a magnetic flux density of the magnet according to the embodiment.

Fig. 18 is a diagram showing a relationship between an electrical angle and a magnetic flux density of the magnet of the comparative example.

Fig. 19 is a circuit diagram of a control system of the rotating electric machine.

Fig. 20 is a functional block diagram showing a current feedback control process of the control device.

Fig. 21 is a functional block diagram showing a torque feedback control process of the control device.

Fig. 22 is a cross-sectional view of a rotor and a stator of the second embodiment.

Fig. 23 is an enlarged view of a part of fig. 22.

Fig. 24 is a diagram specifically showing the flow of the magnetic flux of the magnet unit.

Fig. 25 is a sectional view of a stator according to modification 1.

Fig. 26 is a sectional view of a stator according to modification 1.

Fig. 27 is a sectional view of a stator according to modification 2.

Fig. 28 is a sectional view of a stator according to modification 3.

Fig. 29 is a sectional view of a stator according to modification 4.

Fig. 30 is a cross-sectional view of a rotor and a stator according to modification 7.

Fig. 31 is a functional block diagram showing a part of the processing of the operation signal generation unit in modification 8.

Fig. 32 is a flowchart showing a procedure of the carrier frequency changing process.

Fig. 33 is a diagram showing a connection mode of each lead constituting a lead group in modification 9.

Fig. 34 is a diagram showing a structure in which four pairs of lead wires are stacked in modification 9.

Fig. 35 is a cross-sectional view of the rotor and the stator of the inner rotor type according to modification 10.

Fig. 36 is an enlarged view showing a part of fig. 35.

Fig. 37 is a longitudinal sectional view of the inner rotor type rotating electric machine.

Fig. 38 is a longitudinal sectional view showing a schematic structure of the inner rotor type rotating electric machine.

Fig. 39 is a diagram showing a structure of a rotary electric machine having an inner rotor structure according to modification 11.

Fig. 40 is a diagram showing a structure of a rotary electric machine having an inner rotor structure according to modification 11.

Fig. 41 is a diagram showing a structure of a rotary armature type rotating electric machine according to modification 12.

Fig. 42 is a cross-sectional view showing the structure of a lead wire according to modification 14.

Fig. 43 is a vertical sectional view showing a schematic structure of an inner rotor type rotating electric machine according to modification 15.

Fig. 44 is a plan view showing the structure of the stator.

Fig. 45 is a perspective view showing a structure of the stator.

Fig. 46 is a perspective view showing the structure of the stator winding.

Fig. 47 is a side view of the stator.

Fig. 48 is a conceptual diagram illustrating a method of resin molding.

Fig. 49 is a plan view showing the structure of a stator molded with resin.

Fig. 50 is a perspective view showing a structure of a stator molded with resin.

Fig. 51 is a side view of the stator subjected to resin molding.

Fig. 52 is a perspective view showing the structure of a stator according to another example of modification 15.

Fig. 53 is a side view showing the structure of a stator according to another example of modification 15.

Fig. 54 is a perspective view showing a structure of a stator according to another example of modification 15.

Fig. 55 is a side view showing the structure of a stator according to another example of modification 15.

Fig. 56 is a diagram showing a relationship between reluctance torque, magnet torque, and DM.

Fig. 57 is a view showing a tooth.

Detailed Description

Hereinafter, a plurality of embodiments will be described with reference to the drawings. In the embodiments, the same reference signs may be used for functionally and/or structurally corresponding parts and/or related parts, or reference signs with more than one hundred bits different may be used. For corresponding parts and/or associated parts, reference may be made to the description of the other embodiments.

The rotating electric machine in the present embodiment is used as a vehicle power source, for example. However, the rotating electric machine is widely used for industrial use, vehicles, home appliances, OA equipment, game machines, and the like. In the following embodiments, the same or equivalent portions are denoted by the same reference numerals in the drawings, and the description thereof will be referred to for the portions having the same reference numerals.

(first embodiment)

The rotating electrical machine 10 of the present embodiment is a synchronous multiphase ac motor, and has an outer rotor structure (external rotor structure). Fig. 1 to 5 show an outline of the rotary electric machine 10. Fig. 1 is a longitudinal sectional perspective view of a rotary electric machine 10, fig. 2 is a longitudinal sectional view of the rotary electric machine 10 in a direction along a rotary shaft 11, fig. 3 is a transverse sectional view of the rotary electric machine 10 in a direction perpendicular to the rotary shaft 11 (sectional view taken along line III-III of fig. 2), fig. 4 is a sectional view showing a part of fig. 3 in an enlarged manner, and fig. 5 is an exploded view of the rotary electric machine 10. In fig. 3, for convenience of illustration, hatching indicating a cut surface is omitted except for the rotary shaft 11. In the following description, a direction in which the rotary shaft 11 extends is defined as an axial direction, a direction in which the rotary shaft 11 radially extends from the center thereof is defined as a radial direction, and a direction in which the rotary shaft 11 circumferentially extends around the center thereof is defined as a circumferential direction.

The rotary electric machine 10 generally includes a bearing unit 20, a housing 30, a rotor 40, a stator 50, and an inverter unit 60. The rotating electric machine 10 is configured by disposing the above-described members coaxially with the rotating shaft 11 and assembling them in the axial direction in a predetermined order. The rotating electrical machine 10 of the present embodiment has a structure including a rotor 40 as a "field element" and a stator 50 as an "armature", and is specifically a rotating electrical machine of a rotating field excitation type.

The bearing unit 20 includes: two

bearings

21, 22 arranged apart from each other in the axial direction; and a holding member 23 for holding the

bearings

21 and 22. The

bearings

21 and 22 are, for example, radial ball bearings, and each have an outer ring 25, an inner ring 26, and a plurality of balls 27 arranged between the outer ring 25 and the inner ring 26. The holding member 23 is cylindrical, and the

bearings

21 and 22 are assembled on the radially inner side of the holding member 23. The rotary shaft 11 and the rotor 40 are rotatably supported radially inside the

bearings

21 and 22. The

bearings

21 and 22 constitute a set of bearings, and rotatably support the rotary shaft 11.

In each of the

bearings

21 and 22, the balls 27 are held by a not-shown stopper, and in this state, the pitch between the balls is held. The

bearings

21, 22 have seal members at the upper and lower portions in the axial direction of the stopper, and are filled with non-conductive grease (e.g., non-conductive urea grease) inside thereof. Further, the position of the inner ring 26 is mechanically held by the spacer, and a constant pressure preload that protrudes in the up-down direction is applied from the inside.

The housing 30 has a cylindrical peripheral wall 31. The peripheral wall 31 has first and second ends opposite in the axial direction thereof. The peripheral wall 31 has an end face 32 at a first end and an opening 33 at a second end. The opening 33 is open at the entire second end. A circular hole 34 is formed in the center of the end face 32, and the bearing unit 20 is fixed by a fixing member such as a screw or a rivet in a state inserted through the hole 34. Further, a hollow cylindrical rotor 40 and a hollow cylindrical stator 50 are housed in the housing 30, that is, in an internal space defined by the peripheral wall 31 and the end face 32. In the present embodiment, the rotating electric machine 10 is an outer rotor type, and a stator 50 is disposed inside a casing 30 in the radial direction of a rotor 40 having a cylindrical shape. The rotor 40 is supported by the rotary shaft 11 in an axially cantilevered manner on the end surface 32 side.

The rotor 40 has: a magnet holder 41 formed in a hollow cylindrical shape; and an annular magnet unit 42 provided radially inside the magnet holder 41. The magnet holder 41 has a substantially cup shape and functions as a magnet holding member. The magnet holder 41 has: a cylindrical portion 43 having a cylindrical shape; a fixing portion (connecting portion) 44 which is also cylindrical and has a smaller diameter than the cylindrical portion 43; and an intermediate portion 45 as a portion connecting the cylindrical portion 43 and the fixing portion 44. The magnet unit 42 is attached to the inner circumferential surface of the cylindrical portion 43.

The magnet holder 41 is made of cold-rolled Steel Plate (SPCC), forged steel, Carbon Fiber Reinforced Plastic (CFRP), or the like, which has sufficient mechanical strength.

The rotary shaft 11 is inserted through the through hole 44a of the fixing portion 44. The fixing portion 44 is fixed to the rotating shaft 11 provided in the through hole 44 a. That is, the magnet holder 41 is fixed to the rotating shaft 11 by the fixing portion 44. The fixing portion 44 is preferably fixed to the rotary shaft 11 by spline coupling, key coupling, welding, caulking, or the like using irregularities. Thereby, the rotor 40 and the rotary shaft 11 rotate integrally.

Further, the

bearings

21, 22 of the bearing unit 20 are assembled to the radially outer side of the fixing portion 44. As described above, since the bearing unit 20 is fixed to the end face 32 of the housing 30, the rotary shaft 11 and the rotor 40 are rotatably supported by the housing 30. Thereby, the rotor 40 is rotatable in the housing 30.

The rotor 40 is provided with the fixing portion 44 only at one of the two axially opposite end portions thereof, and thereby the rotor 40 is supported in a cantilever manner on the rotary shaft 11. Here, the fixed portion 44 of the rotor 40 is rotatably supported by the

bearings

21, 22 of the bearing unit 20 at two different positions in the axial direction. That is, the rotor 40 is rotatably supported by the two

bearings

21 and 22 spaced in the axial direction at one of the two axially opposite end portions of the magnet holder 41. Therefore, even in the structure in which the rotor 40 is supported by the rotary shaft 11 in a cantilever manner, stable rotation of the rotor 40 can be achieved. In this case, the rotor 40 is supported by the

bearings

21, 22 at a position offset to one side with respect to the axial center position of the rotor 40.

In the bearing unit 20, the size of the gap between the outer ring 25 and the inner ring 26 and the balls 27 is different between the bearing 22 near the center (lower side in the figure) of the rotor 40 and the bearing 21 on the opposite side (upper side in the figure), and for example, the size of the gap is larger in the bearing 22 near the center of the rotor 40 than in the bearing 21 on the opposite side. In this case, even if vibration due to vibration of the rotor 40 or imbalance caused by component tolerance acts on the bearing unit 20 on the side close to the center of the rotor 40, the influence of the vibration or the vibration can be favorably absorbed. Specifically, the play size (clearance size) is increased by the preload in the bearing 22 near the center (lower side in the figure) of the rotor 40, and the vibration generated in the cantilever structure can be absorbed by the play portion. The preload may be either a constant position preload or a constant pressure preload. In the case of constant-position preload, the outer rings 25 of the

bearings

21 and 22 are both joined to the holding member 23 by press-fitting, bonding, or the like. Further, the bearing 21 and the inner ring 26 of the bearing 22 are both joined to the rotary shaft 11 by press-fitting, bonding, or the like. Here, the preload can be generated by disposing the outer ring 25 of the bearing 21 at a position different from the inner ring 26 of the bearing 21 in the axial direction. The preload can be generated by disposing the outer ring 25 of the bearing 22 at a position different from the inner ring 26 of the bearing 22 in the axial direction.

In the case of using the constant pressure preload, a preload spring, for example, a wave washer 24 or the like is disposed in the region sandwiched between the bearing 22 and the bearing 21 in order to generate the preload from the region sandwiched between the bearing 22 and the bearing 21 toward the outer ring 25 of the bearing 22 in the axial direction. In this case, the bearing 21 and the inner ring 26 of the bearing 22 are also joined to the rotary shaft 11 by press-fitting, bonding, or the like. The outer ring 25 of the bearing 21 or the bearing 22 is disposed on the holding member 23 with a predetermined gap therebetween. With the above configuration, the elastic force of the preload spring acts on the outer ring 25 of the bearing 22 in a direction away from the bearing 21. Then, the force is transmitted to the rotary shaft 11, and a force pressing the inner ring 26 of the bearing 21 in the direction of the bearing 22 acts thereon. Thus, with respect to the

bearings

21, 22, the axial positions of the outer ring 25 and the inner ring 26 are both shifted, so that preload can be applied to both bearings as in the above-described constant-position preload.

In addition, when the constant pressure preload is generated, it is not necessary to apply the elastic force to the outer ring 25 of the bearing 22 as shown in fig. 2. For example, the outer ring 25 of the bearing 21 may be provided with an elastic force. Further, the inner ring 26 of either one of the

bearings

21, 22 may be disposed on the rotary shaft 11 with a predetermined gap therebetween, and the outer ring 25 of the

bearing

21, 22 may be joined to the holding member 23 by a method such as press-fitting or bonding, thereby applying preload to both bearings.

Furthermore, when a force is applied to move the inner ring 26 of the bearing 21 away from the bearing 22, it is preferable to apply a force to move the inner ring 26 of the bearing 22 away from the bearing 21 as well. Conversely, when a force is applied to bring the inner ring 26 of the bearing 21 closer to the bearing 22, it is preferable to apply a force to bring the inner ring 26 of the bearing 22 closer to the bearing 21.

When the rotating electric machine 10 is applied to a vehicle for the purpose of a power source of the vehicle or the like, vibration having a component in the direction of generation of the preload may be applied to the mechanism that generates the preload, and the direction of gravity of the object to which the preload is applied may vary. Therefore, in the case where the present rotating electrical machine 10 is applied to a vehicle, it is desirable to employ a constant position pre-pressure.

The intermediate portion 45 has an annular inner shoulder 49a and an annular outer shoulder 49 b. The outer shoulder 49b is located radially outward of the inner shoulder 49a in the intermediate portion 45. The inner shoulder portion 49a and the outer shoulder portion 49b are separated from each other in the axial direction of the intermediate portion 45. Thereby, the cylindrical portion 43 and the fixing portion 44 partially overlap in the radial direction of the intermediate portion 45. That is, the cylindrical portion 43 protrudes axially outward beyond the base end portion (lower-side end portion in the figure) of the fixing portion 44. According to this configuration, as compared with the case where the intermediate portion 45 is formed into a flat plate shape without a step, the rotor 40 can be supported by the rotary shaft 11 at a position near the center of gravity of the rotor 40, and stable operation of the rotor 40 can be achieved.

According to the configuration of the intermediate portion 45, the rotor 40 is formed with a bearing housing recess 46 that houses a part of the bearing unit 20 in a ring shape at a position radially surrounding the fixed portion 44 and close to the inside of the intermediate portion 45, and with a coil housing recess 47 that houses a coil edge 54 of a stator winding 51 of a stator 50 described later at a position radially surrounding the bearing housing recess 46 and close to the outside of the intermediate portion 45. The receiving recesses 46 and 47 are arranged adjacent to each other radially inward and outward. That is, a part of the bearing unit 20 and the coil side end 54 of the stator winding 51 are arranged to overlap radially inward and outward. This can shorten the axial length of the rotating electric machine 10.

The intermediate portion 45 is provided to protrude radially outward from the rotation shaft 11 side. Further, the intermediate portion 45 is provided with a contact avoiding portion extending in the axial direction, which avoids contact with the coil edge end 54 of the stator winding 51 of the stator 50. The intermediate portion 45 corresponds to a protruding portion.

The axial dimension of the coil edge 54 can be reduced by bending the coil edge 54 radially inward or outward, and the axial length of the stator 50 can be shortened. The direction of the curvature of the coil side ends 54 is preferably considered for assembly with the rotor 40. When the stator 50 is assembled to the radially inner side of the rotor 40, the coil edge 54 is preferably bent radially inward on the insertion tip side of the rotor 40. The direction of bending of the coil edge 54 on the opposite side may be arbitrary, but a shape bent to the outside that is spatially redundant is preferable for manufacturing reasons.

The magnet unit 42 as a magnet portion is configured by a plurality of permanent magnets arranged so that polarities thereof are alternately changed in the circumferential direction on the inner side in the radial direction of the cylindrical portion 43. Thus, the magnet unit 42 has a plurality of magnetic poles in the circumferential direction. The magnet unit 42 is described in detail later.

The stator 50 is provided radially inside the rotor 40. The stator 50 has a stator winding 51 formed in a substantially cylindrical (annular) shape by winding and a stator core 52 as a base member arranged radially inside the stator winding 51, and the stator winding 51 is arranged to face the annular magnet unit 42 with a predetermined air gap therebetween. The stator winding 51 is formed of a plurality of phase windings. The phase windings are formed by connecting a plurality of conductor lines arranged in the circumferential direction at predetermined intervals. In the present embodiment, the stator winding 51 is configured as a six-phase winding by using three-phase windings of U-phase, V-phase, and W-phase, and three-phase windings of X-phase, Y-phase, and Z-phase, and using two sets of the three-phase windings.

The stator core 52 is formed in an annular shape from a laminated steel plate in which electromagnetic steel plates as soft magnetic materials are laminated, and is assembled to the inside in the radial direction of the stator winding 51. The electromagnetic steel sheet is, for example, a silicon steel sheet in which silicon is added to iron by about several percent (e.g., 3%). The stator winding 51 corresponds to an armature winding, and the stator core 52 corresponds to an armature core.

The stator winding 51 has a coil side portion 53 which is a portion overlapping the stator core 52 in the radial direction and is positioned radially outward of the stator core 52, and coil side ends 54, 55 which protrude toward one end side and the other end side of the stator core 52 in the axial direction, respectively. The coil side portion 53 is radially opposed to the stator core 52 and the magnet unit 42 of the rotor 40, respectively. In a state where the stator 50 is disposed inside the rotor 40, the coil edge 54 located on the bearing unit 20 side (upper side in the drawing) of the

coil edge

54 and 55 on both sides in the axial direction is accommodated in the coil accommodating recess 47 formed by the magnet holder 41 of the rotor 40. The stator 50 is described in detail later.

The inverter unit 60 includes: a unit base 61 fixed to the housing 30 by a fastener such as a bolt; and a plurality of electrical components 62 assembled to the unit base 61. The unit base 61 is made of, for example, Carbon Fiber Reinforced Plastic (CFRP). The unit base 61 has: an end plate 63 fixed to an edge of the opening 33 of the housing 30; and a housing 64 integrally provided to the end plate 63 and extending in the axial direction. The end plate 63 has a circular opening 65 at its central portion, and forms a housing 64 so as to stand from the peripheral edge portion of the opening 65.

The stator 50 is assembled to the outer peripheral surface of the housing 64. That is, the outer diameter of the housing 64 is the same as the inner diameter of the stator core 52, or slightly smaller than the inner diameter of the stator core 52. The stator 50 and the unit base 61 are integrated by assembling the stator core 52 to the outside of the housing 64. Further, since the unit base 61 is fixed to the housing 30, the stator 50 is integrated with the housing 30 in a state where the stator core 52 is assembled to the case 64.

The stator core 52 is preferably assembled to the unit base 61 by bonding, shrink fitting, press fitting, or the like. Thereby, the stator core 52 is restrained from being displaced in the circumferential direction or the axial direction with respect to the unit base 61 side.

Further, a radially inner side of the housing 64 is a housing space for housing the electric component 62, and the electric component 62 is disposed in the housing space so as to surround the rotary shaft 11. The housing 64 functions as a housing space forming portion. The electrical component 62 is constituted by: a semiconductor module 66, a control board 67, and a capacitor module 68 that constitute an inverter circuit.

The unit base 61 corresponds to a stator holder (armature holder) that is provided radially inside the stator 50 and holds the stator 50. The housing 30 and the unit base 61 constitute a motor housing of the rotating electric machine 10. In the motor housing described above, the holding member 23 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 are coupled to each other on the other side. For example, in an electric vehicle or the like as an electric vehicle, the rotating electrical machine 10 is mounted on the vehicle or the like by mounting a motor housing on one side of the vehicle or the like.

Here, the structure of the inverter unit 60 will be further described using fig. 6, which is an exploded view of the inverter unit 60, in addition to fig. 1 to 5.

In the unit base 61, the housing 64 has a cylindrical portion 71 and an end surface 72, and the end surface 72 is provided on one of opposite ends (end portion on the bearing unit 20 side) facing in the axial direction. The opposite side of the end face 72 of the cylindrical portion 71 at both ends in the axial direction is opened over the entire surface by the opening 65 of the end plate 63. A circular hole 73 is formed in the center of the end surface 72, and the rotary shaft 11 is inserted through the hole 73. A seal 171 is provided in the hole 73, and the seal 171 closes a gap between the hole 73 and the outer peripheral surface of the rotary shaft 11. The seal 171 is preferably a sliding seal made of, for example, a resin material.

The cylindrical portion 71 of the housing 64 is a partition portion that partitions between the rotor 40 and the stator 50 disposed on the radially outer side thereof and the electrical component 62 disposed on the radially inner side thereof, and the rotor 40, the stator 50, and the electrical component 62 are disposed so as to be arranged radially inward and outward with the cylindrical portion 71 interposed therebetween.

The electric module 62 is an electric component constituting an inverter circuit, and has a power running function of causing currents to flow in a predetermined order to the respective phase windings of the stator winding 51 to rotate the rotor 40, and a power generating function of inputting a three-phase alternating current flowing to the stator winding 51 with rotation of the rotary shaft 11 and outputting the three-phase alternating current as generated power to the outside. The electric module 62 may have only one of a power running function and a power generating function. For example, when the rotating electrical machine 10 is used as a power source for a vehicle, the power generation function is a regeneration function that outputs regenerated electric power to the outside.

As a specific configuration of the electric module 62, as shown in fig. 4, a capacitor module 68 having a hollow cylindrical shape is provided around the rotary shaft 11, and a plurality of semiconductor modules 66 are arranged in parallel in the circumferential direction on the outer circumferential surface of the capacitor module 68. The capacitor module 68 includes a plurality of smoothing capacitors 68a connected in parallel with each other. Specifically, the capacitor 68a is a stacked film capacitor in which a plurality of film capacitors are stacked, and has a trapezoidal cross section. The capacitor module 68 is configured by annularly arranging twelve capacitors 68a in parallel.

In the manufacturing process of the capacitor 68a, for example, a long film having a predetermined width, which is formed by laminating a plurality of films, is used, the film width direction is set to be the trapezoidal height direction, and the long film is cut into isosceles trapezoids so that the upper base and the lower base of the trapezoid alternate with each other, thereby manufacturing a capacitor element. Then, the capacitor 68a is produced by mounting electrodes and the like on the capacitor element.

The Semiconductor module 66 has a Semiconductor switching element such as a MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor) or an IGBT (Insulated Gate Bipolar Transistor), and is formed in a substantially plate shape. In the present embodiment, the rotating electrical machine 10 includes two sets of three-phase windings, and since an inverter circuit is provided for each three-phase winding, a total of twelve semiconductor modules 66 arranged in a ring form are provided in the electrical component 62 as the semiconductor module group 66A.

The semiconductor module 66 is disposed in a state of being sandwiched between the cylindrical portion 71 of the case 64 and the capacitor module 68. The outer peripheral surface of the semiconductor module group 66A abuts against the inner peripheral surface of the cylindrical portion 71, and the inner peripheral surface of the semiconductor module group 66A abuts against the outer peripheral surface of the capacitor module 68. In this case, heat generated in the semiconductor module 66 is transmitted to the end plate 63 through the case 64, and is released from the end plate 63.

