JP7537598B2 - Rotating electric machine and method for manufacturing the same - Google Patents

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Application No. 2021-027628, filed on February 24, 2021, the contents of which are incorporated herein by reference.

The disclosure in this specification relates to a rotating electric machine and a method for manufacturing a rotating electric machine.

Conventionally, a rotating electric machine has been known in which the back surface of the magnet (the peripheral surface opposite the armature) is provided with projections and recesses, and the projections and recesses engage with an engagement portion provided on the inner peripheral surface of the magnet holding portion that holds the magnet, thereby appropriately fixing the magnet and preventing it from rotating (for example, Patent Document 1).

JP 2020-89018 A

Incidentally, when realizing a rotating electric machine with high torque and low vibration, it is desirable to make the surface magnetic flux density of the magnet sinusoidal. In the rotating electric machine of Patent Document 1, it was found that there is room for further ingenuity in the orientation and shape of the magnets in order to bring the surface magnetic flux density of the magnets closer to a sinusoidal wave.

The present disclosure has been made in consideration of the above circumstances, and its main objective is to provide a rotating electric machine and a manufacturing method for a rotating electric machine that can make the surface magnetic flux density of the magnets closer to a sinusoidal wave by implementing innovations in the orientation and shape of the magnets, and that can also position the magnets and prevent them from rotating.

The first means for solving the above problem comprises a field element having a magnet section including a plurality of magnetic poles whose polarity alternates in the circumferential direction, and an armature arranged facing the magnet section in the radial direction, and in a rotating electric machine in which either the field element or the armature is a rotor, the magnet section comprises a plurality of magnets arranged in a line in the circumferential direction, and a magnet yoke to which the plurality of magnets are fixed on the inner or outer circumferential surface, and the magnetization easy axes of the plurality of magnets are oriented so that their orientation is parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis, and a calculation is performed based on the length of the magnetic flux path. In order to make the permeance coefficient of the multiple magnets larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center, a concave portion is provided on the anti-armature side circumferential surface of the multiple magnets on the q-axis side, which is the magnetic pole boundary, or a convex portion is provided on the d-axis side, which is the magnetic pole center, or alternatively a concave portion is provided on the q-axis side, which is the magnetic pole boundary, and a convex portion is provided on the d-axis side, which is the magnetic pole center, and an engaging portion made of a soft magnetic material is provided on the q-axis side, which is the magnetic pole boundary, of the anti-armature side circumferential surface of the multiple magnets. The engaging portion engages circumferentially with the concave portion or convex portion on the anti-armature side circumferential surface of the multiple magnets, and is for exchanging magnetic flux between magnetic poles of different polarity of the multiple magnets.

The magnetization easy axes of the multiple magnets are oriented so that they are parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis. Therefore, compared to forming a magnetic flux path linearly along the radial direction, it is possible to reduce leakage magnetic flux between the magnet poles and make the surface magnetic flux density of the magnet section closer to a sinusoidal wave.

However, due to the manufacturing process of magnets, it is difficult to fine-tune the length and direction of the magnet magnetic path, which is closely related to the magnetic flux density. Even when configured as described above, there was an issue that it was difficult to make the surface magnetic flux density perfectly sinusoidal if the thickness dimension of the magnet in the radial direction was constant.

Therefore, in the above-mentioned means, in order to make the permeance coefficient of the magnet larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center, the anti-armature side peripheral surface of the multiple magnets is provided with a concave portion on the q-axis side, which is the magnetic pole boundary, or a convex portion on the d-axis side, which is the magnetic pole center, or a concave portion on the q-axis side, which is the magnetic pole boundary, and a convex portion on the d-axis side, which is the magnetic pole center, are provided. In other words, the length of the magnet magnetic path is adjusted by providing concaves and convexes on the anti-armature side peripheral surface, so that the permeance coefficient becomes larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. In this way, by suitably superimposing the effect of the magnet shape on the effect of the magnet orientation, which adjusts the direction and length of the magnetization easy axis, it is possible to make the surface magnetic flux density of the magnet part closer to a sine wave.

In addition, on the anti-armature side circumferential surface of the multiple magnets, an engagement portion made of a soft magnetic material is provided on the q-axis side, which is the magnetic pole boundary, and which circumferentially engages with the concave or convex portion of the anti-armature side circumferential surface and transmits magnetic flux between magnetic poles of different polarities of the multiple magnets. This makes it possible to suppress magnetic flux leakage between the magnet poles and to make the surface magnetic flux density of the magnet portion closer to a sinusoidal wave. It also makes it possible to position the magnet and prevent it from rotating.

The second means is the first means, wherein the magnetization easy axes of the magnets are oriented in an arc shape, and the center of orientation of the magnetization easy axes oriented in an arc shape is on the q-axis side, which is the magnetic pole boundary, in the circumferential direction, and is set on the armature side peripheral surface of the magnets or on the armature side of the armature side peripheral surface of the magnets in the radial direction.

This allows the magnetic flux density to be improved while making the wave more sinusoidal.

The third means is the first or second means, wherein the magnetization easy axes of the multiple magnets are linear magnetization easy axes having an inclination angle with respect to the radial direction, and the inclination angle gradually changes depending on the circumferential position, and the inclination angle of each linear magnetization easy axis is set to become smaller with respect to the radial direction as it approaches from the q-axis side, which is the magnetic pole boundary, to the d-axis side, which is the magnetic pole center, in the circumferential direction, so that the linear magnetization easy axes become parallel to the d-axis, which is the magnetic pole center.

This allows the magnetic flux density to be improved while making the wave more sinusoidal.