The semiconductor module group 66A preferably has a spacer 69 between the semiconductor module 66 and the cylindrical portion 71 on the outer peripheral surface side, i.e., in the radial direction. In this case, the cross-sectional shape of the capacitor module 68 in the cross section orthogonal to the axial direction is a regular dodecagon, and the cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 is a circle, so the inner peripheral surface of the spacer 69 is a flat surface and the outer peripheral surface is a curved surface. The spacer 69 may be integrally provided to be connected in a ring shape on the radially outer side of the semiconductor module group 66A. The spacer 69 is preferably a good thermal conductor, such as a metal, e.g., aluminum, or a heat-dissipating gel sheet. The cross-sectional shape of the inner peripheral surface of the cylindrical portion 71 may be a dodecagon similar to the capacitor module 68. In this case, both the inner peripheral surface and the outer peripheral surface of the spacer 69 are preferably flat surfaces.

In the present embodiment, the cooling water passage 74 through which cooling water flows is formed in the cylindrical portion 71 of the housing 64, and the heat generated in the semiconductor module 66 is also released to the cooling water flowing through the cooling water passage 74. That is, the housing 64 includes a water cooling mechanism. As shown in fig. 3 and 4, the cooling water passage 74 is formed in a ring shape so as to surround the electrical components 62 (the semiconductor module 66 and the capacitor module 68). The semiconductor module 66 is disposed along the inner circumferential surface of the cylindrical portion 71, and a cooling water passage 74 is provided at a position overlapping the semiconductor module 66 radially inward and outward.

Since the stator 50 is disposed outside the cylindrical portion 71 and the electric component 62 is disposed inside, heat of the stator 50 is transmitted from the outside to the cylindrical portion 71 and heat of the electric component 62 (for example, heat of the semiconductor module 66) is transmitted from the inside to the cylindrical portion 71. In this case, the stator 50 and the semiconductor module 66 can be cooled at the same time, so that the heat of the heat generating components in the rotary electric machine 10 can be efficiently released.

At least a part of the semiconductor module 66 constituting a part or all of the inverter circuit for operating the rotating electric machine by supplying current to the stator winding 51 is disposed in a region surrounded by the stator core 52 disposed radially outside the cylindrical portion 71 of the housing 64. Preferably, the entire semiconductor module 66 is disposed in the region surrounded by the stator core 52. More preferably, the entire semiconductor modules 66 are disposed in the region surrounded by the stator core 52.

At least a part of the semiconductor module 66 is disposed in a region surrounded by the cooling water passage 74. Preferably, the entire semiconductor module 66 is disposed in the region surrounded by the yoke 141.

Further, the electrical component 62 includes, in the axial direction: an insulating sheet 75 provided on one end surface of the capacitor module 68; and a wiring module 76 provided on the other end surface. In this case, the capacitor module 68 has two end faces, i.e., a first end face and a second end face, which are opposite in the above-described axial direction. A first end face of the capacitor module 68 close to the bearing unit 20 is opposed to an end face 72 of the case 64, and overlaps the end face 72 with the insulating sheet 75 interposed therebetween. The wiring module 76 is assembled to the second end face of the capacitor module 68 close to the opening 65.

The wiring module 76 has a main body portion 76a made of a synthetic resin material and having a circular plate shape, and a plurality of bus bars 76b and 76c embedded therein, and is electrically connected to the semiconductor module 66 and the capacitor module 68 via the bus bars 76b and 76 c. Specifically, the semiconductor module 66 has a connection pin 66a extending from the above-described axial end face, and this connection pin 66a is connected to the bus bar 76b radially outside the main body portion 76 a. Further, the bus bar 76c extends on the opposite side of the capacitor module 68 in the radial direction outside the main body portion 76a, and is connected to a wiring member 79 at the leading end portion thereof (refer to fig. 2).

As described above, according to the configuration in which the insulating sheet 75 is provided on the first end surface of the capacitor module 68 facing in the axial direction and the wiring module 76 is provided on the second end surface of the capacitor module 68, a path from the first end surface and the second end surface of the capacitor module 68 to the end surface 72 and the cylindrical portion 71 is formed as a heat radiation path of the capacitor module 68. That is, a path from the first end face to the end face 72 and a path from the second end face to the cylindrical portion 71 are formed. This allows heat to be dissipated from the end surface of the capacitor module 68 other than the outer peripheral surface of the semiconductor module 66. I.e. not only in the radial direction but also in the axial direction.

Further, since the capacitor module 68 has a hollow cylindrical shape and the rotary shaft 11 is disposed with a predetermined gap between the inner peripheral portion thereof, the heat of the capacitor module 68 can be released from the hollow portion. In this case, since the air flow is generated by the rotation of the rotating shaft 11, the above-described cooling effect is enhanced.

The disk-shaped control board 67 is mounted on the wiring module 76. The control board 67 has a Printed Circuit Board (PCB) on which a predetermined wiring pattern is formed, and a control device 77 corresponding to a control unit including various ICs, a microcomputer, and the like is mounted on the board. The control board 67 is fixed to the wiring module 76 by a fixing member such as a screw. The control board 67 has an insertion hole 67a in the center thereof through which the rotary shaft 11 is inserted.

In addition, the wiring module 76 has a first face and a second face that are opposed to each other in the axial direction, i.e., opposed to each other in the thickness direction thereof. The first face faces the capacitor module 68. A control board 67 is provided on the second surface of the wiring module 76. The bus bar 76c of the wiring module 76 extends from one side of both surfaces of the control board 67 to the other side. In the above configuration, the control board 67 is preferably provided with a notch to avoid interference with the bus bar 76 c. For example, a part of the outer edge of the control board 67 having a circular shape is preferably cut off.

As described above, according to the structure in which the electric module 62 is accommodated in the space surrounded by the case 64 and the housing 30, the rotor 40, and the stator 50 are layered on the outer side thereof, it is possible to desirably shield the electromagnetic noise generated in the inverter circuit. That is, in the inverter circuit, the switching control in each semiconductor module 66 is performed by PWM control based on a predetermined carrier frequency, and although it is considered that the switching control generates electromagnetic noise, the electromagnetic noise can be desirably shielded by the housing 30, the rotor 40, the stator 50, and the like on the radially outer side of the electrical component 62.

Further, by disposing at least a part of the semiconductor module 66 in the region surrounded by the stator core 52 disposed radially outside the cylindrical portion 71 of the housing 64, even if magnetic flux is generated from the semiconductor module 66, it is less likely to affect the stator winding 51, as compared with a configuration in which the semiconductor module 66 and the stator winding 51 are not disposed across the stator core 52. Even if magnetic flux is generated from the stator winding 51, the semiconductor module 66 is less likely to be affected. Further, it is more effective to dispose the entire semiconductor module 66 in the region surrounded by the stator core 52 disposed radially outward of the cylindrical portion 71 of the housing 64. Further, when at least a part of the semiconductor module 66 is surrounded by the cooling water passage 74, an effect is obtained that heat generated from the stator winding 51 and the magnet unit 42 hardly reaches the semiconductor module 66.

In the cylindrical portion 71, a through hole 78 is formed in the vicinity of the end plate 63, and a wiring member 79 (see fig. 2) for electrically connecting the stator 50 on the outer side of the cylindrical portion 71 and the electric module 62 on the inner side is inserted through the through hole 78. As shown in fig. 2, the wiring members 79 are connected to the ends of the stator windings 51 and the bus bars 76c of the wiring module 76, respectively, by crimping, welding, or the like. The wiring member 79 is, for example, a bus bar, and the joint surface thereof is preferably flattened. The through-holes 78 are preferably provided at one location or a plurality of locations, and in the present embodiment, the through-holes 78 are provided at two locations. According to the configuration in which the through holes 78 are provided at two locations, the winding terminals extending from the two sets of three-phase windings can be easily wired by the wiring members 79, respectively, and thus the present invention is suitable for multi-phase wiring.

As described above, in the housing 30, as shown in fig. 4, the rotor 40 and the stator 50 are provided in this order from the radial outside, and the inverter unit 60 is provided on the radial inside of the stator 50. Here, when the radius of the inner circumferential surface of the housing 30 is d, the rotor 40 and the stator 50 are arranged radially outward from the rotational center of the rotor 40 by a distance of d × 0.705. In this case, if a region radially inward from the inner peripheral surface of the stator 50 (i.e., the inner peripheral surface of the stator core 52) of the rotor 40 and the stator 50 is defined as a first region X1, and a region radially between the inner peripheral surface of the stator 50 and the housing 30 is defined as a second region X2, the cross-sectional area of the first region X1 is larger than the cross-sectional area of the second region X2. Further, the volume of the first region X1 is larger than the volume of the second region X2 as viewed in a range where the magnet unit 42 of the rotor 40 and the stator winding 51 overlap in the radial direction.

In addition, when the rotor 40 and the stator 50 are formed as a magnetic circuit assembly, the volume of a first region X1 radially inward from the inner peripheral surface of the magnetic circuit assembly is larger than the volume of a second region X2 radially between the inner peripheral surface of the magnetic circuit assembly and the housing 30 in the housing 30.

Next, the structures of the rotor 40 and the stator 50 will be described in more detail.

In general, as a structure of a stator of a rotating electric machine, there is known a structure in which a plurality of slots are provided in a stator core made of laminated steel plates and having an annular shape in a circumferential direction, and stator windings are wound in the slots. Specifically, the stator core has a plurality of pole teeth extending radially from a yoke portion at regular intervals, and a slot is formed between circumferentially adjacent pole teeth. In the slots, for example, a plurality of layers of lead wires are housed in the radial direction, and the stator winding is formed by the lead wires.

However, according to the above-described stator structure, magnetic saturation occurs in the pole teeth portion of the stator core as the magnetomotive force of the stator winding increases when the stator winding is energized, which is considered to result in limitation of the torque density of the rotating electric machine. That is, in the stator core, it is considered that the rotating magnetic flux generated by the energization of the stator winding is concentrated on the pole teeth, and magnetic saturation occurs.

In general, as a structure of an IPM (Interior Permanent Magnet) rotor of a rotating electrical machine, there is known a structure in which a Permanent Magnet is disposed on a d-axis and a rotor core is disposed on a q-axis in a d-q coordinate system. In this case, by exciting the stator winding in the vicinity of the d-axis, the excitation magnetic flux flows from the stator into the q-axis of the rotor according to fleming's law. And it is thus considered that a wide range of magnetic saturation occurs in the q-axis core portion of the rotor.

FIG. 7 is a torque diagram showing a relationship between ampere-turns [ AT ] and torque density [ Nm/L ] of magnetomotive force of a stator winding. The broken line indicates the characteristics of a general IPM rotor type rotating electrical machine. As shown in fig. 7, in a general rotating electric machine, increasing the magnetomotive force in the stator causes magnetic saturation in two portions, the tooth portion and the q-axis core portion between the slots, and thus increases in torque are restricted. Thus, in the above-described general rotating electrical machine, the ampere-turn scheme value is limited to a 1.

Therefore, in the present embodiment, in order to overcome the limitation caused by the magnetic saturation, the following configuration is provided in the rotating electrical machine 10. That is, as the first means, in order to eliminate magnetic saturation occurring at the pole teeth of the stator core in the stator, the stator 50 has a grooveless structure, and in order to eliminate magnetic saturation occurring at the q-axis core portion of the IPM rotor, an SPM (Surface Permanent Magnet) rotor is used. According to the first aspect, although the two portions where magnetic saturation occurs can be eliminated, it is considered that the torque in the low current region is reduced (see the chain line in fig. 7). Therefore, as a second mode, in order to recover the torque reduction by enhancing the magnetic flux of the SPM rotor, a structure is adopted in which the magnetic path of the magnet is lengthened to increase the magnetic force polarity anisotropy in the magnet unit 42 of the rotor 40.

Further, as a third aspect, a flat wire structure that makes the radial thickness in the stator 50 of the wire smaller is adopted in the coil side portion 53 of the stator winding 51 to recover the reduction of the torque. Here, it is considered that the polar anisotropy structure that enhances the magnetic force generates a larger eddy current in the stator winding 51 facing the magnet unit 42. However, according to the third aspect, since it is a flat wire structure that is thin in the radial direction, it is possible to suppress generation of eddy current in the radial direction in the stator winding 51. As described above, according to the first to third configurations, as shown by the solid line in fig. 7, the torque characteristics can be greatly improved by using the magnet having a high magnetic force, and the possibility that the magnet having a high magnetic force causes a large eddy current can be reduced.

Further, as a fourth aspect, a magnet unit is employed which utilizes a polar anisotropic structure and has a magnetic flux density distribution close to a sine wave. This makes it possible to enhance torque by increasing the sine wave matching rate by pulse control or the like described later, and further suppress eddy current loss (copper loss due to eddy current) because the magnetic flux changes more gently than in the radial magnet.

The sine wave matching rate will be described below. The sine wave matching rate can be obtained by comparing an actually measured waveform of the surface magnetic flux density distribution measured by tracing the surface of the magnet or the like with the magnetic flux probe with a sine wave having the same period and peak value. The ratio of the amplitude of the primary waveform, which is the fundamental wave of the rotating electric machine, to the amplitude of the actually measured waveform, that is, the amplitude obtained by adding the other harmonic component to the fundamental wave corresponds to the sine wave matching ratio. As the sine wave matching rate becomes high, the waveform of the surface magnetic flux density distribution gradually approaches a sine wave shape. Further, when a current of a primary sine wave is supplied from the inverter to the rotating electric machine including the magnet having the improved sine wave matching rate, it is possible to make the waveform of the surface magnetic flux density distribution of the magnet close to a sine wave shape and generate a large torque. The surface magnetic flux density distribution can also be estimated by a method other than actual measurement, for example, electromagnetic field analysis using maxwell's equations.

Further, as a fifth aspect, the stator winding 51 is provided as a wire conductor structure in which a plurality of strands of wire are gathered and bundled. Thereby, since the wires are connected in parallel, a large current can flow, and since the sectional areas of the respective wires become small, it is possible to more effectively suppress the generation of eddy current at the wire expanding in the circumferential direction of the stator 50 in the flat wire structure, as compared with the third scheme of thinning in the radial direction. Further, since the plurality of strands are twisted, eddy current according to the magnetic flux generated according to the right-hand rule with respect to the current feeding direction can be cancelled with respect to the magnetomotive force from the conductor.

In this way, when the fourth aspect and the fifth aspect are further added, while the magnet of the second aspect having a high magnetic force is employed, it is possible to further suppress eddy current loss caused by the above-described high magnetic force and achieve torque enhancement.

Hereinafter, the non-slot structure of the stator 50, the flat wire structure of the stator winding 51, and the polar anisotropy structure of the magnet unit 42 will be described in an increasing manner. First, the non-slotted structure of the stator 50 and the flat wire structure of the stator winding 51 will be described. Fig. 8 is a cross-sectional view of the rotor 40 and the stator 50, and fig. 9 is an enlarged view of a part of the rotor 40 and the stator 50 shown in fig. 8. Fig. 10 is a sectional view showing a cross section of the stator 50 along the X-X line of fig. 11, and fig. 11 is a sectional view showing a longitudinal section of the stator 50. Fig. 12 is a perspective view of the stator winding 51. In fig. 8 and 9, the magnetization direction of the magnet in the magnet unit 42 is indicated by an arrow.

As shown in fig. 8 to 11, the stator core 52 is formed in a cylindrical shape having a predetermined thickness in the radial direction and a plurality of electromagnetic steel sheets are stacked in the axial direction, and the stator winding 51 is assembled on the radial outer side of the stator core 52 on the rotor 40 side. In the stator core 52, the outer peripheral surface on the rotor 40 side is a lead wire installation portion (conductor region). The outer peripheral surface of the stator core 52 is formed into a curved surface without unevenness, and a plurality of lead groups 81 are arranged on the outer peripheral surface at predetermined intervals in the circumferential direction. The stator core 52 functions as a back yoke that forms a part of a magnetic path for rotating the rotor 40. In this case, a structure in which no pole teeth (i.e., cores) made of a soft magnetic material are provided between each of the two circumferentially adjacent conductor sets 81 (i.e., a non-slotted structure) is obtained. In the present embodiment, the resin material constituting the sealing member 57 enters the gap 56 of each lead group 81. That is, in the stator 50, the inter-lead members provided between the lead groups 81 in the circumferential direction are configured as the sealing member 57 of a nonmagnetic material. In the state before the sealing of the sealing member 57, the conductor groups 81 are arranged at predetermined intervals in the circumferential direction outside the stator core 52 in the radial direction so as to separate the gaps 56, which are the inter-conductor regions, respectively, thereby forming the stator 50 having the non-slotting structure. In other words, as will be described later, each of the lead groups 81 is constituted by two lead wires (conductors) 82, and each of the two lead groups 81 adjacent in the circumferential direction of the stator 50 is occupied only by the nonmagnetic material therebetween. The nonmagnetic material includes a nonmagnetic gas such as air, a nonmagnetic liquid, and the like in addition to the seal member 57. Hereinafter, the sealing member 57 is also referred to as an inter-conductor member (conductor-to-conductor member).

The structure in which the pole teeth are provided between the respective conductor groups 81 arranged in the circumferential direction means a structure in which the pole teeth have a predetermined thickness in the radial direction and a predetermined width in the circumferential direction, and a magnetic path of a magnet, which is a part of a magnetic path, is formed between the respective conductor groups 81. In this regard, the structure in which no pole teeth are provided between the lead wire groups 81 means the structure in which the magnetic circuit is not formed.

As shown in fig. 10, the stator winding (i.e., the armature winding) 51 is formed to have a predetermined thickness T2 (hereinafter also referred to as a first dimension) and a width W2 (hereinafter also referred to as a second dimension). The thickness T2 is the shortest distance between the outer side surface and the inner side surface of the stator winding 51 that are opposite to each other in the radial direction. The width W2 is a length in the circumferential direction of the stator winding 51 that is a part of the stator winding 51 that functions as one of the multiple phases (three phases in the embodiment: three phases of U, V, and W, or three phases of X, Y, and Z) of the stator winding 51. Specifically, in fig. 10, when two lead wire groups 81 adjacent in the circumferential direction function as, for example, a U-phase which is one of three phases, the width W2 is a width from one end to the other end of the two lead wire groups 81 in the circumferential direction. Also, thickness T2 is less than width W2.

In addition, the thickness T2 is preferably less than the total width dimension of the two lead groups 81 present within the width W2. When the cross-sectional shape of the stator winding 51 (more specifically, the lead wires 82) is a perfect circle shape, an ellipse shape, or a polygon shape, the maximum length of the lead wires 82 in the radial direction of the stator 50 in the cross section along the radial direction of the stator 50 may be W12, and the maximum length of the stator 50 in the circumferential direction in the cross section may be W11.

As shown in fig. 10 and 11, the stator winding 51 is sealed by a sealing member 57, and the sealing member 57 is made of a synthetic resin material as a sealing material (molding material). That is, the stator winding 51 and the stator core 52 are molded together by a molding material. The resin can be regarded as Bs 0 as a nonmagnetic substance or a nonmagnetic equivalent.

As seen in the cross section of fig. 10, the gaps 56 between the conductor groups 81, i.e., the synthetic resin material, are filled with a sealing member 57, and an insulating member is interposed between the conductor groups 81 through the sealing member 57. That is, the seal member 57 functions as an insulating member in the gap 56. The seal member 57 is provided outside the stator core 52 in the radial direction in a range including all the conductor groups 81, that is, in a range having a radial thickness dimension larger than the radial thickness dimension of each conductor group 81.

Further, as viewed in the vertical cross section of fig. 11, the seal member 57 is provided in a range including the turn portion 84 of the stator winding 51. The seal member 57 is provided in a range including at least a part of the axially opposite end surfaces of the stator core 52 on the radially inner side of the stator winding 51. In this case, the stator winding 51 is sealed with resin substantially entirely except for the end portions of the phase windings of the respective phases, that is, the connection terminals connected to the inverter circuit.

According to the structure in which the seal member 57 is provided in the range including the end face of the stator core 52, the laminated steel plates of the stator core 52 can be pressed inward in the axial direction by the seal member 57. This enables the stacked state of the steel plates to be maintained by the seal member 57. Although the inner peripheral surface of the stator core 52 is not resin-sealed in the present embodiment, the entire stator core 52 including the inner peripheral surface of the stator core 52 may be resin-sealed.

When the rotating electric machine 10 is used as a vehicle power source, the seal member 57 is preferably made of a highly heat-resistant fluororesin, an epoxy resin, a PPS resin, a PEEK resin, an LCP resin, a silicone resin, a PAI resin, a PI resin, or the like. In addition, when considering the linear expansion coefficient from the viewpoint of suppressing cracking due to the expansion difference, it is desirable that the material be the same as the outer film of the lead wire of the stator winding 51. That is, it is desirable to exclude silicone resins whose linear expansion coefficients are generally multiples or more of those of other resins. Among electric products that do not have a device that uses combustion, such as electric vehicles, PP0 resin, phenol resin, and FRP resin, which have heat resistance of about 180 ℃, are also candidates. In the field where the ambient temperature of the rotating electric machine is regarded as lower than 100 ℃, there is no limitation described above.

The torque of the rotating electrical machine 10 is proportional to the magnitude of the magnetic flux. Here, when the stator core has the pole teeth, the maximum magnetic flux at the stator depends on and is limited to the saturation magnetic flux density at the pole teeth, but when the stator core does not have the pole teeth, the maximum magnetic flux at the stator is not limited. Therefore, it is advantageous in increasing the energization current to the stator winding 51 to achieve an increase in the torque of the rotary electric machine 10.

In the present embodiment, the inductance of the stator 50 is reduced by using a structure without pole teeth (a non-slotting structure) in the stator 50. Specifically, in a stator of a general rotating electrical machine in which a lead wire is accommodated in each slot partitioned by a plurality of pole teeth, the inductance is, for example, about 1mH, whereas the inductance is reduced to about 5 to 60 μ H in the stator 50 of the present embodiment. In the present embodiment, the mechanical time constant Tm can be reduced by reducing the inductance of the stator 50 while providing the rotating electric machine 10 having an outer rotor structure. That is, the mechanical time constant Tm can be reduced while achieving high torque. The mechanical time constant Tm is calculated by the following equation, where J is inertia, L is inductance, Kt is a torque constant, and Ke is a back electromotive force constant.

Tm＝(J×L)/(Kt×Ke)

In this case, it was confirmed that the mechanical time constant Tm can be reduced by reducing the inductance L.

A plurality of lead wires 82 having a flat rectangular cross section are arranged in parallel in the radial direction of the stator core 52, and constitute respective lead wire groups 81 on the outer side in the radial direction of the stator core 52. Each of the wires 82 is arranged in a direction of "radial dimension < circumferential dimension" in cross section. This realizes a radial thinning of each lead group 81. Further, the conductor region is extended flatly to the region having the conventional pole teeth while achieving the radial thinning, and the flat wire region structure is obtained. Thus, the sectional area of the conductor is increased by flattening in the circumferential direction, and an increase in the amount of heat generation of the lead wire due to the reduction in the sectional area by thinning is suppressed. Even in the configuration in which a plurality of strands of wires are arranged in the circumferential direction and the wires are connected in parallel, a decrease in the conductor cross-sectional area due to the portion of the conductor film occurs, but the same effect can be obtained for the same reason. In addition, hereinafter, each of the lead group 81 and each of the leads 82 is also referred to as a conductive member (conductive member).

Since there is no slot, according to the stator winding 51 of the present embodiment, the conductor area occupied by the stator winding 51 of one circumferential cycle thereof can be designed to be larger than the nonconductor occupied area where the stator winding 51 is not present. In addition, in the conventional rotating electric machine for a vehicle, the conductor area/nonconductor occupying area of one circumferential periphery of the stator winding is naturally 1 or less. On the other hand, in the present embodiment, each of the lead groups 81 is provided so that the conductor area is equal to the non-conductor occupying area or the conductor area is larger than the non-conductor occupying area. Here, as shown in fig. 10, when a conductor area in which the conductors 82 (i.e., a straight portion 83 described later) are arranged in the circumferential direction is WA and an inter-conductor area between adjacent conductors 82 is WB, the conductor area WA is larger than the inter-conductor area WB in the circumferential direction.

As a structure of the lead wire group 81 of the stator winding 51, a thickness dimension in a radial direction of the lead wire group 81 is smaller than a width dimension corresponding to a circumferential direction of one phase in one magnetic pole. That is, in the configuration in which the lead group 81 is composed of two layers of leads 82 in the radial direction, and two lead groups 81 are provided in the circumferential direction for one phase in one magnetic pole, the configuration is such that "Tc × 2 < Wc × 2" where Tc is the radial thickness of each lead 82 and Wc is the circumferential width of each lead 82. As another configuration, in a configuration in which the lead group 81 is formed of two layers of leads 82 and one lead group 81 is provided in the circumferential direction for one phase in one magnetic pole, it is preferable to set the relationship "Tc × 2 < Wc". In short, the radial thickness dimension of the lead portions (lead group 81) arranged at predetermined intervals in the circumferential direction in the stator winding 51 is smaller than the width dimension corresponding to the circumferential direction of one phase in one magnetic pole.

In other words, the radial thickness Tc of each strand 82 is preferably smaller than the circumferential width Wc. Further, the radial thickness dimension (2Tc) of the lead group 81 composed of the two layers of leads 82 in the radial direction, that is, the radial thickness dimension (2Tc) of the lead group 81 is preferably smaller than the circumferential width dimension Wc.

The torque of the rotating electrical machine 10 is approximately inversely proportional to the radial thickness of the stator core 52 of the lead group 81. In this regard, the thickness of the lead wire group 81 is reduced on the radially outer side of the stator core 52, which is advantageous in that the torque of the rotating electrical machine 10 is increased. The reason is that the distance from the magnet unit 42 of the rotor 40 to the stator core 52 (i.e., the distance of the portion without iron) can be reduced, thereby reducing the magnetic resistance. This can increase the interlinkage magnetic flux between the permanent magnet and the stator core 52, and can increase the torque.

Further, by making the thickness of the lead group 81 thin, even if magnetic flux leaks from the lead group 81, it can be easily recovered to the stator core 52, and leakage of magnetic flux to the outside can be suppressed and is not effectively used for torque improvement. That is, a decrease in magnetic force due to leakage of magnetic flux can be suppressed, and the interlinkage magnetic flux between the permanent magnet and the stator core 52 can be increased to enhance torque.

The lead wires 82 (conductors) are formed of covered lead wires in which the surface of the conductor (conductor body)82a is covered with an insulating film 82b, and insulation is secured between the lead wires 82 overlapping each other in the radial direction and between the lead wires 82 and the stator core 52. If the wire 86 described later is a self-fluxing covered wire, the insulating film 82b is a covered film thereof, or is formed of an insulating member that is different from and overlaps the covered film of the wire 86. In addition, each phase winding constituted by the lead wire 82 is kept insulated by an insulating film 82b except for the exposed portion for connection. The exposed portion is, for example, an input/output terminal portion or a neutral point portion when star connection is formed. In the lead group 81, the leads 82 adjacent in the radial direction are fixed to each other by resin fixation or self-fluxing coating. Thereby, insulation breakdown, vibration, and sound caused by the wires 82 rubbing against each other are suppressed.

In the present embodiment, the conductor 82a is configured as an aggregate of a plurality of strands of wire (wire) 86. Specifically, as shown in fig. 13, the conductor 82a is formed into a twisted shape by twisting a plurality of strands of wire 86. As shown in fig. 14, the wire 86 is a composite body formed by bundling thin fiber-shaped conductive members 87. For example, the wire 86 is a composite of CNT (carbon nanotube) fibers, and as the CNT fibers, fibers including boron-containing microfibers in which at least a part of carbon is substituted with boron are used. As the carbon microfine fibers, in addition to the CNT fibers, Vapor Growth Carbon Fibers (VGCF) and the like can be used, but the CNT fibers are preferably used. The surface of the wire 86 is covered with a polymer insulating layer such as enamel. Further, the surface of the wire 86 is preferably covered with a so-called enamel film composed of a film of polyimide, a film of amide imide.

The wires 82 constitute n-phase windings in the stator winding 51. Also, the respective wires 86 of the lead wires 82 (i.e., the conductors 82a) are adjacent in a state of contact with each other. The lead 82 is a wire assembly in which the winding conductor has a portion formed by twisting a plurality of wires 86 at one or more positions within a phase, and the resistance value between the twisted wires 86 is larger than the resistance value of the wires 86 themselves. In other words, when each of the two adjacent strands of wires 86 has a first resistivity in the adjacent direction and each of the wires 86 has a second resistivity in the longitudinal direction thereof, the first resistivity is a value larger than the second resistivity. The lead 82 may be a wire assembly of: is formed of a plurality of strands 86 and the plurality of strands 86 are covered with a first extremely high resistivity insulating member. Further, the conductor 82a of the wire 82 is constituted by twisted strands 86.

Since the conductor 82a is formed by twisting a plurality of strands of the wire material 86, it is possible to reduce the eddy current of the conductor 82a while suppressing the generation of the eddy current in each wire material 86. Further, by twisting the respective wires 86, portions in which the magnetic fields are applied in mutually opposite directions are generated in one wire 86, and the counter electromotive force is cancelled out. Therefore, eddy current can still be reduced. In particular, by forming the wire 86 with the fibrous conductive member 87, it is possible to make the wire thin and to greatly increase the number of twists, thereby desirably reducing the eddy current.

The method of insulating the wires 86 from each other is not limited to the above-described polymer insulating film, and a method of making it difficult for current to flow between the twisted wires 86 by contact resistance may be used. That is, if the resistance value between the twisted wires 86 is larger than the resistance value of the wire 86 itself, the above-described effect can be obtained by the potential difference generated by the difference in resistance value. For example, it is preferable that the manufacturing equipment for manufacturing the wire 86 and the manufacturing equipment for manufacturing the stator 50 (armature) of the rotating electrical machine 10 be used as separate discontinuous equipment, so that the wire 86 is oxidized according to the moving time, the working interval, and the like, thereby increasing the contact resistance.

As described above, the lead 82 is a member having a flat rectangular cross section and a plurality of members arranged side by side in the radial direction, and the shape is maintained by, for example, gathering a plurality of strands 86 covered with a self-melting covered wire including a fusion layer and an insulating layer in a twisted state and fusing the fusion layers to each other. Further, the wire rod not including the fusion layer or the wire rod of the self-fusing coated wire may be firmly molded in a twisted state into a desired shape using a synthetic resin or the like. When the thickness of the insulating film 82b of the lead wire 82 is set to, for example, 80 to 100 μm, which is thicker than the thickness (5 to 40 μm) of a lead wire used in general, insulation between the lead wire 82 and the stator core 52 can be ensured even if an insulating paper or the like is not interposed between the lead wire 82 and the stator core 52.

Further, it is desirable that the insulating film 82b has a higher insulating performance than the insulating layer of the wire 86, and can insulate the phases. For example, when the thickness of the polymer insulating layer of the wire 86 is about 5 μm, for example, it is desirable that the thickness of the insulating film 82b of the lead 82 is about 80 μm to 100 μm, so that the insulation between the phases can be preferably performed.

The lead 82 may be configured to bundle the plurality of wires 86 without twisting. That is, the lead 82 may have any structure in which the plurality of strands 86 are twisted over the entire length thereof, a structure in which the plurality of strands 86 are twisted over a part of the entire length thereof, or a structure in which the plurality of strands 86 are bound without being twisted over the entire length thereof. In short, each of the leads 82 constituting the lead portion is a wire assembly of: the plurality of strands of wire 86 are bundled and the resistance value between the bundled wires is greater than the resistance value of the wire 86 itself.

Each of the lead wires 82 is bent to be arranged in a predetermined arrangement pattern in the circumferential direction of the stator winding 51, thereby forming a phase winding for each phase as the stator winding 51. As shown in fig. 12, in the stator winding 51, the coil side portions 53 are formed by straight portions 83 extending linearly in the axial direction in the respective lead wires 82, and the coil side ends 54, 55 are formed by bent portions 84 protruding outward in the axial direction on both sides of the coil side portions 53. The straight portions 83 and the bent portions 84 are alternately repeated, and the conductive wires 82 are configured as a series of conductive wires having a waveform. The straight portions 83 are disposed at positions radially opposed to the magnet unit 42, and the straight portions 83 of the same phase disposed at positions axially outward of the magnet unit 42 with a predetermined interval therebetween are connected to each other by a bent portion 84. The linear portion 83 corresponds to a "magnet opposing portion".

In the present embodiment, the stator winding 51 is formed by winding in a distributed winding manner in an annular shape. In this case, the coil side portion 53 has linear portions 83 arranged at intervals corresponding to one pole of the magnet unit 42 in the circumferential direction for each phase, and the linear portions 83 of each phase are connected to each other by a bent portion 84 formed in a substantially V-shape at the

coil edge

54, 55. The directions of currents of the respective linear portions 83 paired with one pole pair are opposite to each other. In addition, the combination of the pair of linear portions 83 connected by the bent portion 84 differs between the one coil side end 54 and the other coil side end 55, and the stator winding 51 is formed into a substantially cylindrical shape by repeating the connection at the coil side ends 54, 55 in the circumferential direction.

More specifically, the stator winding 51 is formed by winding each phase using two pairs of lead wires 82 for each phase, and one three-phase winding (U-phase, V-phase, W-phase) and the other three-phase winding (X-phase, Y-phase, Z-phase) of the stator winding 51 are provided at two radially inner and outer layers. In this case, when the number of phases of the stator winding 51 is S (6 in the embodiment) and the number of the lead wires 82 per phase is m, 2 × S × m — 2Sm lead wires 82 are formed for each pole pair. In the present embodiment, since the rotating electric machine has 6 phases S, 4 numbers m, and 8 pole pairs (16 poles), 192 strands of wires 82 are arranged in the circumferential direction of the stator core 52, that is, 6 × 4 × 8 wires.

In the stator winding 51 shown in fig. 12, the straight portions 83 are arranged in two radially adjacent layers in the coil side portion 53 so as to overlap each other, and the bent portions 84 extend in the circumferential direction in mutually opposite directions in the circumferential direction from the respective straight portions 83 overlapping in the radial direction in the coil side ends 54, 55. That is, in each of the conductive wires 82 adjacent in the radial direction, the directions of the return portions 84 are opposite to each other except for the end portions of the stator winding 51.

Here, a winding structure of the wire 82 in the stator winding 51 will be specifically described. In the present embodiment, the plurality of conductive wires 82 formed by wave winding are arranged to overlap in a plurality of layers (for example, two layers) adjacent in the radial direction. Fig. 15 (a) and 15 (b) are views showing the form of each lead wire 82 of the n-th layer, fig. 15 (a) shows the shape of the lead wire 82 as viewed from the side of the stator winding 51, and fig. 15 (b) shows the shape of the lead wire 82 as viewed from one axial side of the stator winding 51. In fig. 15 (a) and 15 (b), positions where the lead group 81 is arranged are indicated as D1, D2, and D3 …, respectively. For convenience of explanation, only three wires 82 are shown, and the first wire 82_ a, the second wire 82_ B, and the third wire 82_ C are used.

In each of the conductive wires 82_ a to 82_ C, the straight portions 83 are arranged at the position of the nth layer, that is, at the same position in the radial direction, and the straight portions 83 separated at 6 positions (corresponding to 3 × m pairs) in the circumferential direction are connected to each other by the bent portions 84. In other words, in each of the lead wires 82_ a to 82_ C, two of both ends of seven linear portions 83 arranged adjacent to each other in the circumferential direction of the stator winding 51 are connected to each other by one bent portion 84 on the same circle centered on the axial center of the rotor 40. For example, in the first lead 82_ a, a pair of straight portions 83 are disposed at D1 and D7, respectively, and the pair of straight portions 83 are connected to each other by an inverted V-shaped return portion 84. The other conductive wires 82_ B and 82_ C are arranged in the same nth layer so as to be shifted by one position in the circumferential direction. In this case, since the lead wires 82_ a to 82_ C are all disposed on the same layer, the return portions 84 are considered to interfere with each other. Therefore, in the present embodiment, the interference avoiding portion is formed in the turn portion 84 of each of the conductive wires 82_ a to 82_ C so as to be partially offset in the radial direction.

Specifically, the bent portion 84 of each of the lead wires 82_ a to 82_ C includes: one inclined portion 84a as a portion extending in the circumferential direction on the same circle (first circle); a position shifted from the inclined portion 84a to a radially inner side (upper side in fig. 15 b) of the same circle and reaching the apex portion 84b of the other circle (second circle); a slope 84c extending in the circumferential direction on the second circle; and a return portion 84d from the first circle to the second circle. The apex portion 84b, the inclined portion 84c, and the return portion 84d correspond to an interference avoiding portion. The inclined portion 84c may be radially outwardly offset from the inclined portion 84 a.

That is, the bent portions 84 of the respective lead wires 82_ a to 82_ C have one inclined portion 84a and the other inclined portion 84C on both sides thereof with respect to the top portion 84b, which is the circumferential central position, and the radial positions (the position in the front-rear direction of the paper in fig. 15 a, and the position in the up-down direction in fig. 15 b) of the inclined portions 84a and 84C are different from each other. For example, the bent portion 84 of the first lead wire 82_ a extends in the circumferential direction with the D1 position of the n layers as a starting point, is bent radially (for example, radially inward) at the apex portion 84b, which is the circumferential central position, is then bent again in the circumferential direction, is then extended circumferentially again, is further bent again radially (for example, radially outward) at the return portion 84D, and reaches the D7 position of the n layers, which is the end position.

According to the above configuration, the lead wires 82_ a to 82_ C are configured such that the inclined portions 84a on one side are arranged vertically in the order of the first lead wire 82_ a → the second lead wire 82_ B → the third lead wire 82_ C from above, and the top and bottom of the lead wires 82_ a to 82_ C are switched at the apex portion 84B, and the inclined portions 84C on the other side are arranged vertically in the order of the third lead wire 82_ C → the second lead wire 82_ B → the first lead wire 82_ a from above. Therefore, the conductive wires 82_ a to 82_ C can be arranged in the circumferential direction without interfering with each other.

Here, in the configuration in which the plurality of lead wires 82 are stacked in the radial direction to form the lead wire group 81, the return portion 84 connected to the straight portion 83 on the radially inner side among the straight portions 83 in the plurality of layers and the return portion 84 connected to the straight portion 83 on the radially outer side are preferably arranged to be further apart from each other in the radial direction than the straight portions 83. When the multilayer conductive wires 82 are bent radially on the same side at the end of the bent portion 84, that is, near the boundary portion of the straight portion 83, it is preferable that the insulation is not damaged by the interference between the conductive wires 82 of the adjacent layers.

For example, in D7 to D9 in fig. 15 (a) and 15 (b), the respective lead wires 82 that overlap in the radial direction are bent in the radial direction at the return portions 84D of the return portions 84, respectively. In this case, as shown in fig. 16, it is preferable that the curvature radii of the curved portions of the wire 82 of the nth layer and the wire 82 of the (n + 1) th layer are different. Specifically, the radius of curvature R1 of the wire 82 on the radially inner side (nth layer) is made smaller than the radius of curvature R2 of the wire 82 on the radially outer side (n +1 st layer).

In addition, it is preferable that the amount of radial offset of the wire 82 of the nth layer and the wire 82 of the (n + 1) th layer is different. Specifically, the amount of offset S1 of the wire 82 on the radially inner side (nth layer) is made larger than the amount of offset S2 of the wire 82 on the radially outer side (n +1 st layer).

According to the above structure, even in the case where the respective conductive wires 82 overlapped in the radial direction are bent in the same direction, the mutual interference of the respective conductive wires 82 can be desirably avoided. This provides excellent insulation.

Next, the structure of the magnet unit 42 in the rotor 40 will be described. In the present embodiment, it is assumed that magnet unit 42 is formed of a permanent magnet, and residual magnetic flux density Br is 1.0[ T ] and intrinsic coercive force Hcj is 400[ kA/m ] or more. In short, the permanent magnet used in the present embodiment is a sintered magnet obtained by sintering a granular magnetic material and molding and solidifying the sintered magnet, and the intrinsic coercive force Hcj on the J-H curve is 400[ kA/m ] or more, and the residual magnetic flux density Br is 1.0[ T ] or more. When 5000 to 10000[ AT ] are applied by the inter-phase excitation, if a permanent magnet having a magnetic length of N and S poles as one pole pair, that is, a length of 25[ mm ] passing through the magnet in a path through which magnetic flux flows between the N and S poles is used, Hcj becomes 10000[ A ], and demagnetization does not occur.

In other words, regarding the magnet unit 42, the saturation magnetic flux density Js is 1.2[ T ] or more and the crystal grain size is 10[ μm ] or less, and Js × α is 1.0[ T ] or more when the orientation ratio is α.

The magnet unit 42 will be described supplementarily below. The magnet unit 42 (magnet) is characterized in that 2.15[ T ] or more Js or more 1.2[ T ]. In other words, as the magnet used for the magnet unit 42, NdFe11TiN, Nd2Fe14B, Sm2Fe17N3, FeNi magnet having L10 type crystal, and the like are cited. Further, the structure of SmCo5, FePt, Dy2Fe14B, CoPt, etc., which is generally called a samarium-cobalt magnet (samarium-cobalt) cannot be used. It should be noted that although heavy rare earth dysprosium is generally used, such as Dy2Fe14B and Nd2Fe14B, and the high Js characteristic of neodymium is slightly lost, magnets having a high coercive force possessed by Dy can also satisfy 2.15T ≧ Js ≧ 1.2T, and can also be used in such cases. In this case, it is referred to as, for example, ([ Nd1-xDyx ]2Fe 14B). Further, it can be realized by using two or more kinds of magnets having different compositions, for example, a magnet made of two or more kinds of materials such as FeNi + Sm2Fe17N3, or by using a hybrid magnet in which a small amount of, for example, Dy2Fe14B having Js < 1[ T ] is mixed with a magnet of Nd2Fe14B having Js excess such as Js of 1.6[ T ], to increase coercive force.

Further, for a rotating electrical machine that operates at a temperature outside the range of human activity, for example, 60 ℃ or higher exceeding the temperature of a desert, for example, for a vehicle motor application in which the interior temperature of the vehicle approaches 80 ℃ in summer, a component including FeNi or Sm2Fe17N3 having a small temperature dependence coefficient is particularly desirable. This is because, in motor operation from a temperature state in the vicinity of-40 ℃ in northern europe, which is a range of human motion, to the above-described temperature exceeding 60 ℃ in desert or to the heat-resistant temperature of 180 to 240 ℃ or so of the coil enamel film, the motor characteristics largely differ depending on the temperature dependence coefficient, and it is difficult to perform optimal control by the same motor driver or the like. When FeNi or Sm2Fe17N3 having the L10 type crystal is used, the load on the motor driver can be reduced desirably by the characteristic of having a temperature dependency coefficient of half or less as compared with Nd2Fe 14B.

In addition, the magnet unit 42 is characterized in that the size of the particle diameter in a fine powder state before orientation is 10 μm or less and the single domain particle diameter is 10 μm or more by using the above magnet combination. In a magnet, the coercive force can be increased by making the particles of the powder finer to the order of several hundred nm, and therefore, in recent years, as much as possible, finer powder is used. However, if the grain size is too small, the BH product of the magnet is reduced by oxidation or the like, and therefore, the single domain particle diameter or more is preferable. It is known that the coercivity increases due to miniaturization of the particle diameter up to the single domain particle diameter. The particle diameter described here is the particle diameter in a fine powder state in the orientation step in the production process of the magnet.

Further, the first magnet 91 and the second magnet 92 of the magnet unit 42 are respectively sintered magnets formed by firing magnetic powder at a high temperature, that is, by so-called sintering. The magnetic unit 42 has a saturation magnetic flux density Js of 1.2T or more, and the first and second

magnetic bodies

91 and 92 have crystal grain diameters of 10 μm or less, and when the orientation ratio is α, sintering is performed so as to satisfy the condition that Js × α is 1.0T (tesla) or more. Further, the first and

second magnets

91 and 92 are sintered so as to satisfy the following conditions, respectively. Next, the isotropic magnetic material is oriented in the orientation step in the above-described manufacturing step, and has an orientation ratio (orientation ratio) different from the definition of the magnetic force direction in the excitation step of the isotropic magnetic material. The orientation ratio is set high so that the saturation magnetic flux density Js of the magnet unit 42 of the present embodiment is 1.2T or more and the orientation ratio α of the first and

second magnets

91 and 92 is Jr.gtoreq.jslpha.gtoreq.1.0 [ T ]. The orientation factor α here means that, in each of the first magnet 91 and the second magnet 92, when there are 6 easy magnetization axes, for example, 5 of them are oriented in the same direction, i.e., the direction a10, and the remaining one is oriented in the direction B10 inclined at 90 degrees to the direction a10, α is 5/6, and when the remaining one is oriented in the direction B10 inclined at 45 degrees to the direction a10, α is (5+0.707)/6 because the component oriented in the direction a10 of the remaining one is cos45 ° -0.707. In the present embodiment, the first magnetic body 91 and the second magnetic body 92 are formed by sintering, but if the above conditions are satisfied, the first magnetic body 91 and the second magnetic body 92 may be formed by another method. For example, a method of forming MQ3 magnets or the like may be employed.

In the present embodiment, since the permanent magnet whose axis of easy magnetization is controlled by the orientation is used, the magnetic path length inside the magnet can be made longer than that of a conventional linearly oriented magnet having a magnetic path length of 1.0T or more. That is, in addition to the fact that the magnetic path length per pole pair can be realized with a smaller amount of magnet, the reversible demagnetization range can be maintained even when exposed to a severe high temperature condition as compared with the design using the conventional linearly oriented magnet. Further, the inventors of the present application have found a structure that can obtain characteristics close to those of a polar anisotropic magnet even when a magnet of the related art is used.

The easy axis means a crystal orientation that is easily magnetized in a magnet. The direction of the easy magnetization axis in the magnet is a direction in which the orientation rate indicating the degree of alignment of the direction of the easy magnetization axis is 50% or more, or a direction in which the orientation of the magnet is averaged.

As shown in fig. 8 and 9, the magnet unit 42 is annular and is provided inside the magnet holder 41 (specifically, radially inside the cylindrical portion 43). The magnet unit 42 has a first magnet 91 and a second magnet 92 which are respectively polar anisotropic magnets and have mutually different polarities. The first magnets 91 and the second magnets 92 are alternately arranged in the circumferential direction. The first magnet 91 is a magnet having an N pole formed at a portion close to the stator winding 51, and the second magnet 92 is a magnet having an S pole formed at a portion close to the stator winding 51. The first magnet 91 and the second magnet 92 are permanent magnets made of rare earth magnets such as neodymium magnets.