The fourth means is any one of the first to third means, comprising a field element having a magnet section including a plurality of magnetic poles whose polarity alternates in the circumferential direction, and an armature arranged facing the magnet section in the radial direction, and in a rotating electric machine in which either the field element or the armature is a rotor, the magnet section comprises a plurality of magnets arranged in a line in the circumferential direction, and a magnet yoke to which the plurality of magnets are fixed on the inner or outer circumferential surface, the magnetization easy axes of the plurality of magnets are oriented in parallel so that their orientation is linear at a certain inclination angle with respect to the radial direction, a magnet magnetic path is formed along the magnetization easy axes, and the magnet magnetic path length is calculated based on the length of the magnet magnetic path. In order that the permeance coefficient of the multiple magnets becomes larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center, a concave portion is provided on the anti-armature side circumferential surface of the multiple magnets on the q-axis side, which is the magnetic pole boundary, or a convex portion is provided on the d-axis side, which is the magnetic pole center, or alternatively a concave portion is provided on the q-axis side, which is the magnetic pole boundary, and a convex portion is provided on the d-axis side, which is the magnetic pole center, and an engaging portion made of a soft magnetic material is provided on the anti-armature side circumferential surface of the multiple magnets on the q-axis side, which is the magnetic pole boundary, which engages circumferentially with the concave portion or convex portion of the anti-armature side circumferential surface and which exchanges magnetic flux between magnetic poles of different polarities of the multiple magnets.

The above configuration can achieve the same effect as the first means.

The fifth means is any one of the first to fourth means, in which the engagement portion is integrally formed with the magnet yoke so as to protrude from the inner or outer peripheral surface of the magnet yoke.

By integrating the engagement part with the magnet yoke, it is possible to form the engagement part with high precision, improving positioning accuracy. In addition, by integrating them, it is possible to improve the rigidity of the engagement part and the magnet yoke.

The sixth means is any one of the first to fifth means, in which the magnet yoke is a helical core formed into a cylindrical shape by spirally winding and stacking a long, thin, plate-like band member.

This allows for improved material yield. It also makes it easier to change the axial length of the magnet yoke.

The seventh means is any one of the first to sixth means, in which each of the magnets is arranged between the d-axis, which is the center of adjacent magnetic poles in the circumferential direction, and the q-axis, which is the magnetic pole boundary, and end faces are formed on the d-axis, which is the magnetic pole boundary, and on the q-axis, which is the magnetic pole boundary, respectively, and the spacing between adjacent engaging portions in the circumferential direction is set so that the gap between the d-axis side end faces of the magnets in the circumferential direction is narrower than the gap between the q-axis side end faces.

When each magnet is placed between the d-axis, which is the center of adjacent magnetic poles in the circumferential direction, and the q-axis, which is the boundary between magnetic poles, the d-axis end faces have the same polarity and repel each other, so gaps are more likely to form than at the q-axis end faces. Therefore, the spacing of the engagement parts that engage with the magnets in the circumferential direction is adjusted so that the gap between the d-axis end faces of the magnets in the circumferential direction is narrower than the gap between the q-axis end faces. This makes it possible to easily position the magnets so that the gap between the d-axis end faces is narrower than the gap between the q-axis end faces. And because the gap between the d-axis end faces can be suppressed, it is possible to suppress sudden changes in magnetic flux density caused by gaps and suppress torque pulsation.

The eighth means is a manufacturing method for a rotating electric machine comprising a field element having a magnet section including a plurality of magnetic poles whose polarity alternates in the circumferential direction, and an armature arranged facing the magnet section in the radial direction, and using either the field element or the armature as a rotor, wherein the magnet section comprises a plurality of magnets arranged in a line in the circumferential direction, and the magnetization easy axes of the plurality of magnets are oriented so that they are parallel to the d-axis on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, or the magnetization easy axes are oriented in parallel so that they are linear at a certain inclination angle with respect to the radial direction, and a magnetic flux path is formed along the magnetic flux easy axes, and a recess is provided on the q-axis side, which is the magnetic pole boundary, on the peripheral surface opposite the armature, so that the permeance coefficient of the plurality of magnets calculated based on the length of the magnetic flux path becomes larger in the circumferential direction as it approaches the d-axis, which is the magnetic pole center, from the q-axis, which is the magnetic pole boundary, or In a manufacturing method for a rotating electric machine in which a convex portion is provided on the d-axis side, which is the center, or a concave portion is provided on the q-axis side, which is the magnetic pole boundary, and a convex portion is provided on the d-axis side, which is the magnetic pole center, and an engaging portion made of a soft magnetic material is provided on the anti-armature side peripheral surface of the magnet, on the q-axis side, which is the magnetic pole boundary, which engages circumferentially with the concave portion or the convex portion of the anti-armature side peripheral surface, and for exchanging magnetic flux between magnetic poles of different polarities of the multiple magnets, the manufacturing method includes a bending step of bending a long, thin, straight plate member to form a stacked cylindrical magnet yoke by spirally winding a thin, thin, plate-like band member, and a fixing step of fixing the multiple magnets to the magnet yoke, and before the bending step is performed, the engaging portion is integrally formed in advance on the plate member so that it protrudes in the width direction, and the engaging portion is provided with unevenness that absorbs deformation due to the bending process.

In addition to the same effect as the first means, the above configuration can absorb deformation caused by bending, improving the shape precision of the engagement part. This makes it possible to reliably engage with the magnet and improve the positioning precision of the magnet.