In each of the

magnets

91 and 92, as shown in fig. 9, in a known d-q coordinate system, the magnetization direction extends in an arc shape between a d-axis (direct-axis) which is a magnetic pole center and a q-axis (orthogonal axis) which is a magnetic pole boundary between the N-pole and the S-pole (in other words, the magnetic flux density is 0 tesla). In each of the

magnets

91 and 92, the magnetization direction is in the radial direction of the annular magnet unit 42 on the d-axis side, and the magnetization direction of the annular magnet unit 42 is in the circumferential direction on the q-axis side. The following is a further detailed description. As shown in fig. 9, the

magnets

91 and 92 each have: a first portion 250; and two second portions 260 located on both sides of the first portion 250 in the circumferential direction of the magnet unit 42. In other words, the first portion 250 is closer to the d-axis than the second portion 260, and the second portion 260 is closer to the q-axis than the first portion 250. Further, the magnet unit 42 is configured such that the direction of the magnetization easy axis 300 of the first portion 250 is more parallel to the d-axis than the direction of the magnetization easy axis 310 of the second portion 260. In other words, the magnet unit 42 is configured such that the angle θ 11 between the easy axis 300 of the first portion 250 and the d-axis is smaller than the angle θ 12 between the easy axis 310 of the second portion 260 and the q-axis.

In more detail, the angle θ 11 is an angle formed by the d-axis and the magnetization easy axis 300 when the direction from the stator 50 (armature) toward the magnet unit 42 on the d-axis is set to be positive. The angle θ 12 is an angle formed by the q-axis and the magnetization easy axis 310 when the direction from the stator 50 (armature) toward the magnet unit 42 on the q-axis is set to be positive. In the present embodiment, both the angle θ 11 and the angle θ 12 are 90 ° or less. The easy axes 300 and 310 are defined as follows. In each of the portions of the

magnets

91 and 92, when one easy axis is oriented in the direction a11 and the other easy axis is oriented in the direction B11, the absolute value (| cos θ |) of the cosine of the angle θ formed by the direction a11 and the direction B11 is defined as the easy axis 300 or the easy axis 310.

That is, the directions of the magnetization easy axes of the

magnets

91 and 92 are different between the d-axis side (portion close to the d-axis) and the q-axis side (portion close to the q-axis), and the direction of the magnetization easy axis is a direction close to a direction parallel to the d-axis on the d-axis side and a direction close to a direction orthogonal to the q-axis on the q-axis side. Further, a magnetic path of the magnet is formed in a circular arc shape in accordance with the direction of the easy magnetization axis. In the

magnets

91 and 92, the easy magnetization axis may be parallel to the d-axis on the d-axis side and may be perpendicular to the q-axis on the q-axis side.

In the

magnets

91 and 92, the stator-side outer surface on the stator 50 side (lower side in fig. 9) and the q-axis-side end surface in the circumferential direction in the circumferential surfaces of the

magnets

91 and 92 are flux acting surfaces that are inflow and outflow surfaces of magnetic flux, and the magnet magnetic circuit is formed so as to connect the flux acting surfaces (the stator-side outer surface and the q-axis-side end surface).

In the magnet unit 42, the

magnets

91 and 92 cause magnetic flux to flow in an arc between the adjacent N pole and S pole, and therefore the magnetic path of the magnet is longer than that of a radial anisotropic magnet, for example. Therefore, as shown in fig. 17, the magnetic flux density distribution approaches a sine wave. As a result, unlike the magnetic flux density distribution of the radial anisotropic magnet shown as a comparative example in fig. 18, the magnetic flux can be concentrated on the center side of the magnetic pole, and the torque of the rotating electrical machine 10 can be increased. In addition, in the magnet unit 42 of the present embodiment, it was confirmed that there was a difference in magnetic flux density distribution as compared with the magnet of the conventional halbach array. In fig. 17 and 18, the horizontal axis represents the electrical angle, and the vertical axis represents the magnetic flux density. In fig. 17 and 18, 90 ° on the horizontal axis represents the d axis (i.e., the magnetic pole center), and 0 ° and 180 ° on the horizontal axis represent the q axis.

That is, according to the

magnets

91 and 92 configured as described above, the magnet magnetic flux in the d axis is enhanced, and the magnetic flux change in the vicinity of the q axis is suppressed. This makes it possible to realize

magnets

91 and 92 with a reduced surface magnetic flux change from the q-axis to the d-axis in each magnetic pole.

The sine wave matching rate of the magnetic flux density distribution is preferably 40% or more, for example. Thus, the magnetic flux at the center of the waveform can be reliably increased as compared with the case of using a radially oriented magnet having a sine wave matching rate of about 30% or using a parallel oriented magnet. Further, when the sine wave matching rate is 60% or more, the magnetic flux at the center of the waveform can be reliably increased as compared with a flux concentration array such as a halbach array.

In the radial anisotropic magnet shown in fig. 18, the magnetic flux density changes sharply near the q-axis. The more rapid the change in the magnetic flux density, the more the eddy current generated in the stator winding 51 increases. Further, the magnetic flux change on the stator winding 51 side also becomes abrupt. In contrast, in the present embodiment, the magnetic flux density distribution has a waveform close to a sine wave. Therefore, the variation in magnetic flux density is smaller in the vicinity of the q-axis than in the radial anisotropic magnet. This can suppress the generation of eddy current.

In the magnet unit 42, magnetic flux is generated in the vicinity of the d axis (i.e., the magnetic pole center) of each of the

magnets

91 and 92 in a direction perpendicular to the magnetic flux acting surface 280 on the stator 50 side, and the magnetic flux is formed in an arc shape such that the magnetic flux acting surface 280 on the stator 50 side is further from the d axis. The more the magnetic flux is perpendicular to the magnetic flux action surface, the stronger the magnetic flux. In this regard, in the rotating electrical machine 10 of the present embodiment, since the lead wire groups 81 are thinned in the radial direction as described above, the center position in the radial direction of the lead wire groups 81 is close to the magnetic flux acting surface of the magnet unit 42, and strong magnet magnetic flux can be received from the rotor 40 in the stator 50.

Further, a cylindrical stator core 52 is provided on the radially inner side of the stator winding 51 of the stator 50, i.e., on the opposite side of the rotor 40 with the stator winding 51 therebetween. Therefore, while the stator core 52 is used as a part of the magnetic circuit, the magnetic flux extending from the magnetic flux acting surface of each of the

magnets

91, 92 is attracted by the stator core 52 and surrounds the stator core 52 circumferentially. In this case, the direction and path of the magnetic flux of the magnet can be optimized.

Hereinafter, as a method of manufacturing the rotating electric machine 10, an assembly sequence of the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 shown in fig. 5 will be described. As shown in fig. 6, the inverter unit 60 includes a unit base 61 and an electric component 62, and respective working steps including an assembling step of the unit base 61 and the electric component 62 will be described. In the following description, an assembly constituted by the stator 50 and the inverter unit 60 is referred to as a first unit, and an assembly constituted by the bearing unit 20, the housing 30, and the rotor 40 is referred to as a second unit.

The manufacturing process comprises:

a first step of attaching the electrical component 62 to the inside of the unit base 61 in the radial direction;

a second step of attaching the unit base 61 to the inside of the stator 50 in the radial direction to fabricate a first unit;

a third step of inserting the fixing portion 44 of the rotor 40 into the bearing unit 20 assembled to the housing 30 to manufacture a second unit;

a fourth step of attaching the first unit to the inside of the second unit in the radial direction; and

a fifth step of fastening and fixing the housing 30 and the unit base 61.

The steps are carried out in the order of first step → second step → third step → fourth step → fifth step.

According to the above manufacturing method, since the bearing unit 20, the housing 30, the rotor 40, the stator 50, and the inverter unit 60 are assembled into a plurality of assemblies (subassemblies) and then the assemblies are assembled with each other, easy transportation, completion of inspection of each unit, and the like can be achieved, and a rational assembly line can be constructed. Therefore, it is possible to easily cope with production of various varieties.

In the first step, it is preferable that a heat conductor having good heat conduction is attached to at least one of the radially inner side of the unit base 61 and the radially outer side of the electric component 62 by coating, bonding, or the like, and the electric component 62 is attached to the unit base 61 in this state. This enables heat generated by the semiconductor module 66 to be efficiently transferred to the unit base 61.

In the third step, the insertion operation of the rotor 40 is preferably performed while maintaining the coaxial relationship between the housing 30 and the rotor 40. Specifically, for example, a jig for determining the position of the outer peripheral surface of the rotor 40 (the outer peripheral surface of the magnet holder 41) or the inner peripheral surface of the rotor 40 (the inner peripheral surface of the magnet unit 42) with respect to the inner peripheral surface of the housing 30 is used, and the housing 30 and the rotor 40 are assembled while sliding either the housing 30 or the rotor 40 along the jig. This allows the weight member to be assembled without applying an unbalanced load to the bearing unit 20, thereby improving the reliability of the bearing unit 20.

In the fourth step, it is preferable that the first unit and the second unit are assembled while maintaining the same axis. Specifically, for example, a jig for determining the position of the inner peripheral surface of the unit base 61 with respect to the inner peripheral surface of the fixing portion 44 of the rotor 40 is used, and the first unit and the second unit are assembled while sliding one of the units along the jig. Accordingly, since the rotor 40 and the stator 50 can be assembled while preventing interference between the extremely small gaps, it is possible to eliminate damage to the stator winding 51 and defective products due to assembly such as a notch of the permanent magnet.

The order of the steps may be set to second step → third step → fourth step → fifth step → first step. In this case, it is possible to minimize the stress applied to the electrical component 62 in the assembly process by finally assembling the precise electrical component 62.

Next, the configuration of a control system for controlling the rotating electric machine 10 will be described. Fig. 19 is a circuit diagram of a control system of the rotating electric machine 10, and fig. 20 is a functional block diagram showing a control process of the control device 110.

In fig. 19, two sets of three-phase windings 51a and 51b are shown as the stator winding 51, the three-phase winding 51a being configured by a U-phase winding, a V-phase winding, and a W-phase winding, and the three-phase winding 51b being configured by an X-phase winding, a Y-phase winding, and a Z-phase winding. A first inverter 101 and a second inverter 102, which correspond to power converters, are provided for the three-phase windings 51a and 51b, respectively. The

inverters

101 and 102 are constituted by a full bridge circuit having upper and lower arms, the number of which is the same as the number of phases of the phase windings, and the conduction current in each phase winding of the stator winding 51 is adjusted by turning on and off a switch (semiconductor switching element) provided in each arm.

A dc power supply 103 and a smoothing capacitor 104 are connected in parallel to the

inverters

101 and 102. The dc power supply 103 is formed of, for example, a battery pack in which a plurality of cells are connected in series. The switches of the

inverters

101 and 102 correspond to the semiconductor module 66 shown in fig. 1 and the like, and the capacitor 104 corresponds to the capacitor module 68 shown in fig. 1 and the like.

The control device 110 includes a microcomputer including a CPU and various memories, and performs energization control by turning on and off the switches of the

inverters

101 and 102 based on various kinds of detection information in the rotating electric machine 10 and requests for power running drive and power generation. The control device 110 corresponds to the control device 77 shown in fig. 6. The detection information of the rotating electrical machine 10 includes: for example, the rotation angle (electrical angle information) of the rotor 40 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the conduction current of each phase detected by a current sensor. The control device 110 generates and outputs operation signals for operating the switches of the

inverters

101 and 102. In addition, when the rotating electrical machine 10 is used as a power source for a vehicle, for example, the request for power generation is a request for regenerative drive.

The first inverter 101 includes a series connection body of an upper arm switch Sp and a lower arm switch Sn in each of three phases including a U phase, a V phase, and a W phase. The high-potential-side terminal of the upper arm switch Sp of each phase is connected to the positive terminal of the dc power supply 103, and the low-potential-side terminal of the lower arm switch Sn of each phase is connected to the negative terminal of the dc power supply 103 (grounded). One ends of a U-phase winding, a V-phase winding, and a W-phase winding are connected to intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase. The above-mentioned phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at a neutral point.

The second inverter 102 has the same configuration as the first inverter 101, and includes a series connection body of an upper arm switch Sp and a lower arm switch Sn in each of three phases including an X phase, a Y phase, and a Z phase. The high-potential-side terminal of the upper arm switch Sp of each phase is connected to the positive terminal of the dc power supply 103, and the low-potential-side terminal of the lower arm switch Sn of each phase is connected to the negative terminal of the dc power supply 103 (grounded). One ends of an X-phase winding, a Y-phase winding, and a Z-phase winding are connected to intermediate connection points between the upper arm switch Sp and the lower arm switch Sn of each phase. The above-mentioned phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at a neutral point.

Fig. 20 shows a current feedback control process of controlling the respective phase currents of the U-phase, V-phase, and W-phase, and a current feedback control process of controlling the respective phase currents of the X-phase, Y-phase, and Z-phase. First, the control processing on the U-phase, V-phase, and W-phase sides will be described.

In fig. 20, the current command value setting unit 111 sets the d-axis current command value and the q-axis current command value based on the electrical angular velocity ω obtained by time-differentiating the electrical angle θ with respect to the motoring torque command value or the generating torque command value of the rotating electrical machine 10 using the torque-dq map. The current command value setting unit 111 is provided in common on the U-phase, V-phase, and W-phase sides and on the X-phase, Y-phase, and Z-phase sides. In addition, for example, when the rotating electrical machine 10 is used as a power source for a vehicle, the generated torque command value is a regenerative torque command value.

The dq conversion unit 112 converts current detection values (three phase currents) detected by current sensors provided for the respective phases into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system having an excitation direction (magnetic field direction: magnetic field axis direction or magnetic field direction) as a d-axis.

The d-axis current feedback control unit 113 calculates a command voltage of the d-axis as an operation amount for feedback-controlling the d-axis current to a current command value of the d-axis. Further, the q-axis current feedback control unit 114 calculates a command voltage of the q-axis as an operation amount for feedback-controlling the q-axis current to a current command value of the q-axis. In the

feedback control units

113 and 114, the command voltage is calculated by using the PI feedback method based on the deviation between the d-axis current and the q-axis current and the current command value.

The three-phase converter 115 converts the command voltages for the d-axis and q-axis into command voltages for the U-phase, V-phase, and W-phase. The units 111 to 115 are feedback control units for performing feedback control of the fundamental wave current based on the dq conversion theory, and the command voltages for the U-phase, V-phase, and W-phase are feedback control values.

Then, the operation signal generation unit 116 generates operation signals of the first inverter 101 based on the three-phase command voltages by a well-known triangular wave carrier comparison method. Specifically, the operation signal generation unit 116 generates switching operation signals (duty signals) of the upper and lower arms of each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the three-phase command voltage with the power supply voltage and a carrier signal such as a triangular wave signal.

The same configuration is applied to the X-phase, Y-phase, and Z-phase sides, and the dq converter 122 converts current detection values (three phase currents) detected by current sensors provided for the respective phases into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system having the excitation direction as the d-axis.

The d-axis current feedback control unit 123 calculates a command voltage for the d-axis, and the q-axis current feedback control unit 124 calculates a command voltage for the q-axis. The three-phase converter 125 converts the d-axis and q-axis command voltages into X-phase, Y-phase, and Z-phase command voltages. Then, the operation signal generation section 126 generates operation signals of the second inverter 102 based on the three-phase command voltages. Specifically, the operation signal generation unit 126 generates switching operation signals (duty signals) for the upper and lower arms of each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the three-phase command voltage with the power supply voltage and a carrier signal such as a triangular wave signal.

The driver 117 turns on and off the switches Sp and Sn of the three phases in the

inverters

101 and 102 based on the switching operation signals generated by the operation

signal generation units

116 and 126.

Next, the torque feedback control process will be described. Under operating conditions where the output voltage of each

inverter

101, 102 increases, such as a high rotation region and a high output region, the above-described processing is mainly used for the purpose of increasing the output of the rotating electrical machine 10 and reducing the loss. The control device 110 selects and executes one of the torque feedback control process and the current feedback control process based on the operating conditions of the rotating electric machine 10.

Fig. 21 shows torque feedback control processing corresponding to U-phase, V-phase, and W, and torque feedback control processing corresponding to X-phase, Y-phase, and Z. In fig. 21, the same components as those in fig. 20 are denoted by the same reference numerals, and description thereof is omitted. First, the control processing on the U-phase, V-phase, and W-phase sides will be described.

The voltage amplitude calculation unit 127 calculates a voltage amplitude command, which is a command value of the magnitude of the voltage vector, based on the power running torque command value or the power generation torque command value of the rotating electrical machine 10 and the electrical angular velocity ω obtained by time-differentiating the electrical angle θ.

The torque estimating unit 128a calculates torque estimated values corresponding to the U-phase, the V-phase, and the W-phase based on the d-axis current and the q-axis current converted by the dq converting unit 112. The torque estimating unit 128a may calculate the voltage amplitude command based on map information that sets the relationship between the d-axis current, the q-axis current, and the voltage amplitude command.

The torque feedback control unit 129a calculates a voltage phase command, which is a command value of the phase of the voltage vector, as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the power generation torque command value. In the torque feedback control portion 129a, the voltage phase command is calculated by using the PI feedback method based on the deviation of the torque estimated value from the power running torque command value or the power generation torque command value.

The operation signal generation unit 130a generates an operation signal of the first inverter 101 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generating unit 130a calculates the command voltages of the three phases based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates the switching operation signals of the upper and lower arms in each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the calculated command voltages of the three phases by the power supply voltage and a carrier signal such as a triangular wave signal.

The operation signal generating unit 130a may generate the switching operation signal based on pulse pattern information, which is mapping information for setting the relationship between the voltage amplitude command, the voltage phase command, the electrical angle θ, and the switching operation signal, the voltage amplitude command, the voltage phase command, and the electrical angle θ.

The torque estimation unit 128b calculates torque estimation values corresponding to the X-phase, Y-phase, and Z-phase based on the d-axis current and the q-axis current converted by the dq conversion unit 122.

The torque feedback control portion 129b calculates a voltage phase command as an operation amount for feedback-controlling the torque estimation value to the power running torque command value or the power generation torque command value. In the torque feedback control portion 129b, the voltage phase command is calculated by using the PI feedback method based on the deviation of the torque estimated value from the power running torque command value or the power generation torque command value.

The operation signal generation unit 130b generates an operation signal of the second inverter 102 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generating unit 130b calculates command voltages for three phases based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates switching operation signals for the upper and lower arms in each phase by PWM control based on comparison of the magnitude of a signal obtained by normalizing the calculated command voltages for three phases with the power supply voltage and a carrier signal such as a triangular wave signal. The driver 117 turns on and off the switches Sp and Sn of the three phases in the

inverters

101 and 102 based on the switching operation signals generated by the operation

signal generation units

130a and 130 b.

The operation signal generating unit 130b may generate the switching operation signal based on pulse pattern information, which is mapping information for setting the relationship between the voltage amplitude command, the voltage phase command, the electrical angle θ, and the switching operation signal, the voltage amplitude command, the voltage phase command, and the electrical angle θ.

In the rotating electrical machine 10, there is a concern that galvanic corrosion of the

bearings

21 and 22 may occur in association with generation of the shaft current. For example, when the energization of the stator winding 51 is switched by switching, distortion of magnetic flux occurs due to a slight deviation of switching timing (imbalance of switching), and thus there is a concern that galvanic corrosion may occur in the

bearings

21 and 22 supporting the rotary shaft 11. The distortion of the magnetic flux is generated by the inductance of the stator 50, and the electromotive force in the axial direction generated by the distortion of the magnetic flux causes the insulation breakdown in the

bearings

21 and 22, thereby increasing the galvanic corrosion.

In this regard, the following three countermeasures are taken as the galvanic corrosion countermeasures in the present embodiment. The first galvanic corrosion countermeasure is a galvanic corrosion suppression countermeasure: the coreless stator 50 reduces inductance and smoothes the magnetic flux of the magnet unit 42. The second electric corrosion countermeasure is an electric corrosion suppression countermeasure in which the rotating shaft is formed in a cantilever structure supported by the

bearings

21 and 22. The third countermeasure against galvanic corrosion is a countermeasure against galvanic corrosion in which the annular stator winding 51 and the stator core 52 are molded together with a molding material. Hereinafter, each of the above measures will be described in detail.

First, according to the first countermeasure against electrolytic corrosion, in the stator 50, the non-pole teeth are provided between the respective lead groups 81 in the circumferential direction, and the seal member 57 made of a non-magnetic material is provided between the respective lead groups 81 in place of the pole teeth (iron cores) (see fig. 10). This can reduce the inductance of the stator 50. By reducing the inductance of the stator 50, even if the switching timing is varied when the stator winding 51 is energized, the occurrence of magnetic flux distortion due to the variation in the switching timing can be suppressed, and further, the electric corrosion of the

bearings

21 and 22 can be suppressed. Further, the inductance of the d axis is preferably equal to or less than the inductance of the q axis.

In the

magnets

91 and 92, the direction of the magnetization easy axis on the d-axis side is oriented more parallel to the d-axis than on the q-axis side (see fig. 9). This enhances the magnetic flux of the d-axis magnet, and smoothes the change in the surface magnetic flux (increase and decrease in the magnetic flux) from the q-axis to the d-axis in each magnetic pole. Therefore, a rapid voltage change due to switching unevenness can be suppressed, which contributes to suppressing galvanic corrosion.

According to the second countermeasure against electrolytic corrosion, in the rotating electrical machine 10, the

bearings

21 and 22 are disposed offset in the axial direction with respect to the axial center of the rotor 40 (see fig. 2). Thus, the influence of the electric corrosion can be reduced as compared with a structure in which a plurality of bearings are provided on both sides of the rotor in the axial direction. That is, in the structure in which the rotor is supported by the plurality of bearings in the double arm manner, a closed circuit is formed through the rotor, the stator, and the bearings (i.e., the bearings provided on both sides in the axial direction with the rotor interposed therebetween) in accordance with the generation of the high-frequency magnetic flux, and there is a concern that the electric corrosion of the bearings may occur due to the shaft current. In contrast, in the structure in which the rotor 40 is cantilever-supported by the plurality of

bearings

21 and 22, the closed circuit is not formed, and the electric corrosion of the bearings is suppressed.

Further, regarding the structure for one-side arrangement of the

bearings

21, 22, the rotary electric machine 10 has the following structure. In the magnet holder 41, a contact avoiding portion (see fig. 2) extending in the axial direction and avoiding contact with the stator 50 is provided in an intermediate portion 45 protruding in the radial direction of the rotor 40. In this case, when a closed circuit of the shaft current is formed via the magnet holder 41, the closed circuit length can be made longer to increase the circuit resistance thereof. This can suppress galvanic corrosion of the

bearings

21 and 22.

The holding member 23 of the bearing unit 20 is fixed to the housing 30 on one side in the axial direction with the rotor 40 interposed therebetween, and the housing 30 and the unit base 61 (stator holder) are coupled to each other on the other side (see fig. 2). According to this configuration, the

bearings

21 and 22 can be preferably arranged offset to one side in the axial direction of the rotary shaft 11. Further, according to the present configuration, since the unit base 61 is connected to the rotary shaft 11 via the housing 30, the unit base 61 can be disposed at a position electrically separated from the rotary shaft 11. When an insulating member such as resin is interposed between the unit base 61 and the housing 30, the unit base 61 and the rotary shaft 11 are further electrically separated from each other. This can appropriately suppress the galvanic corrosion of the

bearings

21 and 22.