The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view showing an entire rotating electric machine according to a first embodiment; FIG. 2 is a plan view of a rotating electric machine; FIG. 3 is a vertical cross-sectional view of a rotating electric machine; FIG. 4 is a cross-sectional view of a rotating electric machine; FIG. 5 is an exploded cross-sectional view of a rotating electric machine; FIG. 6 is a cross-sectional view of a rotor; FIG. 7 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit; FIG. 8 is a diagram showing the relationship between the electrical angle and the magnetic flux density of the magnet according to the embodiment; FIG. 9 is a diagram showing the relationship between electrical angle and magnetic flux density for a magnet of a comparative example; FIG. 10 is a perspective view of a stator unit; FIG. 11 is a vertical cross-sectional view of a stator unit; FIG. 12 is a perspective view of the core assembly as viewed from one axial side; FIG. 13 is a perspective view of the core assembly as viewed from the other axial side; FIG. 14 is a cross-sectional view of a core assembly; FIG. 15 is an exploded cross-sectional view of a core assembly; FIG. 16 is a circuit diagram showing a connection state of partial windings in each of the three phase windings; FIG. 17 is a side view showing a first coil module and a second coil module arranged side by side for comparison; FIG. 18 is a side view showing a first partial winding and a second partial winding arranged side by side for comparison; FIG. 19 is a diagram showing a configuration of a first coil module; FIG. 20 is a cross-sectional view taken along line 20-20 in FIG. 19(a); FIG. 21 is a perspective view showing a configuration of an insulating cover; FIG. 22 is a diagram showing a configuration of a second coil module; FIG. 23 is a cross-sectional view taken along line 23-23 in FIG. 22(a); FIG. 24 is a perspective view showing a configuration of an insulating cover; FIG. 25 is a diagram showing overlap positions of film materials when the coil modules are arranged in a circumferential direction; FIG. 26 is a plan view showing an assembled state of the first coil module to the core assembly; FIG. 27 is a plan view showing an assembled state of the first coil module and the second coil module to the core assembly; FIG. 28 is a vertical cross-sectional view showing a fixed state by a fixing pin; FIG. 29 is a perspective view of a bus bar module; FIG. 30 is a cross-sectional view showing a portion of a vertical cross section of a bus bar module; FIG. 31 is a perspective view showing a state in which a bus bar module is assembled to a stator holder; FIG. 32 is a vertical cross-sectional view of a fixing portion for fixing a bus bar module; FIG. 33 is a vertical cross-sectional view showing a state in which a relay member is attached to a housing cover; FIG. 34 is a perspective view of a relay member; FIG. 35 is an electric circuit diagram showing a control system for a rotating electric machine; FIG. 36 is a functional block diagram showing a current feedback control process by a control device; FIG. 37 is a functional block diagram showing a torque feedback control process by the control device; FIG. 38 is a partial cross-sectional view showing a cross-sectional structure of a magnet unit in a modified example; FIG. 39 is a diagram showing the configuration of a stator unit having an inner rotor structure; FIG. 40 is a plan view showing an assembled state of the coil module to the core assembly; FIG. 41 is a cross-sectional view of a magnet unit in Modification 2; FIG. 42 is a diagram showing a magnet magnetic path of a magnet unit in Modification 2; FIG. 43 is a diagram showing the relationship between the magnetic flux path of a magnet unit and the contour lines of the permeance coefficient; FIG. 44 is a diagram showing the relationship between the contour lines of the permeance coefficient and the q-axis recess on the opposite side to the stator; FIG. 45 is a diagram showing a comparative example of a magnet unit; FIG. 46 is a diagram showing the operation of the second modified example. FIG. 47 is a diagram showing a magnet unit according to another example of the modified example 2; FIG. 48 is a diagram showing a magnet unit according to another example of the modified example 2; FIG. 49 is a diagram showing a magnet unit according to another example of the modified example 2; FIG. 50 is a diagram showing a magnet yoke in another example of the modified example 2; FIG. 51 is a diagram showing a manufacturing method of a magnet yoke in another example of the modified example 2; FIG. 52 is a diagram showing a manufacturing method of an engagement portion in another example of the modified example 2. In FIG.

Several embodiments will be described with reference to the drawings. In several embodiments, functionally and/or structurally corresponding and/or associated parts may be given the same reference numerals or reference numerals that differ in the hundredth or higher digit. For corresponding and/or associated parts, reference may be made to the descriptions of other embodiments.

The rotating electric machine in this embodiment is used, for example, as a vehicle power source. However, rotating electric machines can be widely used in industry, vehicles, home appliances, office automation equipment, amusement machines, etc. In the following embodiments, parts that are identical or equivalent to each other are given the same reference numerals in the drawings, and the explanations of the parts with the same reference numerals are used.

First Embodiment
The rotating electric machine 10 according to the present embodiment is a synchronous multi-phase AC motor with an outer rotor structure. The rotating electric machine 10 is generally shown in FIGS. 1 to 5. FIG. 1 is a perspective view showing the entire rotating electric machine 10, FIG. 2 is a plan view of the rotating electric machine 10, FIG. 3 is a longitudinal sectional view (sectional view taken along line 3-3 in FIG. 2) of the rotating electric machine 10, FIG. 4 is a transverse sectional view (sectional view taken along line 4-4 in FIG. 3) of the rotating electric machine 10, and FIG. 5 is an exploded sectional view showing components of the rotating electric machine 10 in an exploded manner. In the following description, in the rotating electric machine 10, the direction in which the rotating shaft 11 extends is defined as the axial direction, the direction extending radially from the center of the rotating shaft 11 is defined as the radial direction, and the direction extending circumferentially around the rotating shaft 11 is defined as the circumferential direction.

The rotating electric machine 10 is roughly divided into a rotating electric machine main body having a rotor 20, a stator unit 50, and a busbar module 200, and a housing 241 and a housing cover 242 that are arranged to surround the rotating electric machine main body. All of these components are arranged coaxially with a rotating shaft 11 that is integrally provided with the rotor 20, and the rotating electric machine 10 is configured by assembling them in the axial direction in a predetermined order. The rotating shaft 11 is supported by a pair of bearings 12, 13 provided on the stator unit 50 and the housing 241, respectively, and is rotatable in this state. The bearings 12, 13 are, for example, radial ball bearings having an inner ring, an outer ring, and a plurality of balls arranged between them. The rotation of the rotating shaft 11 rotates, for example, the axle of a vehicle. The rotating electric machine 10 can be mounted on a vehicle by fixing the housing 241 to a vehicle frame or the like.

In the rotating electric machine 10, the stator unit 50 is arranged to surround the rotating shaft 11, and the rotor 20 is arranged radially outside the stator unit 50. The stator unit 50 has a stator 60 and a stator holder 70 assembled to its radially inside. The rotor 20 and the stator 60 are arranged facing each other in the radial direction with an air gap in between, and the rotor 20 rotates integrally with the rotating shaft 11, causing the rotor 20 to rotate radially outside the stator 60. The rotor 20 corresponds to the "field element" and the stator 60 corresponds to the "armature".