In the rotating electrical machine 10 of the present embodiment, the shaft voltage applied to the

bearings

21 and 22 is reduced by the one-side arrangement of the

bearings

21 and 22. Further, the potential difference between the rotor 40 and the stator 50 decreases. Therefore, even if the conductive grease is not used for the

bearings

21 and 22, the potential difference acting on the

bearings

21 and 22 can be reduced. Since the conductive grease generally contains fine particles of carbon or the like, it is considered that noise is generated. In this regard, in the present embodiment, non-conductive grease is used for the

bearings

21 and 22. Therefore, the occurrence of noise in the

bearings

21 and 22 can be suppressed. It is considered that noise countermeasure of the rotating electrical machine 10 is necessary when applied to an electric vehicle such as an electric vehicle, for example, and the above noise countermeasure can be preferably implemented.

According to the third countermeasure against the electrolytic corrosion, the stator winding 51 is molded together with the stator core 52 by using a molding material, thereby suppressing the positional deviation of the stator winding 51 in the stator 50 (refer to fig. 11). In particular, in the rotary electric machine 10 of the present embodiment, since no inter-conductor member (pole tooth) is provided between the conductor groups 81 in the circumferential direction of the stator winding 51, it is considered that there is a possibility of positional deviation occurring in the stator winding 51, but by molding the stator winding 51 together with the stator core 52, the positional deviation of the conductors of the stator winding 51 is suppressed. Therefore, it is possible to suppress the occurrence of magnetic flux distortion due to the positional deviation of the stator winding 51 and the occurrence of electric corrosion of the

bearings

21 and 22 due to the magnetic flux distortion.

Further, since the unit base 61, which is a housing member for fixing the stator core 52, is formed of Carbon Fiber Reinforced Plastic (CFRP), discharge to the unit base 61 can be suppressed as compared with a case where it is formed of, for example, aluminum, and this is an ideal countermeasure against electric corrosion.

In addition, as a countermeasure against the galvanic corrosion of the

bearings

21 and 22, at least one of the outer ring 25 and the inner ring 26 may be formed of a ceramic material, or an insulating sleeve or the like may be provided outside the outer ring 25.

Hereinafter, the other embodiments will be described mainly focusing on differences from the first embodiment.

(second embodiment)

In the present embodiment, the polar anisotropy structure of the magnet unit 42 in the rotor 40 is changed, and the following description will be made in detail.

As shown in fig. 22 and 23, the magnet unit 42 is configured using a magnet array called a halbach array. That is, the magnet unit 42 has: the first magnets 131 whose magnetization direction (direction of magnetization vector) is the radial direction and the second magnets 132 whose magnetization direction (direction of magnetization vector) is the circumferential direction are arranged at predetermined intervals in the circumferential direction, and the second magnets 132 are arranged at positions between the first magnets 131 adjacent in the circumferential direction. The first magnet 131 and the second magnet 132 are permanent magnets made of rare earth magnets such as neodymium magnets.

The first magnets 131 are arranged so as to be circumferentially spaced apart from each other such that poles on the side (radially inner side) opposite to the stator 50 are alternately N poles and S poles. Further, the second magnets 132 are arranged so as to alternate in polarity in the circumferential direction at positions adjacent to the respective first magnets 131. The cylindrical portion 43 surrounding the

magnetic bodies

131 and 132 is preferably a soft magnetic iron core made of a soft magnetic material and functions as a back yoke. The relationship between the magnetization easy axis, the d axis, and the q axis of the magnet unit 42 of the second embodiment in the d-q coordinate system is the same as that of the first embodiment.

Further, a magnetic body 133 made of a soft magnetic material is disposed radially outward of the first magnetic body 131, that is, on the cylindrical portion 43 side of the magnet holder 41. For example, the magnetic body 133 is preferably made of an electromagnetic steel plate, soft iron, or a dust core material. In this case, the circumferential length of the magnetic body 133 is the same as the circumferential length of the first magnet 131 (particularly, the circumferential length of the outer peripheral portion of the first magnet 131). In a state where the first magnet 131 and the magnetic body 133 are integrated, the radial thickness of the integrated body is the same as the radial thickness of the second magnet 132. In other words, the radial thickness of the first magnet 131 is thinner than the radial thickness of the second magnet 132 by the amount of the magnetic body 133. The

magnets

131 and 132 and the magnetic body 133 are fixed to each other by, for example, an adhesive. The radially outer side of the first magnet 131 in the magnet unit 42 is the side opposite to the stator 50, and the magnetic body 133 is provided on the side opposite to the stator 50 (the opposite-stator side) of both sides of the first magnet 131 in the radial direction.

A key 134 is formed on the outer peripheral portion of the magnetic body 133, and the key 134 is a convex portion protruding radially outward, i.e., on the side of the cylindrical portion 43 of the magnet holder 41. In addition, a key groove 135 is formed in the inner peripheral surface of the cylindrical portion 43, and the key groove 135 is a recess for receiving the key 134 of the magnetic body 133. The protruding shape of the key 134 is the same as the groove shape of the key groove 135, and the same number of key grooves 135 as the number of keys 134 are formed corresponding to the keys 134 formed in each magnetic body 133. The positional displacement in the circumferential direction (rotational direction) of the first and

second magnets

131, 132 and the magnet holder 41 is suppressed by the engagement of the key 134 and the key groove 135. Note that, the key 134 and the key groove 135 (convex portion and concave portion) may be provided in either one of the cylindrical portion 43 of the magnet holder 41 and the magnetic body 133, and the key groove 135 may be provided on the outer peripheral portion of the magnetic body 133 and the key 134 may be provided on the inner peripheral portion of the cylindrical portion 43 of the magnet holder 41, in contrast to the above.

Here, in the magnet unit 42, the magnetic flux density in the first magnet 131 can be increased by alternately arranging the first magnet 131 and the second magnet 132. Therefore, the magnet unit 42 can generate single-sided concentration of magnetic flux, and thus strengthen the magnetic flux on the side closer to the stator 50.

Further, by disposing the magnetic body 133 on the radially outer side of the first magnetic body 131, that is, on the opposite side of the stator, local magnetic saturation on the radially outer side of the first magnetic body 131 can be suppressed, and further, demagnetization of the first magnetic body 131 due to the magnetic saturation can be suppressed. Thereby, the magnetic force of the magnet unit 42 can be increased finally. In other words, the magnet unit 42 of the present embodiment is configured such that a portion of the first magnet 131 that is likely to be demagnetized is replaced with the magnetic body 133.

Fig. 24 (a) and 24 (b) are diagrams specifically showing the flow of magnetic flux in the magnet unit 42, fig. 24 (a) shows a case where a conventional configuration having no magnetic body 133 in the magnet unit 42 is used, and fig. 24 (b) shows a case where the configuration of the present embodiment having the magnetic body 133 in the magnet unit 42 is used. In fig. 24 (a) and 24 (b), the cylindrical portion 43 of the magnet holder 41 and the magnet unit 42 are linearly developed, and the lower side of the drawing is the stator side and the upper side is the opposite side to the stator.

In the structure of fig. 24 (a), the magnetic flux acting surface of the first magnet 131 and the side surface of the second magnet 132 are in contact with the inner circumferential surface of the cylindrical portion 43, respectively. Further, the magnetic flux acting surface of the second magnet 132 is in contact with the side surface of the first magnet 131. In this case, a resultant magnetic flux of a magnetic flux F1 entering the contact surface with the first magnet 131 through the outer path of the second magnet 132 and a magnetic flux F2 that is substantially parallel to the cylindrical portion 43 and attracts the second magnet 132 is generated in the cylindrical portion 43. Therefore, there is a fear that local magnetic saturation occurs in the vicinity of the contact surface of the first magnet 131 and the second magnet 132 in the cylindrical portion 43.

In contrast, in the configuration of fig. 24 (b), since the magnetic body 133 is provided between the magnetic flux acting surface of the first magnet 131 and the inner circumferential surface of the cylindrical portion 43 on the side of the first magnet 131 opposite to the stator 50, the magnetic flux is allowed to pass through the magnetic body 133. Therefore, magnetic saturation in the cylindrical portion 43 can be suppressed, and the resistance to demagnetization can be improved.

In the configuration of fig. 24 (b), unlike fig. 24 (a), F2 that promotes magnetic saturation can be canceled out. This effectively improves the flux guide of the entire magnetic circuit. With the above configuration, the magnetic circuit characteristics can be maintained even under severe high temperature conditions.

Further, the magnetic path through the magnet inside the magnet is longer than that through the radial magnet in the conventional SPM rotor. Therefore, the magnetic conductance of the magnet can be increased, the magnetic force can be increased, and the torque can be increased. Further, the sine wave matching rate can be improved by concentrating the magnetic flux at the center of the d-axis. In particular, when the current waveform is changed to a sine wave or a trapezoidal wave by PWM control or when a switching IC for conducting current at 120 degrees is used, torque can be more effectively increased.

In addition, in the case where the stator core 52 is formed of electromagnetic steel plates, the radial thickness of the stator core 52 is preferably greater than or equal to 1/2, which is the radial thickness of the magnet unit 42. For example, the radial thickness of the stator core 52 is preferably greater than 1/2 of the radial thickness of the first magnet 131 provided at the center of the magnetic pole in the magnet unit 42. Further, the radial thickness of the stator core 52 is preferably smaller than the radial thickness of the magnet unit 42. In this case, since the magnet magnetic flux is about 1T and the saturation magnetic flux density of the stator core 52 is 2T, leakage of the magnetic flux to the inner peripheral side of the stator core 52 can be prevented by setting the radial thickness of the stator core 52 to 1/2 or more of the radial thickness of the magnet unit 42.

In the magnetic body having the halbach structure and the polar anisotropic structure, the magnetic path is substantially circular arc-shaped, and therefore the magnetic flux can be increased in proportion to the thickness of the magnetic body receiving the magnetic flux in the circumferential direction. In the above-described structure, it is considered that the magnetic flux flowing through the stator core 52 does not exceed the magnetic flux in the circumferential direction. That is, when an iron-based metal having a saturation magnetic flux density of 2T is used for the magnetic flux 1T of the magnet, a small-sized and lightweight rotating electrical machine can be provided ideally without causing magnetic saturation by setting the thickness of the stator core 52 to be at least half the thickness of the magnet. Here, since the counter magnetic field from the stator 50 acts on the magnet magnetic flux, the magnet magnetic flux is usually 0.9T or less. Therefore, if the stator core has a thickness half that of the magnet, the magnetic permeability can be desirably kept high.

A modified example in which a part of the above-described structure is changed will be described below.

(modification 1)

In the above embodiment, the outer peripheral surface of the stator core 52 is formed into a curved surface shape without unevenness, and a plurality of lead groups 81 are arranged in parallel on the outer peripheral surface at predetermined intervals. For example, as shown in fig. 25, the stator core 52 includes an annular yoke portion 141 and a protrusion portion 142, the yoke portion 141 being provided on the side (lower side in the figure) opposite to the rotor 40 of both sides in the radial direction of the stator winding 51, and the protrusion portion 142 extending from the yoke portion 141 to protrude between the straight portions 83 adjacent in the circumferential direction. The protrusions 142 are provided at predetermined intervals on the rotor 40 side, which is the radially outer side of the yoke 141. Each of the lead wire groups 81 of the stator winding 51 is engaged with the protrusions 142 in the circumferential direction, and the protrusions 142 are arranged side by side in the circumferential direction while serving as positioning portions of the lead wire groups 81. The protrusion 142 corresponds to an "inter-wire member".

The protrusion 142 is configured such that a thickness dimension in the radial direction from the yoke 141, in other words, as shown in fig. 25, a distance W from an inner surface 320 of the linear portion 83 adjacent to the yoke 141 to a vertex of the protrusion 142 in the radial direction of the yoke 141 is smaller than 1/2 (H1 in the drawing) of the thickness dimension in the radial direction of the linear portion 83 adjacent to the yoke 141 in the radial direction among the plurality of layers of linear portions 83 inside and outside in the radial direction. In other words, it suffices if the range of three quarters of the dimension (thickness) T1 of the lead wire group 81 (conductive member) in the radial direction of the stator winding 51 (stator core 52) (twice the thickness of the lead wire 82, in other words, the shortest distance between the surface 320 of the lead wire group 81 in contact with the stator core 52 and the surface 330 of the lead wire group 81 facing the rotor 40) is occupied by the nonmagnetic member (seal member 57). Due to the thickness limitation of the projection 142, the projection 142 does not function as a pole tooth between the circumferentially adjacent lead groups 81 (i.e., the linear portions 83), and a magnetic path formed by the pole tooth cannot be formed. The protrusions 142 may not be provided for all of the lead groups 81 arranged in the circumferential direction, and the protrusions 142 may be provided between at least one pair of lead groups 81 adjacent in the circumferential direction. For example, the protrusions 142 may be provided at equal intervals in the circumferential direction for every predetermined number of conductor groups 81. The shape of the protrusion 142 may be any shape such as a rectangle or an arc.

Further, the outer peripheral surface of the stator core 52 may be provided with one layer of the linear portion 83. Therefore, in a broad sense, the radial thickness of the projection 142 from the yoke 141 may be smaller than 1/2, which is the radial thickness of the linear portion 83.

When an imaginary circle is assumed which passes through the center position in the radial direction of the straight portion 83 adjacent to the yoke portion 141 in the radial direction with the axial center of the rotating shaft 11 as the center, the protrusion 142 preferably has a shape which protrudes from the yoke portion 141 within the range of the imaginary circle, in other words, a shape which does not protrude outward in the radial direction of the imaginary circle (i.e., the rotor 40 side).

According to the above configuration, since the thickness dimension of the projection 142 in the radial direction is restricted and the linear portions 83 adjacent in the circumferential direction do not function as a tooth, the adjacent linear portions 83 can be pulled closer than the case where a tooth is provided between the linear portions 83. This can increase the cross-sectional area of the conductor 82a, thereby reducing heat generation associated with the energization of the stator winding 51. In the above configuration, magnetic saturation can be eliminated by not providing pole teeth, and the current to be supplied to the stator winding 51 can be increased. In this case, it is possible to ideally cope with a case where the heat generation amount increases with an increase in the above-described energization current. In the stator winding 51, since the return portions 84 have interference avoiding portions that are offset in the radial direction to avoid interference with other return portions 84, different return portions 84 can be arranged apart from each other in the radial direction. This can improve heat dissipation even in the bent portion 84. As a result, the heat radiation performance of the stator 50 can be optimized.

Note that, if the yoke portion 141 of the stator core 52 and the magnet unit 42 of the rotor 40 (i.e., the magnets 91 and 92) are separated by a predetermined distance or more, the radial thickness dimension of the protrusion 142 is not limited to H1 in fig. 25. Specifically, when the yoke 141 and the magnet unit 42 are separated by 2mm or more, the radial thickness of the projection 142 may be H1 or more in fig. 25. For example, when the radial thickness dimension of the linear portion 83 exceeds 2mm and the lead group 81 is formed of two layers of the leads 82 radially inside and outside, the protrusion 142 may be provided in the linear portion 83 not adjacent to the yoke portion 141, that is, in a range of a half position of the lead 82 of the second layer from the yoke portion 141. In this case, if the radial thickness dimension of the protrusion 142 does not exceed "H1 × 3/2", the above-described effect can be significantly obtained by increasing the conductor cross-sectional area in the lead group 81.

The stator core 52 may have the structure shown in fig. 26. In fig. 26, the seal member 57 is omitted, but the seal member 57 may be provided. In fig. 26, the magnet unit 42 and the stator core 52 are shown linearly expanded for convenience of explanation.

In the structure of fig. 26, the stator 50 has the protrusion 142 as an inter-wire member between the circumferentially adjacent wires 82 (i.e., the straight portions 83). The stator 50 has a portion 350, the portion 350 magnetically acts together with one of the magnetic poles (N pole or S pole) of the magnet unit 42 when the stator winding 51 is energized, and the portion 350 extends in the circumferential direction of the stator 50. When the length of the portion 350 in the circumferential direction of the stator 50 is Wn, the total width of the protrusions 142 existing in the length range Wn (i.e., the total dimension in the circumferential direction of the stator 50) is Wt, the saturation magnetic flux density of the protrusions 142 is Bs, the width of the magnet unit 42 in the circumferential direction corresponding to one pole is Wm, and the residual magnetic flux density of the magnet unit 42 is Br, the protrusions 142 are made of a magnetic material satisfying the following equation.

Wt×Bs≤Wm×Br…(1)

In addition, the range Wn is set to include a plurality of conductor groups 81 adjacent in the circumferential direction and overlapping in excitation time. In this case, it is preferable to set the center of the gap 56 of the lead group 81 as a reference (boundary) in the setting range Wn. For example, in the case of the configuration illustrated in fig. 26, the plurality of lead groups 81 are arranged in order from the lead group 81 having the shortest distance from the center of the magnetic pole of the N-pole to the lead group 81 having the fourth shortest distance in the circumferential direction. The range Wn is set to include the four lead groups 81. At this time, one end (starting point and end point) of the range Wn is the center of the gap 56.

In fig. 26, since half of the projection 142 is included at both ends of the range Wn, the range Wn includes four projection 142 in total. Therefore, when the width of the projection 142 (i.e., the size of the projection 142 in the circumferential direction of the stator 50, in other words, the interval between adjacent lead groups 81) is a, the total width of the projections 142 included in the range Wn is 1/2A + 1/2A-4A.

Specifically, in the present embodiment, the three-phase winding of the stator winding 51 is a distributed winding, and in the above-described stator winding 51, the number of the protrusions 142, that is, the number of the gaps 56 between the respective conductor wire groups 81, is "number of phases × Q" for one pole of the magnet unit 42. Here, Q refers to the number of wires 82 of one phase that contact the stator core 52. In the case where the lead wire group 81 is configured such that the lead wires 82 are stacked in the radial direction of the rotor 40, Q may be the number of lead wires 82 on the inner peripheral side of the lead wire group 81 of one phase. In this case, when the three-phase windings of the stator winding 51 are energized in a predetermined order for each phase, the protrusions 142 corresponding to two phases are excited in one pole. Therefore, assuming that the circumferential width dimension of the projection 142 (i.e., the gap 56) is a, the total circumferential width dimension Wt of the projection 142 excited by energization of the stator winding 51 in the range corresponding to one pole of the magnet unit 42 is "the number of excited phases × Q × a is 2 × 2 × a".

Next, after the total width Wt is defined in this way, in the stator core 52, the protrusion 142 is made of a magnetic material satisfying the relationship of the above (1). The total width Wt is a circumferential dimension of a portion having a relative permeability greater than 1 in the one pole. In consideration of the margin, the total width Wt may be set to the circumferential width of the projection 142 in one magnetic pole. Specifically, since the number of the protrusions 142 corresponding to one pole of the magnet unit 42 is "phase number × Q", the circumferential width dimension (total width dimension Wt) of the protrusions 142 in one magnetic pole may be "phase number × Q × a — 3 × 2 × a — 6A".

The distributed winding referred to herein is a winding in which one pole pair of the stator winding 51 is present in one pole pair period (N pole and S pole) of the magnetic pole. One pole pair of the stator winding 51 described here is composed of two straight portions 83 and a bent portion 84 in which currents flow in opposite directions to each other and are electrically connected to each other at the bent portion 84. As long as the above condition is satisfied, even a Short Pitch Winding (Short Pitch Winding) is considered as an equivalent of a distributed Winding of a Full Pitch Winding (Full Pitch Winding).

Next, an example when the windings are concentrated is shown. The concentrated winding referred to herein means that the width of one pole pair of the magnetic poles is different from the width of one pole pair of the stator winding 51. As an example of the concentrated winding, the following relationship is listed: the number of the magnetic pole pair wire groups 81 is 3 for one magnetic pole pair wire group 81, 3 for two magnetic pole pair wire groups 81, 9 for four magnetic pole pair wire groups 81, and 9 for five magnetic pole pair wire groups 81.

When the stator windings 51 are concentrated windings, the stator windings 51 corresponding to two phases are excited when three-phase windings of the stator windings 51 are energized in a predetermined order. As a result, the protrusions 142 corresponding to the two phases are excited. Therefore, in the range corresponding to one pole of the magnet unit 42, the width Wt in the circumferential direction of the protruding portion 142 excited by energization of the stator winding 51 is "a × 2". Then, after the width Wt is defined in this way, the protrusion 142 is made of a magnetic material satisfying the relationship (1) above. In the case of the concentrated winding described above, the total width of the protrusions 142 located in the circumferential direction of the stator 50 in the region surrounded by the lead group 81 of the same phase is a. In addition, Wm of the concentrated winding corresponds to "the entire circumference of the surface of the magnet unit 42 facing the air gap" x "the number of phases"/"the number of dispersions of the conductor group 81".

The BH product of neodymium magnet, samarium-cobalt magnet, and ferrite magnet is 20[ MGOe (kJ/m)³)]In the above magnet, Bd is 1.0[ T ]]Above, Br in iron is 2.0[ T ]]The above. Therefore, as a high-output motor, the protrusion 142 of the stator core 52 may be made of a magnetic material that satisfies the relationship Wt < 1/2 × Wm.

When the lead wires 82 include the outer layer film 182, as described later, the lead wires 82 may be arranged along the circumferential direction of the stator core 52 so that the outer layer films 182 of the lead wires 82 contact each other. In this case, Wt may be considered to be 0, or the thickness of the outer film 182 of the two conductive wires 82 in contact.

In the configuration of fig. 25 and 26, the inter-wire member (the protrusion 142) is configured to have a smaller magnetic flux than the magnet on the rotor 40 side. In addition, the rotor 40 is a surface magnet type rotor having low inductance and flatness, and has no saliency in magnetic resistance. With the above configuration, the inductance of the stator 50 is reduced, the occurrence of magnetic flux distortion due to variations in the switching timing of the stator winding 51 is suppressed, and the galvanic corrosion of the

bearings

21 and 22 is suppressed.

(modification 2)

As the stator 50 using the member between the conductive wires satisfying the relationship of the above expression (1), the following configuration can be adopted. In fig. 27, a tooth 143 is provided as an inter-wire member on the outer circumferential surface side (upper surface side in the figure) of the stator core 52. The tooth-like portions 143 are provided to protrude from the yoke portion 141 at predetermined intervals in the circumferential direction and have the same thickness dimension as the lead group 81 in the radial direction. The side surfaces of the serrations 143 contact the respective lead wires 82 of the lead wire group 81. However, a gap may be provided between the serration 143 and each of the wires 82.

The tooth 143 is a member that imposes a limit on the width dimension in the circumferential direction and includes pole teeth (stator pole teeth) that are too thin with respect to the amount of magnet. According to the above configuration, the tooth 143 can be reliably saturated by the magnetic flux of the magnet of 1.8T or more, and the inductance can be reduced by the decrease in the permeance.

Here, in the magnet unit 42, when the surface area of each pole of the magnetic flux acting surface on the stator side is Sm and the residual magnetic flux density of the magnet unit 42 is Br, the magnetic flux on the magnet unit side is, for example, "Sm × Br". When the rotor-side surface area of each tooth 143 is St, the number of phases of the lead wire 82 is m, and the teeth 143 corresponding to two phases in one pole are excited by the energization of the stator winding 51, the stator-side magnetic flux is, for example, "St × m × 2 × Bs". In this case, by passing

In a manner that the relation St × m × 2 × Bs < Sm × Br … (2) holds, the inductance is reduced by limiting the size of the serrations 143.