6 is a longitudinal cross-sectional view of the rotor 20. As shown in FIG. 6, the rotor 20 has a substantially cylindrical rotor carrier 21 and an annular magnet unit 22 fixed to the rotor carrier 21. The rotor carrier 21 has a cylindrical portion 23 and an end plate portion 24 provided at one axial end of the cylindrical portion 23, which are integrated together. The rotor carrier 21 functions as a magnet holding member, and the magnet unit 22 is fixed in an annular shape to the radial inside of the cylindrical portion 23. A through hole 24a is formed in the end plate portion 24, and the rotating shaft 11 is fixed to the end plate portion 24 by a fastener 25 such as a bolt while being inserted into the through hole 24a. The rotating shaft 11 has a flange 11a extending in a direction intersecting (orthogonal to) the axial direction, and the rotor carrier 21 is fixed to the rotating shaft 11 while the flange 11a and the end plate portion 24 are surface-jointed.

The magnet unit 22 has a cylindrical magnet holder 31, a plurality of magnets 32 fixed to the inner circumferential surface of the magnet holder 31, and an end plate 33 fixed to the axially opposite end plate portion 24 of the rotor carrier 21. The magnet holder 31 has the same length dimension in the axial direction as the magnet 32. The magnet 32 is arranged in a state in which it is surrounded by the magnet holder 31 from the radially outside. The magnet holder 31 and the magnet 32 are fixed in a state in which they abut against the end plate 33 at one end on the axial direction. The magnet unit 22 corresponds to the "magnet portion".

Figure 7 is a partial cross-sectional view showing the cross-sectional structure of magnet unit 22. In Figure 7, the direction of the magnetization easy axis of magnet 32 is indicated by an arrow.

In the magnet unit 22, the magnets 32 are arranged so that their polarity alternates along the circumferential direction of the rotor 20. This gives the magnet unit 22 multiple magnetic poles in the circumferential direction. The magnets 32 are polar anisotropic permanent magnets, and are constructed using sintered neodymium magnets with an intrinsic coercive force of 400 kA/m or more and a residual magnetic flux density Br of 1.0 T or more.

The radially inner peripheral surface of the magnet 32 is the magnetic flux action surface 34 where magnetic flux is exchanged. In the magnet 32, the orientation of the magnetization easy axis differs between the d-axis side (part closer to the d-axis) and the q-axis side (part closer to the q-axis), with the magnetization easy axis oriented parallel to the d-axis on the d-axis side and perpendicular to the q-axis on the q-axis side. In this case, an arc-shaped magnetic flux path is formed along the direction of the magnetization easy axis. In short, the magnet 32 is configured so that the magnetization easy axis is oriented parallel to the d-axis on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary.

In magnet 32, the magnetic flux path is formed in an arc shape, so that the magnetic flux path length is longer than the radial thickness dimension of magnet 32. This increases the permeance of magnet 32, making it possible to exert the same performance as a magnet with a larger amount of magnet, despite the same amount of magnet.

The magnets 32 are arranged in pairs, two adjacent to each other in the circumferential direction, to form one magnetic pole. In other words, the magnets 32 arranged in the circumferential direction in the magnet unit 22 have cut surfaces on the d-axis and q-axis, and the magnets 32 are arranged in contact with or in close proximity to each other. As described above, the magnets 32 have an arc-shaped magnetic flux path, and the N pole and S pole of the magnets 32 adjacent to each other in the circumferential direction face each other on the q-axis. This makes it possible to improve the permeance near the q-axis. In addition, the magnets 32 on both sides of the q-axis attract each other, so that the magnets 32 can maintain contact with each other. This also contributes to improving the permeance.

In the magnet unit 22, the magnetic flux flows in an arc between the adjacent N and S poles due to each magnet 32, so the magnetic path is longer than that of a radial anisotropic magnet, for example. Therefore, as shown in FIG. 8, the magnetic flux density distribution is close to a sine wave. As a result, unlike the magnetic flux density distribution of a radial anisotropic magnet shown as a comparative example in FIG. 9, the magnetic flux can be concentrated toward the center of the magnetic pole, making it possible to increase the torque of the rotating electric machine 10. In addition, in the magnet unit 22 of this embodiment, it can be confirmed that there is a difference in the magnetic flux density distribution compared to the conventional Halbach array magnet. In addition, in FIG. 8 and FIG. 9, the horizontal axis indicates the electrical angle, and the vertical axis indicates the magnetic flux density. In addition, in FIG. 8 and FIG. 9, 90° on the horizontal axis indicates the d-axis (i.e., the magnetic pole center), and 0° and 180° on the horizontal axis indicate the q-axis.

In other words, with each magnet 32 configured as described above, the magnetic flux on the d-axis in the magnet unit 22 is strengthened and the magnetic flux change near the q-axis is suppressed. This makes it possible to preferably realize a magnet unit 22 in which the surface magnetic flux change from the q-axis to the d-axis at each magnetic pole is smooth.

The sine wave matching rate of the magnetic flux density distribution may be, for example, 40% or more. In this way, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to the use of radially oriented magnets or parallel oriented magnets, which have a sine wave matching rate of about 30%. Furthermore, if the sine wave matching rate is 60% or more, the amount of magnetic flux in the central part of the waveform can be reliably improved compared to a magnetic flux concentration array such as a Halbach array.

In the radially anisotropic magnet shown in FIG. 9, the magnetic flux density changes sharply near the q-axis. The sharper the change in magnetic flux density, the more eddy currents increase in the stator winding 61 of the stator 60 described below. The magnetic flux change on the stator winding 61 side also becomes sharper. In contrast, in this embodiment, the magnetic flux density distribution has a magnetic flux waveform that is close to a sine wave. Therefore, the change in magnetic flux density near the q-axis is smaller than the change in magnetic flux density of a radially anisotropic magnet. This makes it possible to suppress the generation of eddy currents.

The magnet 32 has a recess 35 formed on the outer peripheral surface on the radially outer side in a predetermined range including the d-axis, and a recess 36 formed on the inner peripheral surface on the radially inner side in a predetermined range including the q-axis. In this case, according to the direction of the easy axis of magnetization of the magnet 32, the magnetic flux path is short near the d-axis on the outer peripheral surface of the magnet 32, and the magnetic flux path is short near the q-axis on the inner peripheral surface of the magnet 32. Therefore, in consideration of the difficulty of generating sufficient magnetic flux in the areas of the magnet 32 where the magnetic flux path length is short, the magnet is removed in the areas where the magnetic flux is weak.

The magnet unit 22 may be configured to use the same number of magnets 32 as the number of magnetic poles. For example, the magnets 32 may be provided between two circumferentially adjacent magnetic poles, with one magnet being provided between the d-axis, which is the center of each magnetic pole. In this case, the magnet 32 is configured so that the circumferential center is the q-axis and has a cut surface on the d-axis. The magnet 32 may also be configured so that the circumferential center is the d-axis, rather than the q-axis. Instead of using magnets with twice the number of magnetic poles or the same number of magnets as the number of magnetic poles, the magnet 32 may be configured to use a ring magnet connected in a ring shape.

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

Next, the configuration of the stator unit 50 will be described. Figure 10 is a perspective view of the stator unit 50, and Figure 11 is a vertical cross-sectional view of the stator unit 50. Note that Figure 11 is a vertical cross-sectional view at the same position as Figure 3.

The stator unit 50 generally comprises a stator 60 and a stator holder 70 located radially inside the stator 60. The stator 60 comprises a stator winding 61 and a stator core 62. The stator core 62 and the stator holder 70 are integrated together to form a core assembly CA, to which multiple partial windings 151 constituting the stator winding 61 are attached. The stator winding 61 corresponds to the "armature winding", the stator core 62 corresponds to the "armature core", and the stator holder 70 corresponds to the "armature holding member". The core assembly CA corresponds to the "support member".

Here, we will first explain the core assembly CA. Figure 12 is a perspective view of the core assembly CA seen from one axial side, Figure 13 is a perspective view of the core assembly CA seen from the other axial side, Figure 14 is a cross-sectional view of the core assembly CA, and Figure 15 is an exploded cross-sectional view of the core assembly CA.

As described above, the core assembly CA has the stator core 62 and the stator holder 70 attached to its radially inner side. In other words, the stator core 62 is integrally attached to the outer peripheral surface of the stator holder 70.

The stator core 62 is configured as a core sheet laminate in which core sheets 62a made of magnetic steel sheets are laminated in the axial direction, and has a cylindrical shape with a predetermined thickness in the radial direction. The stator winding 61 is assembled to the radial outside of the stator core 62, which is the rotor 20 side. The outer peripheral surface of the stator core 62 is curved without any unevenness. The stator core 62 functions as a back yoke. The stator core 62 is configured by laminating multiple core sheets 62a, for example, punched into a circular plate shape, in the axial direction. However, a stator core 62 having a helical core structure may also be used. In the helical core structure stator core 62, a strip-shaped core sheet is used, and this core sheet is wound in an annular shape and laminated in the axial direction to form a cylindrical stator core 62 as a whole.

In this embodiment, the stator 60 has a slotless structure that does not have teeth for forming slots, but the configuration may be any of the following (A) to (C).
(A) In the stator 60, inter-conductor members are provided between each conductor portion (intermediate conductor portion 152 described later) in the circumferential direction, and the inter-conductor member is made of a magnetic material that satisfies the relationship Wt×Bs≦Wm×Br, where Wt is the circumferential width of the inter-conductor member at one magnetic pole, Bs is the saturation magnetic flux density of the inter-conductor member, Wm is the circumferential width of the magnet 32 at one magnetic pole, and Br is the residual magnetic flux density of the magnet 32.
(B) In the stator 60, inter-conductor members are provided between each conductor portion (intermediate conductor portion 152) in the circumferential direction, and a non-magnetic material is used for the inter-conductor members.
(C) In the stator 60, no inter-conductor members are provided between each conductor portion (intermediate conductor portion 152) in the circumferential direction.

15, the stator holder 70 has an outer cylinder member 71 and an inner cylinder member 81, which are assembled together with the outer cylinder member 71 on the radial outside and the inner cylinder member 81 on the radial inside. Each of these members 71, 81 is made of metal such as aluminum or cast iron, or carbon fiber reinforced plastic (CFRP).

The outer tube member 71 is a cylindrical member whose outer and inner peripheral surfaces are both perfectly circular curved surfaces, and an annular flange 72 extending radially inward is formed on one axial end side. This flange 72 has a plurality of protrusions 73 extending radially inward at a predetermined interval in the circumferential direction (see FIG. 13). In addition, the outer tube member 71 has opposing surfaces 74, 75 formed on one and the other axial ends, respectively, which face the inner tube member 81 in the axial direction, and the opposing surfaces 74, 75 have annular grooves 74a, 75a extending annularly.

The inner tube member 81 is a cylindrical member having an outer diameter smaller than the inner diameter of the outer tube member 71, and its outer circumferential surface is a perfectly circular curved surface concentric with the outer tube member 71. An annular flange 82 extending radially outward is formed on one axial end of the inner tube member 81. The inner tube member 81 is assembled to the outer tube member 71 in a state in which it abuts against the opposing surfaces 74, 75 of the outer tube member 71 in the axial direction. As shown in FIG. 13, the outer tube member 71 and the inner tube member 81 are assembled to each other by a fastener 84 such as a bolt. Specifically, a plurality of protrusions 83 extending radially inward are formed at a predetermined interval in the circumferential direction on the inner circumferential side of the inner tube member 81, and the protrusions 73, 83 are fastened to each other by a fastener 84 in a state in which the axial end faces of the protrusions 83 and the protrusions 73 of the outer tube member 71 are overlapped.

As shown in FIG. 14, when the outer tube member 71 and the inner tube member 81 are assembled to each other, an annular gap is formed between the inner peripheral surface of the outer tube member 71 and the outer peripheral surface of the inner tube member 81, and the gap space serves as a refrigerant passage 85 through which a refrigerant such as cooling water flows. The refrigerant passage 85 is provided in an annular shape in the circumferential direction of the stator holder 70. More specifically, the inner tube member 81 is provided with a passage forming portion 88 that protrudes radially inward on its inner peripheral side and has an inlet side passage 86 and an outlet side passage 87 formed therein, and each of these passages 86, 87 opens to the outer peripheral surface of the inner tube member 81. In addition, a partition portion 89 is provided on the outer peripheral surface of the inner tube member 81 to divide the refrigerant passage 85 into an inlet side and an outlet side. As a result, the refrigerant flowing in from the inlet side passage 86 flows circumferentially through the refrigerant passage 85 and then flows out from the outlet side passage 87.