When the magnet unit 42 and the tooth 143 have the same axial dimension, the above equation (2) is replaced with equation (3) where Wm is the circumferential width of the magnet unit 42 corresponding to one pole and Wst is the circumferential width of the tooth 143.

Wst×m×2×Bs＜Wm×Br…(3)

More specifically, when it is assumed that, for example, Bs is 2T, Br is 1T and m is 2, the above formula (3) is in the relationship "Wst < Wm/8". In this case, the reduction in inductance is achieved by 1/8 in which the width dimension Wst of the tooth 143 is made smaller than the width dimension Wm of the magnet unit 42 corresponding to one pole. If the number m is 1, the width Wst of the tooth 143 is preferably smaller than 1/4 of the width Wm of the magnet unit 42 corresponding to one pole.

In the above equation (3), "Wst × m × 2" corresponds to a circumferential width dimension of the tooth 143 excited by energization of the stator winding 51 in a range corresponding to one pole of the magnet unit 42.

In the configuration of fig. 27, similarly to the configurations of fig. 25 and 26 described above, the inter-wire member (the tooth-like portion 143) having a small magnetic flux with respect to the magnet on the rotor 40 side is provided. According to the above configuration, the inductance of the stator 50 can be reduced, the occurrence of magnetic flux distortion due to variation in the switching timing of the stator winding 51 can be suppressed, and further the galvanic corrosion of the

bearings

21 and 22 can be suppressed.

(modification 3)

In the above embodiment, the seal member 57 covering the stator winding 51 is provided outside the stator core 52 in the radial direction in a range including all the respective lead groups 81, that is, in a range in which the thickness dimension in the radial direction is larger than the thickness dimension in the radial direction of the respective lead groups 81. For example, as shown in fig. 28, the seal member 57 is configured such that a part of the lead 82 protrudes. More specifically, the seal member 57 is configured to expose a portion of the lead wire 82 closest to the radially outer side of the lead wire group 81 to the radially outer side, that is, the stator 50 side. In this case, the radial thickness dimension of the seal member 57 is preferably the same as or smaller than the radial thickness dimension of each lead group 81.

(modification 4)

As shown in fig. 29, in the stator 50, each lead group 81 may not be sealed by the sealing member 57. That is, the sealing member 57 covering the stator winding 51 is not used. In this case, no inter-wire member is provided between the respective wire groups 81 arranged in the circumferential direction, and a space is left. In short, no inter-conductor member is provided between the conductor groups 81 arranged in the circumferential direction. Air may be regarded as a nonmagnetic substance or the equivalent of a nonmagnetic substance, and Bs is 0, and air may be disposed in the gap.

(modification 5)

When the members between the wires of the stator 50 are made of a nonmagnetic material, a material other than resin may be used as the nonmagnetic material. For example, a metal-based nonmagnetic material such as SUS304, which is austenitic stainless steel, may be used.

(modification 6)

The stator 50 may be configured without the stator core 52. In this case, the stator 50 is constituted by a stator winding 51 shown in fig. 12. In the stator 50 not having the stator core 52, the stator winding 51 may be sealed by a sealing member. Alternatively, the stator 50 may include an annular winding holder made of a non-magnetic material such as synthetic resin, instead of the stator core 52 made of a soft magnetic material.

(modification 7)

Although the plurality of

magnets

91 and 92 arranged in the circumferential direction are used as the magnet unit 42 of the rotor 40 in the first embodiment, it is also possible to change this and use an annular magnet, which is an annular permanent magnet, as the magnet unit 42. Specifically, as shown in fig. 30, a ring-shaped magnet 95 is fixed to the inside in the radial direction of the cylindrical portion 43 of the magnet holder 41. The annular magnet 95 has a plurality of magnetic poles with alternating polarities in the circumferential direction, and a magnet is integrally formed on either the d-axis or the q-axis. The annular magnet 95 has an arc-shaped magnet magnetic path, and the direction of the arc-shaped magnet magnetic path oriented along the d-axis of each magnetic pole is the radial direction, and the direction of the arc-shaped magnet magnetic path oriented along the q-axis between the magnetic poles is the circumferential direction.

In the ring-shaped magnet 95, the following arc-shaped magnet magnetic paths may be formed by orienting the magnet: the magnetization easy axis is a direction parallel to or close to parallel to the d axis in a portion close to the d axis, and the magnetization easy axis is a direction orthogonal to or close to orthogonal to the q axis in a portion close to the q axis.

(modification 8)

In the present modification, a part of the control method of the control device 110 is changed. In this modification, a description will be given mainly of a portion different from the configuration described in the first embodiment.

First, the processing in the operation

signal generation units

116 and 126 shown in fig. 20 and the operation

signal generation units

130a and 130b shown in fig. 21 will be described with reference to fig. 31. The processing in the operation

signal generation units

116, 126, 130a, and 130b is basically the same. Therefore, the following description will be given taking the processing of the operation signal generation unit 116 as an example.

The operation signal generator 116 includes a carrier generator 116a and U and V comparators 116bU, 116bV, and 116W comparators 116 bW. In the present embodiment, the carrier generation unit 116a generates and outputs a triangular wave signal as a carrier signal SigC.

The U-phase comparator 116bU, the V-phase comparator 116bV, and the W-phase comparator 116bW receive as input the carrier signal SigC generated by the carrier generation unit 116a and the U-phase, V-phase, and W-phase command voltages calculated by the three-phase conversion unit 115. The U-phase, V-phase, and W-phase command voltages are, for example, sine-wave-shaped waveforms, and are shifted in phase by every 120 ° in electrical angle.

The U-phase comparators 116bU, the V-phase comparators 116bV, and the W-phase comparator 116bW generate operation signals of the switches Sp and Sn of the upper arm and the lower arm of the U-phase, the V-phase, and the W-phase in the first inverter 101 by PWM (pulse width modulation) control based on magnitude comparison of the U-phase, the V-phase, and the W-phase command voltages and the carrier signal SigC. Specifically, the operation signal generation unit 116 generates the operation signals for the respective switches Sp and Sn of the U-phase, V-phase, and W-phase by PWM control based on a comparison between the magnitude of the carrier signal and a signal obtained by normalizing the U-phase, V-phase, and W-phase command voltages by the power supply voltage. The driver 117 turns on and off the switches Sp and Sn of the U-phase, V-phase, and W-phase in the first inverter 101 based on the operation signal generated by the operation signal generating unit 116.

The control device 110 performs a process of changing the carrier frequency fc of the carrier signal SigC, that is, the switching frequency of each of the switches Sp, Sn. The carrier frequency fc is set higher in a low torque region or a high rotation region of the rotary electric machine 10, and is set lower in a high torque region of the rotary electric machine 10. The above setting is performed to suppress a decrease in controllability of the current flowing through each phase winding.

That is, the inductance of the stator 50 can be reduced as the stator 50 is coreless. Here, as the inductance becomes lower, the electrical time constant of the rotating electrical machine 10 becomes smaller. As a result, the ripple of the current flowing through the windings of each phase increases, and the controllability of the current flowing through the windings deteriorates, and there is a fear that the current control may diverge. The influence of the above-described decrease in controllability when included in the low current region is more significant than when the current flowing through the winding (for example, the actual effective value of the current) is included in the high current region. In order to solve the above problem, in the present modification, the control device 110 changes the carrier frequency fc.

The process of changing the carrier frequency fc will be described with reference to fig. 32. The above-described processing is repeatedly executed by the control device 110 as processing of the operation signal generation unit 116, for example, at a predetermined control cycle.

In step S10, it is determined whether or not the current flowing through the winding 51a of each phase is included in the low current region. The above processing is processing for determining that the current torque of the rotating electric machine 10 is in the low torque region. For example, the following first and second methods are cited as methods for determining whether or not the current is included in the low current region.

< first method >

The torque estimation value of the rotating electric machine 10 is calculated based on the d-axis current and the q-axis current converted by the dq conversion unit 112. When the calculated torque estimation value is determined to be lower than the torque threshold value, it is determined that the current flowing through the winding 51a is included in the low current region, and when the torque estimation value is determined to be equal to or higher than the torque threshold value, it is determined that the current is included in the high current region. Here, the torque threshold value may be set to 1/2 of the starting torque (also referred to as the lock torque) of the rotating electrical machine 10, for example.

< second method >

When it is determined that the rotation angle of the rotor 40 detected by the angle detector is equal to or greater than the speed threshold, it is determined that the current flowing through the winding 51a is included in the low current region, i.e., the high rotation region. Here, the speed threshold value may be set to, for example, the rotation speed at which the maximum torque of the rotating electrical machine 10 is the torque threshold value.

When a negative determination is made in step S10, it is determined to be in the high current region, and the process proceeds to step S11. In step S11, the carrier frequency fc is set to the first frequency fL.

When an affirmative determination is made in step S10, the process proceeds to step S12, and the carrier frequency fc is set to the second frequency fH that is higher than the first frequency fL.

According to the present modification described above, carrier frequency fc when the current flowing through each phase winding is included in the low current region is set higher than when the current flowing through each phase winding is included in the high current region. Therefore, in the low current region, the switching frequency of the switches Sp and Sn can be increased, and an increase in current ripple can be suppressed. This can suppress a decrease in current controllability.

On the other hand, carrier frequency fc when the current flowing through each phase winding is included in the high current region is set lower than when the current flowing through each phase winding is included in the low current region. In the high current region, since the amplitude of the current flowing through the winding is larger than that in the low current region, the influence of the increase in the current ripple caused by the inductance becoming lower on the current controllability is small. Therefore, the carrier frequency fc in the high current region can be set lower than that in the low current region, and the switching loss of each

inverter

101, 102 can be reduced.

In this modification, the following modes can be implemented.

When the carrier frequency fc is set to the first frequency fL and an affirmative determination is made in step S10 of fig. 32, the carrier frequency fc may be gradually changed from the first frequency fL to the second frequency fH.

Further, in the case where the carrier frequency fc is set to the second frequency fH, the carrier frequency fc may be gradually changed from the second frequency fH to the first frequency fL when a negative determination is made in step S10.

Instead of PWM control, the operation signal of the switch may also be generated by Space Vector Modulation (SVM) control. In this case, the above-described change of the switching frequency can also be applied.

(modification 9)

In each of the above embodiments, as shown in fig. 33 (a), two pairs of wires for each phase constituting the wire group 81 are connected in parallel. Fig. 33 (a) is a diagram showing electrical connection between two pairs of conductive wires, i.e., a first conductive wire 88a and a second conductive wire 88 b. Here, instead of the configuration shown in fig. 33 (a), the first lead 88a and the second lead 88b may be connected in series as shown in fig. 33 (b).

Three or more pairs of multilayer conductors may be stacked and arranged in the radial direction. Fig. 34 shows a structure in which four pairs of conductive lines, i.e., first conductive line 88a to fourth conductive line 88d, are arranged in layers. First to fourth lead wires 88a to 88d are arranged in order of first to

fourth lead wires

88a, 88b, 88c, 88d in a radial direction from one side close to stator core 52.

Here, as shown in fig. 33 (c), the third lead wire 88c and the fourth lead wire 88d may be connected in parallel, and the first lead wire 88a may be connected to one end of the parallel connection body and the second lead wire 88b may be connected to the other end. When the wires are connected in parallel, the current density of the wires connected in parallel can be reduced, and heat generation during energization can be suppressed. Therefore, in the configuration in which the cylindrical stator winding is assembled to the housing (unit base 61) in which the cooling water passage 74 is formed, the first lead wire 88a and the second lead wire 88b, which are not connected in parallel, are disposed on the stator core 52 side in contact with the unit base 61, and the third lead wire 88c and the fourth lead wire 88d, which are connected in parallel, are disposed on the opposite side of the stator core. This can equalize the cooling performance of the leads 88a to 88d in the multilayer lead structure.

The radial thickness of the lead group 81 including the first to fourth leads 88a to 88d may be smaller than the circumferential width corresponding to 1 in the magnetic pole 1.

(modification 10)

The rotary electric machine 10 may have an inner rotor structure (inner rotor structure). In this case, for example, in the housing 30, it is preferable that the stator 50 is provided on the radially outer side and the rotor 40 is provided on the radially inner side. Further, it is preferable that the inverter unit 60 is provided on one or both of the axial ends of the stator 50 and the rotor 40. Fig. 35 is a cross-sectional view of the rotor 40 and the stator 50, and fig. 36 is an enlarged view showing a part of the rotor 40 and the stator 50 shown in fig. 35.

The structures of fig. 35 and 36, which are premised on the inner rotor structure, are the same as those of fig. 8 and 9, which are premised on the outer rotor structure, except that the rotor 40 and the stator 50 are diametrically opposed to each other. In short, the stator 50 has a stator winding 51 of a flat wire structure and a stator core 52 having no pole teeth. The stator winding 51 is assembled to the radially inner side of the stator core 52. The stator core 52 has any of the following configurations as in the case of the outer rotor configuration.

(A) In the stator 50, an inter-wire member is provided between each of the circumferential wire portions, and as the inter-wire member, a magnetic material satisfying a relationship of Wt × Bs ≦ Wm × Br is used, where Wt is a circumferential width of the inter-wire member of one magnetic pole, Bs is a saturation magnetic flux density of the inter-wire member, Wm is a circumferential width of the magnet unit of one magnetic pole, and Br is a residual magnetic flux density of the magnet unit.

(B) In the stator 50, an inter-wire member is provided between the respective wire portions in the circumferential direction, and a non-magnetic material is used as the inter-wire member.

(C) The stator 50 is configured such that no inter-wire member is provided between the respective circumferential wire portions.

The

magnets

91 and 92 of the magnet unit 42 are also the same. That is, the magnet unit 42 is configured by using the

magnets

91 and 92, and the direction of the magnetization easy axis is oriented more parallel to the d axis on the d axis side, which is the magnetic pole center, than on the q axis side, which is the magnetic pole boundary. The magnetization direction and the like of each

magnet

91, 92 are as described above. A ring magnet 95 (see fig. 30) can also be used in the magnet unit 42.

Fig. 37 is a vertical sectional view of the rotary electric machine 10 in the case of the inner rotor type, and corresponds to fig. 2. The difference from the configuration of fig. 2 will be briefly described. In fig. 37, a ring-shaped stator 50 is fixed inside a housing 30, and a rotor 40 is rotatably provided inside the stator 50 with a predetermined air gap therebetween. As in fig. 2, the

bearings

21 and 22 are arranged offset to either one side in the axial direction with respect to the axial center of the rotor 40, thereby cantilever-supporting the rotor 40. Further, an inverter unit 60 is provided inside the magnet holder 41 of the rotor 40.

Fig. 38 shows the rotary electric machine 10 of another structure as an inner rotor structure. In fig. 38, a rotary shaft 11 is rotatably supported by a housing 30 via

bearings

21 and 22, and a rotor 40 is fixed to the rotary shaft 11. As in the configuration shown in fig. 2 and the like, the

bearings

21 and 22 are arranged offset in either axial direction with respect to the axial center of the rotor 40. The rotor 40 has a magnet holder 41 and a magnet unit 42.

In the rotary electric machine 10 of fig. 38, as a difference from the rotary electric machine 10 of fig. 37, the inverter unit 60 is not provided radially inside the rotor 40. The magnet holder 41 is coupled to the rotary shaft 11 at a position radially inward of the magnet unit 42. Further, the stator 50 has a stator winding 51 and a stator core 52, and is mounted to the housing 30.

(modification 11)

Hereinafter, another structure of the rotating electric machine as the inner rotor structure will be described. Fig. 39 is an exploded perspective view of rotary electric machine 200, and fig. 40 is a side sectional view of rotary electric machine 200. Here, the vertical direction is shown with reference to the state of fig. 39 and 40.

As shown in fig. 39 and 40, the rotating electric machine 200 includes: a stator 203 having a ring-shaped stator core 201 and a multi-phase stator winding 202; and a rotor 204 rotatably disposed inside stator core 201. The stator 203 corresponds to an armature, and the rotor 204 corresponds to a field element. The stator core 201 is formed by laminating a plurality of silicon steel plates, and the stator winding 202 is mounted on the stator core 201. Although illustration is omitted, the rotor 204 has a rotor core and a plurality of permanent magnets as magnet units. A plurality of magnet insertion holes are provided in the rotor core at equal intervals in the circumferential direction. Permanent magnets are respectively mounted in the magnet insertion holes, and the magnetization directions of the permanent magnets are alternately changed for adjacent magnetic poles. In addition, the permanent magnets of the magnet unit preferably have a halbach array as illustrated in fig. 23 or a similar structure. Alternatively, it is preferable that the permanent magnet of the magnet unit has a polarity anisotropy property in which the orientation direction (magnetization direction) extends in an arc shape between the d axis, which is the magnetic pole center, and the q axis, which is the magnetic pole boundary, as described with reference to fig. 9 and 30.

Here, the stator 203 is preferably configured as any one of the following.

(A) In the stator 203, an inter-wire member is provided between each of the circumferential wire portions, and as the inter-wire member, a magnetic material satisfying a relationship of Wt × Bs ≦ Wm × Br is used, where Wt is a circumferential width of the inter-wire member of one magnetic pole, Bs is a saturation magnetic flux density of the inter-wire member, Wm is a circumferential width of the magnet unit of one magnetic pole, and Br is a residual magnetic flux density of the magnet unit.

(B) In the stator 203, an inter-wire member is provided between each of the wire portions in the circumferential direction, and a non-magnetic material is used as the inter-wire member.

(C) The stator 203 is configured such that no inter-conductor member is provided between the respective conductor portions in the circumferential direction.

In the rotor 204, a plurality of magnets oriented such that the direction of the easy axis of magnetization is more parallel to the d axis at the magnetic pole center, i.e., the d axis side than the q axis side, which is the magnetic pole boundary, constitute a magnet unit.

An annular inverter case 211 is provided at one axial end of the rotating electric machine 200. The inverter case 211 is disposed such that the case lower surface is in contact with the upper surface of the stator core 201. Inside the inverter case 211 are provided: a plurality of power modules 212 constituting an inverter circuit; a smoothing capacitor 213 that suppresses ripples (ripples) of a voltage and a current generated by a switching operation of the semiconductor switching element; a control board 214 having a control section; a current sensor 215 that detects a phase current; and a resolver stator 216 that is a rotational speed sensor of the rotor 204. The power supply module 212 includes semiconductor switching elements, i.e., IGBTs and diodes.

The inverter case 211 has, at its peripheral edge: a power supply connector 217 connected to a direct current circuit of a battery mounted on the vehicle; and a signal connector 218 for transmitting various signals between the rotating electrical machine 200 side and the vehicle side control device. The inverter case 211 is covered by a top cover 219. Dc power from the vehicle-mounted battery is input via the power connector 217, converted into ac by the switches of the power module 212, and transmitted to the stator winding 202 of each phase.

A bearing unit 221 that rotatably holds the rotary shaft of the rotor 204 and an annular rear case 222 that houses the bearing unit 221 are provided on the opposite side of the inverter case 211 from the axial direction both sides of the stator core 201. The bearing unit 221 includes, for example, a pair of two bearings, and is disposed so as to be offset to either one of the axial directions with respect to the axial center of the rotor 204. However, the plurality of bearings in the bearing unit 221 may be provided at both sides of the stator core 201 in the axial direction in a distributed manner, and the rotating shaft may be supported by the bearings in a double-arm manner. Rear case 222 is fixed by bolting to a mounting portion of a gear box, a transmission, or the like of the vehicle, and mounts rotating electric machine 200 on the vehicle side.

A cooling flow passage 211a through which a refrigerant flows is formed in the inverter case 211. The cooling passage 211a is formed by closing a space recessed annularly from the lower surface of the inverter case 211 by the upper surface of the stator core 201. The cooling passage 211a is formed to surround the coil edge end of the stator winding 202. A module case 212a of the power module 212 is inserted into the cooling flow path 211 a. The rear case 222 also has a cooling flow path 222a formed so as to surround the coil edge end of the stator winding 202. The cooling passage 222a is formed by closing a space annularly recessed from the upper surface of the rear case 222 by the lower surface of the stator core 201.

(modification 12)

Although the structure in which the rotating-field-excited rotating electrical machine is embodied has been described above, the rotating-armature-type rotating electrical machine may be embodied by modifying the structure. Fig. 41 shows a structure of a rotary armature type rotating electric machine 230.

In the rotating electric machine 230 of fig. 41, bearings 232 are fixed to the housings 231a and 231b, respectively, and a rotating shaft 233 is rotatably supported by the bearings 232. The bearing 232 is an oil-retaining bearing in which oil is contained in, for example, a porous metal. A rotor 234 as an armature is fixed to the rotating shaft 233. The rotor 234 includes a rotor core 235 and a multiphase rotor winding 236 fixed to an outer peripheral portion of the rotor core 235. In the rotor 234, the rotor core 235 has a non-slotted structure, and the rotor winding 236 has a flat wire structure. That is, the rotor winding 236 is a flat structure in which the circumferential dimension of the area of each phase is larger than the radial dimension.

Further, a stator 237 as a field element is provided radially outside the rotor 234. The stator 237 includes: a stator core 238 fixed to the housing 231 a; and a magnet unit 239 fixed to an inner peripheral side of the stator core 238. The magnet unit 239 includes a plurality of magnetic poles having polarities alternating in the circumferential direction, and is oriented such that the direction of the axis of easy magnetization is more parallel to the d-axis, which is the magnetic pole center, than the q-axis, which is the magnetic pole boundary, similarly to the above-described magnet unit 42 and the like. The magnet unit 239 has an oriented sintered neodymium magnet, has an intrinsic coercive force of 400[ kA/m ] or more, and has a residual magnetic flux density of 1.0[ T ] or more.

The rotating electric machine 230 of this example is a two-pole three-coil coreless motor with brushes, the rotor winding 236 is divided into three, and the magnet unit 239 is two poles. The number of poles and coils of the motor with brushes is various according to the application, such as 2:3, 4:10, 4: 21.

A commutator 241 is fixed to the rotating shaft 233, and a plurality of brushes 242 are arranged radially outward of the commutator 241. The rectifier 241 is electrically connected to the rotor winding 236 via a wire 243 embedded in the rotating shaft 233. The rectifier 241, the brush 242, and the lead 243 supply and discharge dc current to and from the rotor winding 236. The rectifier 241 is configured to be divided appropriately in the circumferential direction according to the number of phases of the rotor winding 236. The brush 242 may be connected directly to a dc power supply such as a battery via an electric wiring, or may be connected to the dc power supply via a terminal block or the like.

A resin washer 244 is provided as a sealing member between the bearing 232 and the commutator 241 on the rotary shaft 233. The resin washer 244 prevents oil that has leaked from the oil-retaining bearing, i.e., the bearing 232, from flowing out to the rectifier 241 side.

(modification 13)

In the stator winding 51 of the rotating electric machine 10, each of the lead wires 82 may have a plurality of insulating films inside and outside. For example, it is preferable that the lead wire 82 is formed by bundling a plurality of lead wires (wire rods) with an insulating film and covering the lead wires with an outer layer film. In this case, the insulating film of the wire rod constitutes an inner insulating film, and the outer layer film constitutes an outer insulating film. In particular, it is preferable that the insulating ability of the outer insulating film among the plurality of insulating films in the wire 82 is set higher than the insulating ability of the inner insulating film. Specifically, the thickness of the insulating film on the outer side is set to be larger than the thickness of the insulating film on the inner side. For example, the thickness of the outer insulating film is set to 100 μm, and the thickness of the inner insulating film is set to 40 μm. Alternatively, it is preferable to use a material having a lower dielectric constant than the inner insulating film as the outer insulating film. As long as at least any one of the above can be applied. Further, the wire is preferably configured as an aggregate of a plurality of conductive members.