The inlet side passage 86 and the outlet side passage 87 have one end extending radially and opening on the outer circumferential surface of the inner cylinder member 81, and the other end extending axially and opening on the axial end surface of the inner cylinder member 81. Figure 12 shows an inlet opening 86a leading to the inlet side passage 86 and an outlet opening 87a leading to the outlet side passage 87. The inlet side passage 86 and the outlet side passage 87 lead to an inlet port 244 and an outlet port 245 (see Figure 1) attached to the housing cover 242, and the refrigerant flows in and out through these ports 244, 245.

At the joint between the outer tube member 71 and the inner tube member 81, sealing materials 101, 102 are provided to prevent leakage of the refrigerant from the refrigerant passage 85 (see FIG. 15). Specifically, the sealing materials 101, 102 are, for example, O-rings, which are housed in the annular grooves 74a, 75a of the outer tube member 71 and are provided in a compressed state by the outer tube member 71 and the inner tube member 81.

12, the inner tube member 81 has an end plate portion 91 at one axial end, and the end plate portion 91 is provided with a hollow cylindrical boss portion 92 extending in the axial direction. The boss portion 92 is provided to surround an insertion hole 93 for inserting the rotating shaft 11. The boss portion 92 is provided with a plurality of fastening portions 94 for fixing the housing cover 242. The end plate portion 91 is provided with a plurality of support portions 95 extending in the axial direction on the radial outside of the boss portion 92. The support portions 95 are portions that serve as fixing portions for fixing the busbar module 200, and will be described in detail later. The boss portion 92 is a bearing holding member that holds the bearing 12, and the bearing 12 is fixed to a bearing fixing portion 96 provided on the inner periphery of the boss portion 92 (see FIG. 3).

In addition, as shown in Figures 12 and 13, recesses 105, 106 are formed in the outer tube member 71 and the inner tube member 81, which are used to fix multiple coil modules 150 described later.

Specifically, as shown in Figure 12, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of the inner tube member 81, more specifically, on the axial outer end face of the end plate portion 91 which surrounds the boss portion 92. Also, as shown in Figure 13, a plurality of recesses 106 are formed at equal intervals in the circumferential direction on the axial end face of the outer tube member 71, more specifically, on the axial outer end face of the flange 72. These recesses 105, 106 are arranged so as to be aligned on an imaginary circle concentric with the core assembly CA. The recesses 105, 106 are each provided at the same position in the circumferential direction, and the intervals and numbers thereof are also the same.

The stator core 62 is assembled in a state where it generates a radial compressive force on the stator holder 70 in order to ensure the strength of the assembly to the stator holder 70. Specifically, the stator core 62 is fitted and fixed to the stator holder 70 with a predetermined tightening margin by shrink fitting or press fitting. In this case, it can be said that the stator core 62 and the stator holder 70 are assembled in a state where one of them generates a radial stress on the other. In addition, when increasing the torque of the rotating electric machine 10, for example, it is considered to increase the diameter of the stator 60, and in such a case, the tightening force of the stator core 62 is increased to strengthen the connection of the stator core 62 to the stator holder 70. However, if the compressive stress (in other words, the residual stress) of the stator core 62 is increased, there is a concern that the stator core 62 may be damaged.

Therefore, in this embodiment, in a configuration in which the stator core 62 and the stator holder 70 are fitted and fixed to each other with a predetermined tightening margin, a restricting portion is provided on the radially opposing portions of the stator core 62 and the stator holder 70, which restricts the circumferential displacement of the stator core 62 by engaging in the circumferential direction. In other words, as shown in Figures 12 to 14, a plurality of engaging members 111 are provided as restricting portions at a predetermined interval in the circumferential direction between the stator core 62 and the outer tube member 71 of the stator holder 70 in the radial direction, and the engaging members 111 suppress the circumferential positional deviation between the stator core 62 and the stator holder 70. In this case, it is preferable to provide a recess in at least one of the stator core 62 and the outer tube member 71, and to engage the engaging member 111 in the recess. Instead of the engaging member 111, a convex portion may be provided in either the stator core 62 or the outer tube member 71.

In the above configuration, the stator core 62 and the stator holder 70 (outer tube member 71) are fitted and fixed with a predetermined tightening margin, and are provided in a state in which their mutual circumferential displacement is restricted by the restriction of the engaging member 111. Therefore, even if the tightening margin in the stator core 62 and the stator holder 70 is relatively small, the circumferential displacement of the stator core 62 can be suppressed. Furthermore, since the desired displacement suppression effect can be obtained even if the tightening margin is relatively small, damage to the stator core 62 caused by an excessively large tightening margin can be suppressed. As a result, the displacement of the stator core 62 can be appropriately suppressed.

An annular internal space is formed on the inner periphery of the inner cylinder member 81 so as to surround the rotating shaft 11, and the internal space may be configured to accommodate electrical components constituting, for example, an inverter as a power converter. The electrical components are, for example, electrical modules in which semiconductor switching elements and capacitors are packaged. By arranging the electrical module in contact with the inner periphery of the inner cylinder member 81, it is possible to cool the electrical module by the refrigerant flowing through the refrigerant passage 85. It is also possible to eliminate the multiple protrusions 83 on the inner periphery of the inner cylinder member 81 or to reduce the protruding height of the protrusions 83, thereby expanding the internal space on the inner periphery of the inner cylinder member 81.

Next, the configuration of the stator winding 61 to be assembled to the core assembly CA will be described in detail. The state in which the stator winding 61 is assembled to the core assembly CA is as shown in Figures 10 and 11, where the multiple partial windings 151 that make up the stator winding 61 are assembled in a circumferentially aligned state on the radial outside of the core assembly CA, i.e., on the radial outside of the stator core 62.

The stator winding 61 has a plurality of phase windings, and is formed into a cylindrical (annular) shape by arranging the phase windings of each phase in a predetermined order in the circumferential direction. In this embodiment, the stator winding 61 is configured to have three phase windings by using U-phase, V-phase, and W-phase windings.