As described above, the present invention can be applied to a vehicle system for high voltage by enhancing the insulation of the outermost layer of the lead 82. The rotating electric machine 10 can be appropriately driven even in a plateau where the air pressure is low.

(modification 14)

In the lead 82 having a plurality of insulating films inside and outside, at least one of the linear expansion coefficient (linear expansion coefficient) and the adhesive strength may be different between the insulating film on the outside and the insulating film on the inside. Fig. 42 shows a structure of a lead wire 82 of the present modification.

In fig. 42, the lead 82 has: a plurality of strands (4 strands in the figure) of wire 181; an outer layer film 182 (outer layer insulating film) made of, for example, resin surrounding the plurality of strands of wires 181; and an intermediate layer 183 (intermediate insulating film) filling the outer layer film 182 around each wire 181. The wire 181 has a conductive portion 181a made of a copper material and a conductive film 181b (inner insulating film) made of an insulating material. In the case of a stator winding, the phases are insulated by the outer layer film 182. The wire 181 is preferably configured as an aggregate of a plurality of conductive members.

The intermediate layer 183 has a higher linear expansion rate than the conductive film 181b of the wire 181, and has a lower linear expansion rate than the outer layer film 182. That is, the linear expansion coefficient of the lead 82 is higher toward the outer side. Normally, the outer layer film 182 has a higher linear expansion coefficient than the conductive film 181b, but by providing the intermediate layer 183 having an intermediate linear expansion coefficient between the outer layer film 182 and the conductive film 181b, the intermediate layer 183 can function as a buffer member, and simultaneous cracking on the outer layer side and the inner layer side can be prevented.

In the lead 82, the conductive portion 181a and the conductive film 181b are bonded to each other in the wire 181, and the conductive film 181b and the intermediate layer 183, and the outer layer film 182 are bonded to each other, and the bonding strength is weaker in each of the bonded portions as the portion becomes closer to the outside of the lead 82. That is, the adhesion strength between the conductive portion 181a and the conductive film 181b is weaker than the adhesion strength between the conductive film 181b and the intermediate layer 183 and the adhesion strength between the intermediate layer 183 and the outer layer film 182. When the adhesion strength to the conductive film 181b and the intermediate layer 183 is compared with the adhesion strength to the intermediate layer 183 and the outer layer film 182, it is preferable that one of the latter (outer side) is weak or the same. The magnitude of the adhesive strength between the films can be determined by, for example, the tensile strength required when peeling the two films. By setting the bonding strength of the lead 82 as described above, even if a difference in temperature between the inside and the outside occurs due to heat generation or cooling, cracking (co-cracking) can be suppressed on both the inner layer side and the outer layer side.

Here, the heat generation and temperature change of the rotating electric machine are mainly caused by copper loss generated from the conductive portion 181a of the wire 181 and iron loss generated from the inside of the core, but these two types of loss are transmitted from the conductive portion 181a in the lead wire 82 or the outside of the lead wire 82, and the heat generation source is not in the intermediate layer 183. In this case, the intermediate layer 183 has an adhesive force that can serve as a buffer for both sides, thereby preventing the simultaneous cracking. Therefore, the present invention can be suitably used even in a high withstand voltage field such as a vehicle application or a field where a temperature change is large.

Supplementary explanation is provided below. The wire 181 may be, for example, a porcelain enamel wire, and in this case, has a resin film layer (conductor film 181b) such as PA, PI, PAI, or the like. Further, the outer layer film 182 on the outer side of the wire 181 is preferably made of the same PA, PI, PAI, or the like, and is thick. Thus, the destruction of the film due to the difference in linear expansion coefficient is suppressed. In addition to the above-described materials such as PA, PI, and PAI, the outer layer film 182 is preferably made thicker by using a material having a lower dielectric constant than PA and PAI, such as PPS, PEEK, fluorine, polycarbonate, silicon, epoxy resin, polyethylene naphthalate, and LCP, so as to increase the conductor density of the rotating electric machine. Even if the resin is thinner than PI or PAI films that are the same as the conductive film 181b or has the same thickness as the conductive film 181b, the insulating ability is improved, and thus the occupation ratio of the conductive portions is increased. Generally, the above resin has better insulation of dielectric constant than the insulating film of the enamel wire. Of course, there are also cases where the dielectric constant is deteriorated due to the molding state or the mixture. Among them, PPS and PEEK are generally suitable as an outer layer film of the second layer because they have a linear expansion coefficient larger than that of the enamel film but smaller than that of other resins.

Further, the adhesion strength between the two films (the intermediate insulating film and the outer insulating film) on the outer side of the wire 181 and the enamel film of the wire 181 is preferably weaker than the adhesion strength between the copper wire and the enamel film in the wire 181. This suppresses the phenomenon that the porcelain glaze film and the above-mentioned both films are once destroyed.

When a water cooling structure, a liquid cooling structure, or an air cooling structure is added to the stator, basically, it is considered that a thermal stress or an impact stress is applied from the outer layer film 182. However, even when the insulating layer of the wire 181 and the two films are made of different resins, the thermal stress and the impact stress can be reduced by providing a portion where the films are not bonded. That is, the insulating structure is completed by providing a gap with the wire (enamel wire) and disposing fluorine, polycarbonate, silicon, epoxy resin, polyethylene naphthalate, and LCP. In this case, it is preferable to bond the outer layer film and the inner layer film using an adhesive material having a low dielectric constant and a low linear expansion coefficient, such as an epoxy resin. Thus, not only can the mechanical strength be improved, but also the film breakage due to friction caused by vibration or the like of the conductive portion or the breakage of the outer layer film due to a difference in linear expansion coefficient can be suppressed.

As the outermost layer of the lead 82 having the above-described structure, which is generally used as a final step of winding the stator, and which is responsible for mechanical strength, fixation, and the like, it is preferable to use a resin having good moldability and properties close to those of the enamel film, such as an epoxy resin, PPS, PEEK, and LCP.

The resin potting is generally performed using polyurethane or silicon, but the linear expansion coefficient of the resin is nearly twice as low as that of other resins, and thermal stress capable of shearing the resin is generated. Therefore, it is not suitable for use in applications of 60V or more, which are strictly used for insulation in the world. In this regard, the above-described respective requirements can be achieved by a final insulation process which is easily performed by injection molding or the like using an epoxy resin, PPS, PEEK, LCP, or the like.

(modification 15)

Next, a rotary electric machine 400 according to modification 15 will be described. Fig. 43 is a longitudinal sectional view showing a schematic structure of an outer rotor type rotating electric machine 400.

As shown in fig. 43, the rotating electric machine 400 includes: a rotor 410 integrally rotatably fixed to the rotary shaft 401; and a stator 420 provided radially inward of the rotor 410. As in the above-described structure, the rotary shaft 401 is rotatably supported by a bearing, not shown. The rotor 410 corresponds to a "field element", and the stator 420 corresponds to an "armature".

The rotor 410 has: a magnet holder 411 formed in a hollow cylindrical shape; and a ring-shaped magnet unit 412 fixed to the radially inner side of the magnet holder 411. The magnet holder 411 is fixed to the rotation shaft 401, and has a function as a magnet holding member. The magnet unit 412 is composed of a plurality of permanent magnets arranged to alternately change polarity along the circumferential direction of the rotor 410. The magnet unit 412 corresponds to a "magnet portion". Thus, the magnet unit 412 has a plurality of magnetic poles in the circumferential direction. Magnet unit 412 has the structure described as magnet unit 42 in fig. 8 and 9 of the first embodiment, and a permanent magnet is constituted by using a sintered neodymium magnet having an intrinsic coercive force of 400kA/m or more and a residual magnetic flux density Br of 1.0T or more,

like the magnet unit 42 of fig. 9 and the like, the magnet unit 412 has a first magnet 91 and a second magnet 92 which are respectively polar anisotropic magnets and differ in polarity from each other. As described with reference to fig. 8 and 9, the directions of the magnetization easy axes of the

magnets

91 and 92 are different between the d-axis side (portion close to the d-axis) and the q-axis side (portion close to the q-axis), and the direction of the magnetization easy axis is close to the direction parallel to the d-axis on the d-axis side and the direction of the magnetization easy axis is close to the direction orthogonal to the q-axis on the q-axis side. Further, a magnet magnetic path in the shape of a circular arc is formed in accordance with the orientation corresponding to the direction of the easy magnetization axis. In the

magnets

91 and 92, the easy magnetization axis may be parallel to the d-axis on the d-axis side and may be perpendicular to the q-axis on the q-axis side. In short, the magnet unit 412 is configured to be oriented such that the direction of the magnetization easy axis is more parallel to the d axis at the magnetic pole center, i.e., the d axis side than the q axis side, which is the magnetic pole boundary. As the magnet unit 412, the structure of the magnet unit 42 shown in fig. 22 and 23 and the structure of the magnet unit 42 shown in fig. 30 can be used.

The stator 420 includes a stator winding 421 as an armature winding and a stator core 422. The stator winding 421 is formed by winding a plurality of phase windings formed in a substantially cylindrical shape (annular shape), and a stator core 422 as a base member is attached to the inside in the radial direction of the stator winding 421. In this example, the stator winding 421 is configured as a three-phase winding by using U-phase, V-phase, and W-phase windings. Each phase winding is star-connected (Y-connected). However, each phase winding may be in a delta-connected configuration.

A stator holding member 430 is assembled radially inside the stator core 422, and the stator 420 is held by the stator holding member 430. The stator holding member 430 has a cylindrical portion 431 disposed radially inside the stator core 422, and a refrigerant passage 432 through which a refrigerant such as cooling water flows annularly is formed in the cylindrical portion 431. Further, an electric module including a semiconductor switching element or the like may be disposed radially inward of the cylindrical portion 431, and the electric module may be cooled by the refrigerant flowing through the refrigerant passage 432.

Next, the structure of the stator 420 will be described in detail. Fig. 44 is a plan view showing the structure of stator 420, fig. 45 is a perspective view showing the structure of stator 420, fig. 46 is a perspective view showing the structure of stator winding 421, and fig. 47 is a side view of stator 420. In fig. 47, the phase windings of the same phase (for example, U-phase windings) in stator winding 421 are indicated by dot marks.

The structure of stator core 422 will be explained. As in the stator core 52 described above, the stator core 422 is formed in a cylindrical shape having a plurality of electromagnetic steel plates stacked in the axial direction and a predetermined thickness in the radial direction, and the stator winding 421 is assembled on the radially outer side of the stator core 422 on the rotor 410 side. The outer circumferential surface of stator core 422 has a curved surface shape having no concavity and convexity in the circumferential direction, and in a state where stator winding 421 is assembled, wires 423 constituting stator winding 421 are arranged side by side in the circumferential direction along the outer circumferential surface of stator core 422. The stator core 422 functions as a back yoke.

The stator 420 preferably has any one of the following configurations (a) to (C).

(A) In the stator 420, the inter-lead members are provided between the respective lead wires 423 in the circumferential direction, and as the inter-lead members, a magnetic material is used that satisfies the relationship Wt × Bs ≦ Wm × Br when the circumferential width of the inter-lead members of one magnetic pole is Wt, the saturation magnetic flux density of the inter-lead members is Bs, the circumferential width of the magnet unit 412 of one magnetic pole is Wm, and the residual magnetic flux density of the magnet unit 412 is Br.

(B) In the stator 420, an inter-wire member is provided between the respective wires 423 in the circumferential direction, and a non-magnetic material is used as the inter-wire member.

(C) The stator 420 is configured such that no inter-wire member is provided between the respective conductive wires 423 in the circumferential direction.

According to the configuration of the stator 420, the inductance can be reduced as compared with a rotating electric machine having a normal pole tooth configuration in which pole teeth (iron cores) for establishing a magnetic circuit are provided between the respective lead portions as the stator winding. Specifically, the inductance can be made below 1/10. In this case, since the impedance decreases as the inductance decreases, the output power with respect to the input power is increased in the rotating electrical machine 400, and the torque can be increased. Further, a rotating electrical machine with a large output can be provided as compared with a rotating electrical machine using an embedded magnet type rotor that performs torque output using a voltage of an impedance component (in other words, using reluctance torque).

In addition, since the inductance can be reduced in the stator 420 of this example, magnetic saturation is less likely to occur. Therefore, the thickness (radial thickness) of the stator core 422 can be reduced.

Further, according to the above configuration, since the conventional pole teeth or the structure corresponding to the pole teeth is not included, the magnet flux waveform actually interlinked with the stator winding 421 can be made close to the magnet flux waveform of the magnet unit 412 for achieving high torque. As a result, the effect of increasing the torque of the rotating electric machine 400 can be improved.

In this example, the stator winding 421 and the stator core 422 are integrally molded together with a molding material (insulating member) made of resin or the like, and the molding material is sandwiched between the respective conductive wires 423 arranged in the circumferential direction. With the above configuration, the stator 420 of the present example corresponds to the configuration of (B) in the above (a) to (C). The molding will be described later. In addition, in each of the conductive wires 423 adjacent in the circumferential direction, end surfaces in the circumferential direction are in contact with each other, or are disposed adjacent to each other with a slight interval therebetween. In the case of the configuration of the above (a), it is preferable that the protrusions having a predetermined size (width or protrusion height) satisfying the above (a) be provided on the outer peripheral surface of the stator core 422 at predetermined intervals in the circumferential direction.

When the stator 420 is manufactured by assembling the stator core 422 to the stator winding 421, it is preferable that a part of the stator winding 421 is cut out in an annular shape so as not to be connected (that is, the stator winding 421 is formed in a substantially C-shape), and after the stator core 422 is assembled to the inner peripheral side of the stator winding 421, the cut-out parts are connected to each other so as to form the stator winding 421 in an annular shape. In addition, the stator core 422 may be divided into a plurality of pieces (for example, three or more pieces) in the circumferential direction, and the divided pieces may be assembled to the inner circumferential side of the stator winding 421 formed in an annular shape.

Next, the stator winding 421 will be described in more detail.

The stator winding 421 includes

phase windings

421U, 421V, and 421W for respective phases, which are arranged in parallel in the circumferential direction in a predetermined order (see fig. 47). The stator winding 421 is formed of one layer of conductive wires 423 radially inside and outside each phase winding, and is formed into an annular shape by distributed winding. As shown in fig. 47, the stator winding 421 has: a coil side portion 425 juxtaposed in the radial direction to the stator core 422; and a coil side end 426 located axially outward of the coil side 425. The coil edge ends 426 are provided on both axial end sides of the stator winding 421. The coil side 425 is a portion that faces the magnet unit 412 of the rotor 410 in the radial direction, and the coil edge 426 is a winding portion that winds the phase winding in the circumferential direction on the axially outer side of the coil side 425.

The stator winding 421 preferably has the following structure (i.e., a flat wire structure): in the coil side 425, the thickness dimension in the radial direction of the wire 423 is smaller than the circumferential tail width dimension corresponding to 1 in one pole.

The phase windings of the respective phases of the stator winding 421 are respectively formed in the coil edge 426 so as to be bent perpendicularly to the axial direction toward the radially inner side. In this case, the phase windings of the respective phases are formed by bending the coil side ends 426 toward the stator core 422, and the coil side ends 426 are configured to face (engage) the axial end faces of the stator core 422. As shown in fig. 44, the phase winding of each phase has, at the coil side end 426: an inner extension 427a extending radially inward; and a circumferentially extending portion 427b extending in the circumferential direction, the circumferentially extending portion 427b being configured to face an axial end surface of the stator core 422 on a radially outer side of the inner circumferential surface of the stator core 422 (i.e., not to protrude radially inward from the inner circumferential surface of the stator core 422).

As shown in fig. 47, in the phase windings of the respective phases, the coil side ends 426 on the same side in the respective phases are different in the axial projection height, and the wire lengths from one end to the other end in the axial direction are the same. The axial projection height is Hu, Hv, and Hw for each phase at the coil edge 426 on the upper side of the figure (Hu > Hv > Hw). In the lower coil side end 426 in the figure, the projection heights in the axial direction of the respective phases are opposite in size. Further, the length of the wire from one end to the other end in the axial direction is LA in each phase. The phase winding of each phase is configured such that the position of the bending point of the coil edge 426 differs for each phase by at least the radial thickness of the phase winding.

In the coil edge 426, the axial projection heights of the phase windings of the respective phases are different from each other, so that the phase windings of the respective phases can be prevented from interfering with each other at the coil edge 426. Further, by making the lead lengths from the one end to the other end in the axial direction the same in the phase windings of the respective phases, the overall lengths of the phase windings of the respective phases, that is, the lead lengths from the end portion on the neutral point side to the end portion on the input/output side of the respective phase windings can be equalized. Thus, even if the projection height at the coil side end 426 is made different for each phase, the resistance values of the phase windings of each phase can be equalized.

In addition, in the phase winding of each phase, it is preferable that the wires 423 of different phases are spaced apart from each other at the coil side end 426 more than at the coil side portion 425. For example, at the coil edge 426, the inner extension 427a and the circumferential extension 427b of the phase winding of each phase are preferably axially spaced apart from each other. For example, according to a structure in which no inter-wire member is provided in the stator 420, the wires 423 are arranged adjacent to each other as compared with a structure in which an inter-wire member is provided, and therefore, there is a concern about an influence of heat generation in the stator winding 421. In this regard, since a configuration is employed in which the intervals between the conductive wires 423 of different phases at the coil side end 426 of each phase winding are larger than those of the coil side portion 425, it is considered that it is not necessary to increase the concentration of the conductive wires 423 at the coil side end 426 (for example, the conductor density in the conductive wire arrangement space) to be higher than that of the coil side portion 425, and thus the intervals between the conductive wires 423 of different phases can be increased, and the heat radiation of the stator winding 421 can be optimized. Further, insulation between mutually different phases can be appropriately achieved. The stator winding 421 is formed by a lead wire 423 in which a plurality of strands of wire material (thin wires) are bundled into 1 bundle.

In addition, the stator 420 is resin-molded (resin-molded) in a state where the stator winding 421 is wound around the stator core 422. Thus, as shown in fig. 49 to 51, stator 420 is configured such that stator core 422 and stator winding 421 are covered with resin member 1001. That is, stator core 422 and stator winding 421 are embedded in resin member 1001. In fig. 49 to 51, the stator core 422 and the stator winding 421 covered with the resin member 1001 are shown by broken lines.

Here, a method of general resin molding will be described. As shown in fig. 48 (a), a resin such as a thermoplastic resin is liquefied by heating in an oven 2001. Then, a predetermined pressure is applied to pass the liquefied resin through a passage 2002 in a mold such as a runner. Thereafter, the molten metal flows into the mold 2004 through the gate 2003. In the mold 2004, the stator winding 421 is housed in a state fixed to the stator core 422, and the resin flowed into the mold 2004 from the gate 2003 passes through a gap between the stator winding 421 and the mold 2004. Next, after the resin is poured into the mold 2004 so as to cover the circumferential surface of the stator winding 421, the resin is cooled and solidified. After being cured, the resin-molded stator 420 is taken out of the mold 2004. Next, excess resin is cut off from the stator 420 at the gate 2003. As described above, the stator 420 is resin-molded. In addition, a gate 2003 is an inlet of the resin, and this gate 2003 is provided to adjust the speed at which the resin flows in.

As described above, the stator winding 421 is wound around the stator core 422. Therefore, the winding shape is a complicated shape. Specifically, the coil edge 426 is provided with a predetermined concave-convex pattern that is concave-convex in the axial direction in the circumferential direction. On the other hand, the housing space in the die 2004 is cylindrical.

Therefore, as shown in fig. 48 (b), the dimensions of the upper path (path through which the resin flows, the same applies hereinafter) and the lower path may differ in the axial direction. That is, the gap size from the surface of the stator winding 421 to the inner peripheral surface of the die 2004 may be different vertically in the axial direction.

In this case, the inflow pressure of the resin differs in the vertical path, and as shown in fig. 48 (c), the inflow speed of the resin (indicated by the length of the arrow) may differ. That is, as shown in fig. 48 (c), the resin flows into the upper side faster than the lower side. Therefore, the time until the resin reaches the opposite side of the gate 2003 is different between the upper path and the lower path. Further, if the resin flowing in through one path (upper side in fig. 48 c) reaches the opposite side of the gate 2003 earlier than the other path (lower side), there is a possibility that the resin is solidified in this state. Further, when the resin is cured first, the resin cannot be smoothly connected to each other on the opposite side of the gate 2003, and there is a possibility that the resin is cracked or cracked.

Therefore, in the present embodiment, as shown in fig. 49 to 51, a plurality of gates 1002 into which the resin flows are provided. That is, by providing a plurality of the resin flow paths, the difference in the paths (the length, size, etc. of the paths) through which the resin flows in the mold can be reduced. This prevents a large difference in the resin arrival speed. In fig. 49 to 50, the position (mark) of the gate 1002 is indicated by a diagonal line, and in fig. 51, a passage through which the resin flows in the mold is indicated by a dashed-dotted line.

Further, when a plurality of gates are provided, at each gate, when the positions in the axial direction and the radial direction are different, a difference is easily generated in the path and the speed at which the resin flows in. Therefore, each gate 1002 is provided on an upper end surface 1001a in the axial direction of the resin member 1001. Further, each gate 1002 is provided at substantially the same distance from the center of the resin member 1001 in the radial direction. More specifically, each gate 1002 is disposed at a position intermediate between the outer circumferential surface and the inner circumferential surface of the resin member 1001 in the radial direction. This allows the resin to flow in from each gate 1002 in the axial direction and the radial direction at the same time.

For the same reason, when the plurality of gates 1002 are provided unevenly in the circumferential direction, there is a possibility that the speed until the stator winding 421 is covered in the circumferential direction varies due to the difference in the path such as the path length in the circumferential direction. Therefore, the gates 1002 are equally arranged in the circumferential direction. This allows the resin to flow in from each gate 1002 uniformly in the circumferential direction.

In the present embodiment as described above, in the resin member 1001, a plurality of gates 1002 are provided at equal intervals in the circumferential direction at the same positions in the axial direction and the radial direction. Therefore, when the resin is caused to flow in from the gate 1002, the resin can be caused to flow in the same direction in the axial direction and the radial direction. This makes it possible to make the time until the resin reaches the opposite side of the gate 1002 the same regardless of the route, and to suppress the resin flowing in through a certain route from reaching the opposite side of the gate 1002 first and being solidified.

Further, since the gates 1002 are provided at equal intervals in the circumferential direction, the resin can be uniformly flowed in the circumferential direction. This can prevent the resin flowing from one gate 1002 from reaching the middle point of the circumferentially adjacent gates 1002 before the other gate and being solidified. Therefore, cracking or crazing of the resin can be suppressed in the resin member 1001.

Further, as described above, the stator winding 421 is wound in a constant winding pattern in the circumferential direction. That is, in the stator winding 421, a predetermined uneven pattern which is uneven in the axial direction is repeatedly provided in the circumferential direction by the coil side end 426. If the winding shape of the stator winding 421 is different, the path formed between the stator winding 421 and the mold is also different. Therefore, when the positions and the number of the gates 1002 in the circumferential direction are provided regardless of the winding pattern or the uneven pattern, the possibility of a large difference in path length or the like becomes high.

Thus, each gate 1002 is provided for the winding pattern. That is, in the present embodiment, each gate 1002 may be provided for the uneven pattern. Specifically, as shown in fig. 51, each gate 1002 is provided directly above the W-phase lead 423 so as to overlap the W-phase lead 423 in the axial direction. This can further reduce the difference in the path of each gate 1002, thereby allowing the resin to flow uniformly. In the present embodiment, one gate 1002 is provided for each pattern, but a plurality of gates may be provided.

The coil edge 426 of the present embodiment is bent radially toward (inside) the stator core 422 and engages with an end of the stator core 422 in the axial direction. Therefore, in resin member 1001, each gate 1002 is provided on upper end surface 1001a of resin member 1001 in the axial direction. Thus, the resin member 1001 can be molded so that the pressure for pressing the coil side end 426 toward the stator core 422 is applied in the axial direction. Therefore, the stator winding 421 can be desirably fixed to the stator core 422.

Here, a method of manufacturing the rotating electric machine 400 of the present embodiment, particularly, a method of resin molding the stator 420 will be described.

First, a step of winding stator winding 421 around stator core 422 is performed so that lead wires 423 as lead portions arranged at predetermined intervals in the circumferential direction are formed at positions facing rotor 40. Next, a step of housing the stator core 422 and the stator winding 421 in a mold is performed in a state where the stator winding 421 is wound around the stator core 422. Next, a step of molding resin member 1001 is performed so that resin flows into the mold through gates 1002 to cover stator core 422 and stator winding 421. After the resin is poured into the mold, a step of cooling the resin to solidify the resin is performed. After the curing, a process of taking out the stator 420 subjected to the resin molding from the mold is performed. Next, a step of cutting off an excess resin from the stator 420 at the gate 1002 is performed. As described above, the stator 420 is resin-molded.

(other example of modification 15)

The structure of modification 15 may be changed as follows.

In the modification described above, the position of each gate 1002 may be changed. For example, as shown in fig. 52, a plurality of gates 1011 may be provided on a surface (i.e., an inner circumferential surface) of the resin member 1001 on the opposite side to the magnet unit 412 in the radial direction. In this case, the position in the axial direction of the gate 1011 is preferably the same. Further, similarly to the gates 1002, they are preferably provided at equal intervals in the circumferential direction. As with the gate 1002, it is preferably provided for each winding pattern, that is, the uneven pattern, in the circumferential direction. Thereby, the resin flowing from the gate 1011 flows from the inside to the outside in the radial direction. This facilitates formation of the resin layer between stator winding 421 and stator core 422. Therefore, the stator winding 421 and the stator core 422 can be insulated from each other desirably.

Further, for example, as shown in fig. 53, a plurality of gates 1021 may be provided on a surface (i.e., an outer peripheral surface) of the resin member 1001 on the magnet unit 412 side in the radial direction. In this case, the position of the gate 1021 in the axial direction is preferably the same. Further, similarly to the gates 1002, they are preferably provided at equal intervals in the circumferential direction. As with the gate 1002, it is preferably provided for each winding pattern, i.e., the concave-convex pattern, in the circumferential direction. This allows stator winding 421 to be pressed and fixed toward stator core 422 by the resin at the time of resin molding. Therefore, the air gap between the stator winding 421 and the magnet unit 412 can be reduced and equalized.

When the gate is provided on the surface (i.e., the inner circumferential surface) on the opposite side of the magnet unit 412 in the radial direction, for example, as shown in fig. 54, a plurality of gates 1031 may be provided between the coil side end 426 and the coil side portion 425 in the axial direction. In this case, the positions of the gates 1031 in the axial direction are preferably the same. Further, similarly to the gates 1002, they are preferably provided at equal intervals in the circumferential direction. As with the gate 1002, it is preferably provided for each winding pattern, i.e., the concave-convex pattern, in the circumferential direction. This facilitates formation of the resin layer between the coil edge 426 and the axial end face of the stator core 422. Therefore, the coil edge 426 can be insulated from the stator core 422 desirably.

Two or more of the

gates

1002, 1011, 1021, and 1031 may be combined.

In the above modification, the stator core 422 and the stator winding 421 may be divided into a plurality of (for example, three or more) segments in the circumferential direction, and the resin molding may be performed on each of the divided segments. After resin molding, stator core 422 and stator winding 421 may be combined into an annular shape. This enables resin molding by division. Therefore, the mold is easily manufactured according to the shape of the stator winding 421. That is, a mold in which resin flows uniformly is easily manufactured.

In the modification described above, the gates 1002 may be provided on both end surfaces in the axial direction.

In the modification described above, as shown in fig. 55, the resin member 1001 may be formed along the uneven pattern of the coil side end 426 such that the thickness of the resin member 1001 covering the coil side end 426 is constant. This makes it possible to equalize the shapes of the paths in the circumferential direction, thereby allowing the resin to flow in uniformly. When the thickness of the resin member 1001 covering the coil side end 426 is constant, the inner surface shape of the mold may be formed along the uneven pattern of the coil side end 426. In fig. 55, only the shape of the outer peripheral surface of the stator 420 is illustrated.

In the stator winding 421 having the configuration shown in fig. 44 to 47, the phase windings of the respective phases are bent perpendicularly to the axial direction toward the stator core 422 side, that is, toward the radially inner side at the coil edge 426, but the configuration may be modified. For example, the phase windings of the respective phases may be bent radially outward at the coil edge 426 on the opposite side of the stator core 422, or bent at an angle not perpendicular to the axial direction.

The bending angles of the phase windings of the respective phases with respect to the axial direction may be made different at the coil edge 426. For example, it is preferable that the coil edge 426 on the same side has a smaller bending angle with respect to the axial direction as the axial projection height of the phase winding increases.

Instead of the outer rotor type rotating electric machine, an inner rotor type rotating electric machine may be embodied. In this case, in the stator 420, a stator core 422 is assembled radially outside the stator winding 421. In order to allow the coil side end 426 of the stator winding 421 to face the axial end face of the stator core 422, the phase windings of the respective phases are preferably formed by being bent outward in the radial direction.

Modifications other than the above are described below.

The distance DM in the radial direction between the surface of the magnet unit 42 on the armature side in the radial direction and the axial center of the rotor may be 50mm or more. Specifically, for example, the distance DM in the radial direction between the radially inner surface of the magnet unit 42 (specifically, the first magnet 91 and the second magnet 92) shown in fig. 4 and the axial center of the rotor 40 may be 50mm or more.

As a rotary electric machine having a non-slot structure, a small-sized rotary electric machine for a model or the like having an output of several tens W to several hundreds W is known. The present inventors have not found a case where a grooveless structure is adopted in a large industrial rotating electrical machine of generally more than 10 kW. The inventors of the present application have studied the reason.

In recent years, the mainstream rotating electrical machines are roughly classified into the following four types. The rotating electric machine includes a brush motor, a cage induction motor, a permanent magnet synchronous motor, and a reluctance motor.

In the brush motor, a field current is supplied via a brush. Therefore, in the case of a brush motor of a large-sized device, the brush becomes large, and maintenance becomes complicated. With the remarkable development of semiconductor technology, brushless motors such as induction motors have been replaced. On the other hand, in the field of small motors, many coreless motors are also being supplied to the market from the viewpoint of low inertia and economical efficiency.

In a cage type induction motor, the principle is as follows: the torque is generated by receiving a magnetic field generated by the stator winding on the primary side with the iron core of the rotor on the secondary side to cause induced currents to flow intensively toward the cage-type conductors to form a reaction magnetic field. Therefore, from the viewpoint of downsizing and high efficiency of the equipment, it is not necessarily a good measure to remove the iron core on both the stator side and the rotor side.

A reluctance motor is an electric motor that utilizes variation in the reluctance of an iron core, and elimination of the iron core is undesirable in principle.

In recent years, IPM (i.e., embedded magnet rotor) has become the mainstream of permanent magnet synchronous motors, and IPM is generally used in large-sized equipment in particular unless otherwise specified.

The IPM has a characteristic of combining a magnet torque and a reluctance torque, and operates while adjusting the ratio of the above-described torques at appropriate times by inverter control. Therefore, the IPM is a small motor with excellent controllability.

According to the analysis of the present inventors, when a radial distance DM between a surface on the armature side in the radial direction in the magnet unit and the axial center of the rotor, that is, the radius of the stator core of a general inner rotor is plotted on the horizontal axis, the torque of the rotor surface generating the magnet torque and the reluctance torque is as shown in fig. 56.

While the magnet torque is expressed by the following equation (eq1), and the potential thereof is determined by the magnetic field strength generated by the permanent magnet, the reluctance torque is expressed by the following equation (eq2), and the magnitude of the inductance, particularly the q-axis inductance, determines the potential thereof.

Magnet torque k · Ψ · Iq · · · · · · · · · · · · · · · · · · · · · · · · · · · · · eq1)

Reluctance torque k (Lq-Ld) · (Lq · Id · · eq · 2)

Here, the magnitude of the magnetic field strength of the permanent magnet and the inductance of the winding are compared with DM. The magnetic field strength generated by the permanent magnet, i.e. the magnetic flux Ψ, is proportional to the total area of the permanent magnet at the face opposite the stator. In the case of a cylindrical rotor, the surface area of the cylinder is defined. Strictly speaking, it is proportional to the specific area of half of the surface of the cylinder, due to the presence of the N and S poles. The surface area of the cylinder is proportional to the radius of the cylinder and the length of the cylinder. That is, if the cylinder length is constant, it is proportional to the radius of the cylinder.

On the other hand, although the inductance Lq of the winding is affected by the shape of the core, the sensitivity is low, and since the inductance Lq of the winding is proportional to the square of the number of turns of the stator winding, it is highly correlated with the number of turns. In addition, when mu is to be measuredWhen the magnetic permeability of the magnetic circuit, N, S, and δ are respectively set to the number of turns, the cross-sectional area, and the effective length of the magnetic circuit, the inductance L is μ · N²XS/delta. Since the number of turns of the winding depends on the size of the winding space, the winding space of the stator, that is, the slot area, is determined in the case of a cylindrical motor. As shown in fig. 57, since the shape of the slit is substantially quadrangular, the slit area is proportional to the product a × b of the circumferential length a and the radial length b.

The length of the cutting groove in the circumferential direction is proportional to the diameter of the cylinder because the length increases as the diameter of the cylinder increases. The length dimension in the radial direction of the cutting groove is proportional to the diameter of the cylinder. That is, the area of the cut groove is proportional to the square of the diameter of the cylinder. Further, it can also be seen from the above equation (eq2) that the reluctance torque is proportional to the square of the stator current, and therefore the performance of the rotating electric machine is determined by how much current flows, and the performance depends on the slot area of the stator. In summary, if the length of the cylinder is constant, the reluctance torque is proportional to the square of the diameter of the cylinder. Fig. 56 is a graph plotting the relationship between the magnet torque and the reluctance torque and DM based on this.

As shown in fig. 56, the magnet torque increases linearly with respect to DM, and the reluctance torque increases quadratically with respect to DM. It can be seen that when DM is relatively small, magnet torque dominates, and as the stator core radius becomes larger, reluctance torque dominates. The inventors of the present application reached the following conclusions: under predetermined conditions, the intersection point of the magnet torque and the reluctance torque in fig. 56 is approximately in the vicinity of the stator core radius of 50 mm. That is, in a10 kW-class motor in which the radius of the stator core is sufficiently larger than 50mm, since it is currently the mainstream to use reluctance torque, it is difficult to eliminate the core, and this is presumed to be one of the reasons why the non-grooving structure is not adopted in the field of large-sized equipment.

In the case of a rotating electrical machine in which a stator uses an iron core, magnetic saturation of the iron core is always a technical problem. In particular, in the radial gap type rotating electrical machine, the longitudinal sectional shape of the rotating shaft is fan-shaped for each magnetic pole, and the width of the magnetic path becomes narrower toward the inner periphery side of the machine and the inner periphery side dimension of the tooth portion forming the notch determines the performance limit of the rotating electrical machine. No matter what kind of high-performance permanent magnet is used, when magnetic saturation occurs in the above portion, the performance of the permanent magnet cannot be fully utilized. In order to prevent the magnetic saturation in the above-described portion, the inner peripheral diameter is designed to be large, which leads to an increase in size of the apparatus.

For example, in a distributed-winding rotary electric machine, if a three-phase winding is used, each magnetic pole is divided by three to six pole teeth and flows, but since the magnetic flux tends to concentrate on the pole teeth in the circumferential front direction, the magnetic flux does not uniformly flow in the three to six pole teeth. In this case, the magnetic flux flows concentratedly to a part (for example, one or two) of the pole teeth, and the pole teeth magnetically saturated as the rotor rotates also move in the circumferential direction. This also becomes a main cause of the notch ripple.

In summary, in the rotary electric machine having the grooveless structure with the DM of 50mm or more, it is desired to remove the pole teeth to eliminate the magnetic saturation. However, when the pole teeth are removed, the magnetic resistance of the magnetic circuit in the rotor and the stator increases, resulting in a decrease in the torque of the rotary electric machine. For example, an air gap between the rotor and the stator may be increased as a cause of an increase in magnetic resistance. Therefore, in the rotary electric machine having the grooveless structure in which the DM is 50mm or more, there is room for improvement in torque enhancement. Therefore, in the rotary electric machine having the grooveless structure in which the DM is 50mm or more, there is a great advantage in applying the structure capable of enhancing the torque.

In addition, not limited to the rotating electric machine of the outer rotor structure, the rotating electric machine of the inner rotor structure may be configured such that the radial distance DM between the surface of the magnet unit on the armature side in the radial direction and the axial center of the rotor is 50mm or more.

In the stator winding 51 of the rotating electrical machine 10, the straight portion 83 of the lead wire 82 may be formed in a single layer in the radial direction. In the case where the straight portion 83 is arranged in a plurality of layers radially inward and outward, the number of the layers may be arbitrary, and 3 layers, 4 layers, 5 layers, 6 layers, or the like may be provided.

For example, in the configuration of fig. 2, the rotary shaft 11 is provided to protrude in the axial direction toward both one end side and the other end side of the rotary electric machine 10, but this may be modified so as to protrude only toward one end side. In this case, the rotary shaft 11 is preferably provided with a portion cantilevered by the bearing unit 20 as an end portion, and extends axially outward thereof. In the present configuration, since the rotary shaft 11 does not protrude into the inverter unit 60, the internal space of the inverter unit 60, specifically, the internal space of the cylindrical portion 71 can be used in a larger amount.

In the rotating electrical machine 10 configured as described above, the

bearings

21 and 22 are configured to use non-conductive grease, but it is possible to change this configuration so that conductive grease is used for the

bearings

21 and 22. For example, conductive grease containing metal particles, carbon particles, or the like is used.

As a structure for rotatably supporting the rotary shaft 11, bearings may be provided at two positions on one end side and the other end side in the axial direction of the rotor 40. In this case, in the configuration of fig. 1, the bearings are preferably provided at two locations on one end side and the other end side with the inverter unit 60 interposed therebetween.

In the rotating electrical machine 10 having the above-described configuration, the intermediate portion 45 of the magnet holder 41 in the rotor 40 has the inner shoulder 49a and the outer shoulder 49b, but may be configured to have a flat surface without providing the shoulders 49a and 49 b.

In the rotating electric machine 10 configured as described above, the conductor 82a is formed as an aggregate of the plurality of strands 86 in the lead wire 82 of the stator winding 51, but this may be changed, and a rectangular lead wire having a rectangular cross section may be used as the lead wire 82. Further, a round wire having a circular or elliptical cross section may be used as the wire 82.

In the rotating electrical machine 10 configured as described above, the inverter unit 60 is provided on the radially inner side of the stator 50, but in addition to this, the inverter unit 60 may not be provided on the radially inner side of the stator 50. In this case, the inner region on the radially inner side of the stator 50 can be used as a space. Further, a member different from the inverter unit 60 may be disposed in the internal region.

The rotating electric machine 10 configured as described above may be configured without the casing 30. In this case, the rotor 40, the stator 50, and the like may be held in a part of a wheel or another vehicle component, for example.

In the above-described embodiment and modification, the control unit and the method of the control unit according to the present invention may be realized by a dedicated computer provided by configuring a processor and a memory, and the processor is programmed to execute one or more functions embodied by a computer program. Alternatively, the control unit and the method of the control unit according to the present invention may be implemented by a dedicated computer provided by configuring a processor using one or more dedicated hardware logic circuits. Alternatively, the control unit and the method of the control unit described in the present invention are realized by one or more special purpose computers that are configured by a combination of a processor and a memory that are programmed to execute one to a plurality of functions, and a processor using one or more hardware logic circuits. Further, the computer program may also be stored on a computer-readable, non-transitory tangible storage medium as instructions that are executed by a computer.

The invention of the present specification is not limited to the illustrated embodiments. The invention includes the illustrated embodiments and variations thereon as would be apparent to those skilled in the art. For example, the present invention is not limited to the combinations of components and/or elements shown in the embodiments. The invention may be implemented in various combinations. The present invention may have an additional portion that can be added to the embodiment. The present invention includes a configuration in which components and/or elements of the embodiments are omitted. The invention encompasses permutations and combinations of parts and/or elements between one embodiment and another embodiment. The technical scope of the invention is not limited to the description of the embodiments. The technical scope of the invention is to be understood as being indicated by the description of the claims, and all modifications equivalent in meaning and scope to the description of the claims are also included.

Although the present invention has been described in terms of embodiments, it should be understood that the present invention is not limited to the embodiments and configurations described above. The present invention also includes various modifications and modifications within an equivalent range. In addition, various combinations and modes, and other combinations and modes including only one element, one or more elements, and one or less elements also belong to the scope and the idea of the present invention.

Claims

1. A rotating electrical machine (400) comprising: an excitation element (410) having a magnet portion (412) including a plurality of magnetic poles whose polarities alternate in the circumferential direction; and an armature (420) having a multiphase armature winding (421) and a base member (422) to which the armature winding is fixed, either one of the field element and the armature being a rotor,

the armature winding has a conductor portion (423) disposed at a predetermined interval in the circumferential direction at a position facing the field element,

the armature is configured such that the base member and the armature winding are covered with a resin member (1001) in a state where the armature winding is wound around the base member,

in the resin member, a plurality of gates (1002, 1011, 1021, 1031) into which resin flows at the time of resin molding of the resin member are provided at the same positions in the axial direction and the radial direction at equal intervals in the circumferential direction,

the wire guide portion includes: a coil side portion opposed to the magnet portion in a radial direction; and a coil edge end disposed on an outer side of the magnet portion in an axial direction,

the coil edge is bent toward the base member in the radial direction to engage with an end of the base member in the axial direction,

in the resin member, the gate is provided at least one of both end portions of the resin member in an axial direction,

the gate is disposed at a position overlapping the coil edge when viewed in the axial direction.

2. A rotating electrical machine (400) comprising: an excitation element (410) having a magnet portion (412) including a plurality of magnetic poles whose polarities alternate in the circumferential direction; and an armature (420) having a multiphase armature winding (421) and a base member (422) to which the armature winding is fixed, either one of the field element and the armature being a rotor,

the armature winding has lead portions (423) arranged at positions facing the field element at predetermined intervals in the circumferential direction,

the base member is a stator core that,

in the resin member, the gate is provided on a side opposite to the magnet portion in a radial direction,

in the resin member, the gate is provided between the coil edge end and the coil side portion in the axial direction.

3. The rotating electric machine according to claim 2,

the stator iron core is of an electrodeless tooth structure.

4. The rotating electric machine according to any one of claims 1 to 3,

the armature winding is wound in a constant pattern in the circumferential direction,

the gate is provided for each of the patterns in the circumferential direction.

5. The rotating electric machine according to any one of claims 1 to 3,

the wire portion includes: a coil side portion (425) that is diametrically opposite to the magnet portion; and a coil edge end (426) disposed axially outside the magnet portion,

in the armature winding, a predetermined concavo-convex pattern which is concavo-convex in the axial direction is repeatedly provided in the circumferential direction by the coil edge,

the gate is provided for each of the concave-convex patterns in the circumferential direction.

6. The rotating electric machine according to claim 5,

forming the resin member along the concave-convex pattern of the coil edge end in such a manner that a thickness dimension of the resin member covering the coil edge end is constant.

7. The rotating electric machine according to any one of claims 1 to 3,

the armature is divided into a plurality of members in a circumferential direction.

8. The rotating electric machine according to any one of claims 1 to 3,

the magnetic body portion is oriented such that the direction of the axis of easy magnetization is more parallel to the d-axis at the magnetic pole center, i.e., the d-axis side, than the q-axis side, which is the magnetic pole boundary.

9. The rotating electric machine according to any one of claims 1 to 3,

the magnetic part has an intrinsic coercive force of 400kA/m or more and a residual magnetic flux density of 1.0T or more.

10. The rotating electric machine according to any one of claims 1 to 3,

the thickness dimension of the wire portion in the radial direction is smaller than the width dimension of a magnetic pole in the circumferential direction corresponding to the radial direction.

11. The rotating electric machine according to any one of claims 1 to 3,

in the above-mentioned armature, a magnetic pole is provided,

the magnetic material or the nonmagnetic material is configured to satisfy a relation of Wt × Bs ≦ Wm × Br when the width in the circumferential direction of the inter-wire member of one magnetic pole is Wt, the saturation magnetic flux density of the inter-wire member is Bs, the width in the circumferential direction of the magnet portion of one magnetic pole is Wm, and the residual magnetic flux density of the magnet portion is Br,

alternatively, no inter-wire member may be provided between the respective wire portions in the circumferential direction.

12. The rotating electric machine according to any one of claims 1 to 3,

each of the wires constituting the wire portion is a wire assembly of: a plurality of wires (86) are bundled and the electrical resistance between the bundled wires is greater than the electrical resistance of the wires themselves.

13. A method of manufacturing a rotating electric machine (400),

the rotating electric machine includes: an excitation element (410) having a magnet portion (412) including a plurality of magnetic poles whose polarities alternate in the circumferential direction; and an armature (420) having a multiphase armature winding (421) and a base member (422) to which the armature winding is fixed, either one of the field element and the armature being a rotor,

the method for manufacturing the rotating electric machine comprises the following steps:

winding the armature winding around the base member so that a lead portion is formed at a position facing the field element and is arranged at a predetermined interval in a circumferential direction;

a step of housing the base member and the armature winding in a mold in a state where the armature winding is wound around the base member; and

a step of molding a resin member (1001) so that the resin flows into the mold through gates (1002, 1011, 1021, 1031) to cover the base member and the armature winding,

the gates are provided in plurality at equal intervals in the circumferential direction at the same positions in the axial direction and the radial direction of the resin member,

the wire portion includes: a coil side portion opposed to the magnet portion in a radial direction; and a coil edge end disposed on an outer side of the magnet portion in an axial direction,

in the resin member, the gate is provided at least one of both end portions in an axial direction of the resin member,

14. A method of manufacturing a rotating electric machine (400),

the base member is a stator core that,

the coil edge end is bent toward the base member side in the radial direction so as to engage with an end portion of the base member in the axial direction,

in the resin member, the gate is provided between the coil side end and the coil side portion in the axial direction.