11, the stator 60 has, in the axial direction, a portion corresponding to the coil side CS that faces radially the magnet unit 22 in the rotor 20, and a portion corresponding to the coil end CE that is axially outside the coil side CS. In this case, the stator core 62 is provided in a range corresponding to the coil side CS in the axial direction.

In the stator winding 61, each phase winding has a plurality of partial windings 151 (see FIG. 16), and the partial windings 151 are individually provided as coil modules 150. In other words, the coil module 150 is configured by integrally providing the partial windings 151 in the phase windings of each phase, and the stator winding 61 is configured by a predetermined number of coil modules 150 according to the number of poles. The coil modules 150 (partial windings 151) of each phase are arranged in a predetermined order in the circumferential direction, so that the conductor parts of each phase are arranged in a predetermined order on the coil side CS of the stator winding 61. FIG. 10 shows the order of the conductor parts of the U phase, V phase, and W phase on the coil side CS. In this embodiment, the number of magnetic poles is 24, but the number is arbitrary.

In the stator winding 61, the partial windings 151 of each coil module 150 are connected in parallel or in series for each phase to form a phase winding. Figure 16 is a circuit diagram showing the connection state of the partial windings 151 in each of the three phase windings. Figure 16 shows the partial windings 151 in the phase windings of each phase connected in parallel.

11, the coil module 150 is assembled to the radial outside of the stator core 62. In this case, the coil module 150 is assembled with both axial end portions protruding axially outward (i.e., toward the coil end CE) from the stator core 62. In other words, the stator winding 61 has a portion corresponding to the coil end CE that protrudes axially outward from the stator core 62, and a portion corresponding to the coil side CS that is axially inward from that.

The coil module 150 has two types of shapes. One has a shape in which the partial winding 151 is bent radially inward, i.e., toward the stator core 62, at the coil end CE. The other has a shape in which the partial winding 151 is not bent radially inward at the coil end CE and extends linearly in the axial direction. In the following description, for convenience, the partial winding 151 having a bent shape at both axial ends is also referred to as the "first partial winding 151A," and the coil module 150 having the first partial winding 151A is also referred to as the "first coil module 150A." In addition, the partial winding 151 not having a bent shape at both axial ends is also referred to as the "second partial winding 151B," and the coil module 150 having the second partial winding 151B is also referred to as the "second coil module 150B."

17 is a side view showing the first coil module 150A and the second coil module 150B side by side for comparison, and FIG. 18 is a side view showing the first partial winding 151A and the second partial winding 151B side by side for comparison. As shown in these figures, the coil modules 150A, 150B and the partial windings 151A, 151B have different axial lengths and different end shapes on both axial sides. The first partial winding 151A is approximately C-shaped in side view, and the second partial winding 151B is approximately I-shaped in side view. The first partial winding 151A is fitted with insulating covers 161, 162 as "first insulating covers" on both axial sides, and the second partial winding 151B is fitted with insulating covers 163, 164 as "second insulating covers" on both axial sides.

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

Here, we will first explain the first coil module 150A of the coil modules 150A and 150B. Figure 19(a) is an oblique view showing the configuration of the first coil module 150A, and Figure 19(b) is an oblique view showing the components of the first coil module 150A disassembled. Also, Figure 20 is a cross-sectional view taken along line 20-20 in Figure 19(a).

19(a) and (b), the first coil module 150A has a first partial winding 151A formed by multiple windings of conductive wire CR, and insulating covers 161, 162 attached to one and the other axial ends of the first partial winding 151A. The insulating covers 161, 162 are made of an insulating material such as synthetic resin.

The first partial winding 151A has a pair of intermediate conductor parts 152 arranged parallel to each other and linearly, and a pair of crossover parts 153A that connect the pair of intermediate conductor parts 152 at both axial ends, and is formed into a ring shape by the pair of intermediate conductor parts 152 and the pair of crossover parts 153A. The pair of intermediate conductor parts 152 are arranged at a predetermined coil pitch apart, and the intermediate conductor parts 152 of the partial winding 151 of the other phase can be arranged between the pair of intermediate conductor parts 152 in the circumferential direction. In this embodiment, the pair of intermediate conductor parts 152 are arranged at a distance of two coil pitches, and one intermediate conductor part 152 of the partial winding 151 of the other two phases is arranged between the pair of intermediate conductor parts 152.

The pair of transition sections 153A have the same shape on both axial sides, and each is provided as a part corresponding to the coil end CE (see FIG. 11). Each transition section 153A is provided so as to be bent in a direction perpendicular to the intermediate conductor section 152, i.e., in a direction perpendicular to the axial direction.

18, the first partial winding 151A has a crossover portion 153A on both axial sides, and the second partial winding 151B has a crossover portion 153B on both axial sides. The crossover portions 153A, 153B of the partial windings 151A, 151B have different shapes, and to clearly distinguish between them, the crossover portion 153A of the first partial winding 151A is also referred to as the "first crossover portion 153A," and the crossover portion 153B of the second partial winding 151B is also referred to as the "second crossover portion 153B."

In each partial winding 151A, 151B, the intermediate conductor portions 152 are provided as coil side conductor portions arranged one by one in the circumferential direction at the coil side CS. Also, each jumper portion 153A, 153B is provided as a coil end conductor portion that connects the intermediate conductor portions 152 of the same phase at two different positions in the circumferential direction at the coil end CE.

As shown in FIG. 20, the first partial winding 151A is formed by winding the conductor wire CR in multiple layers so that the cross section of the conductor assembly portion is rectangular. FIG. 20 shows a cross section of the intermediate conductor portion 152, in which the conductor wire CR is wound in multiple layers so as to be aligned in the circumferential and radial directions. In other words, the first partial winding 151A is formed so that the conductor wire CR is arranged in multiple rows in the circumferential direction and multiple rows in the radial direction in the intermediate conductor portion 152, so that the cross section is approximately rectangular. In addition, at the tip of the first crossover portion 153A, the conductor wire CR is wound in multiple layers so as to be aligned in the axial and radial directions by bending in the radial direction. In this embodiment, the first partial winding 151A is formed by winding the conductor wire CR in a concentric manner. However, the winding method of the conductor wire CR is arbitrary, and the conductor wire CR may be wound multiple times by alpha winding instead of concentric winding.

In the first partial winding 151A, an end of the conductor wire CR is pulled out from one of the first jumper portions 153A on both axial sides (the upper first jumper portion 153A in Figure 19 (b)), and these ends serve as winding ends 154, 155. The winding ends 154, 155 are the start and end of the winding of the conductor wire CR, respectively. One of the winding ends 154, 155 is connected to a current input/output terminal, and the other is connected to a neutral point.

In the first partial winding 151A, each intermediate conductor portion 152 is provided covered with a sheet-like insulating cover 157. Note that in FIG. 19(a), the first coil module 150A is shown in a state in which the intermediate conductor portion 152 is covered with the insulating cover 157 and the intermediate conductor portion 152 is present inside the insulating cover 157, but for convenience, the corresponding portion is referred to as the intermediate conductor portion 152 (the same applies to FIG. 22(a) described later).

The insulating cover 157 is provided by using a film material FM having an axial dimension of at least the length of the axial insulating cover range of the intermediate conductor portion 152, and wrapping the film material FM around the intermediate conductor portion 152. The film material FM is made of, for example, a PEN (polyethylene naphthalate) film. More specifically, the film material FM includes a film base material and a foaming adhesive layer provided on one of the two surfaces of the film base material. The film material FM is then wrapped around the intermediate conductor portion 152 while being adhered to the intermediate conductor portion 152 by the adhesive layer. It is also possible to use a non-foaming adhesive as the adhesive layer.

20, the intermediate conductor portion 152 has a substantially rectangular cross section due to the conductor material CR arranged in the circumferential and radial directions, and the intermediate conductor portion 152 is covered with a film material FM with its circumferential ends overlapped to provide an insulating cover 157. The film material FM is a rectangular sheet whose vertical dimension is longer than the axial length of the intermediate conductor portion 152 and whose horizontal dimension is longer than the circumference of the intermediate conductor portion 152, and is wound around the intermediate conductor portion 152 with creases made to match the cross-sectional shape of the intermediate conductor portion 152. When the film material FM is wound around the intermediate conductor portion 152, the gap between the conductor material CR of the intermediate conductor portion 152 and the film base material is filled by foaming in the adhesive layer. In addition, in the overlap portion OL of the film material FM, the circumferential ends of the film material FM are joined together by an adhesive layer.

The intermediate conductor portion 152 is provided with an insulating cover 157 so as to cover all of the two circumferential side surfaces and two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate conductor portion 152 is provided with an overlap portion OL where the film material FM overlaps the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., one of the two circumferential side surfaces of the intermediate conductor portion 152. In this embodiment, the overlap portion OL is provided on the same circumferential side of each of the pair of intermediate conductor portions 152.

In the first partial winding 151A, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portion of the first crossover portion 153A on both axial sides that is covered by the insulating covers 161, 162 (i.e., the portion inside the insulating covers 161, 162). In FIG. 17, the range AX1 in the first coil module 150A is the portion not covered by the insulating covers 161, 162, and the insulating cover 157 is provided in a range extending above and below the range AX1.

Next, the configuration of insulating covers 161, 162 will be described.

The insulating cover 161 is attached to the first crossover portion 153A on one axial side of the first partial winding 151A, and the insulating cover 162 is attached to the first crossover portion 153A on the other axial side of the first partial winding 151A. The configuration of the insulating cover 161 is shown in Figures 21(a) and (b). Figures 21(a) and (b) are perspective views of the insulating cover 161 viewed from two different directions.

21(a) and (b), the insulating cover 161 has a pair of side portions 171 that are circumferential side surfaces, an outer surface portion 172 on the axially outer side, an inner surface portion 173 on the axially inner side, and a front surface portion 174 on the radially inner side. Each of these portions 171 to 174 is formed in a plate shape and is connected to each other in a three-dimensional shape so that only the radially outer side is open. Each of the pair of side portions 171 is provided in a direction that extends toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when a plurality of first coil modules 150A are arranged in a circumferential line, the side portions 171 of the insulating cover 161 of the adjacent first coil modules 150A face each other in abutment or close proximity. This allows the first coil modules 150A adjacent in the circumferential direction to be insulated from each other while being preferably arranged in an annular arrangement.

In the insulating cover 161, the outer surface portion 172 is provided with an opening 175a for pulling out the winding end 154 of the first partial winding 151A, and the front surface portion 174 is provided with an opening 175b for pulling out the winding end 155 of the first partial winding 151A. In this case, one winding end 154 is pulled out axially from the outer surface portion 172, while the other winding end 155 is pulled out radially from the front surface portion 174.

In addition, in the insulating cover 161, a pair of side portions 171 are provided with semicircular recesses 177 extending in the axial direction at positions that are both circumferential ends of the front portion 174, i.e., positions where each side portion 171 intersects with the front portion 174. Furthermore, the outer surface portion 172 is provided with a pair of protrusions 178 extending in the axial direction at positions that are symmetrical on both sides in the circumferential direction with respect to the center line of the insulating cover 161 in the circumferential direction.

Additional explanation on the recess 177 of the insulating cover 161. As shown in FIG. 20, the first crossover portion 153A of the first partial winding 151A is curved so as to be convex toward the inner radial side, i.e., toward the core assembly CA side. In this configuration, a gap is formed between adjacent first crossover portions 153A in the circumferential direction, which becomes wider toward the tip side of the first crossover portion 153A. Therefore, in this embodiment, the gap between the first crossover portions 153A arranged in the circumferential direction is utilized to provide a recess 177 at a position on the side portion 171 of the insulating cover 161 that is outside the curved portion of the first crossover portion 153A.

A temperature detector (thermistor) may be provided in the first partial winding 151A. In such a configuration, an opening may be provided in the insulating cover 161 for drawing out a signal line extending from the temperature detector. In this case, the temperature detector can be conveniently housed within the insulating cover 161.

Although detailed explanation using the drawings will be omitted, the other insulating cover 162 in the axial direction has a configuration generally similar to that of the insulating cover 161. Like the insulating cover 161, the insulating cover 162 has a pair of side portions 171, an outer surface portion 172 on the axial outside, an inner surface portion 173 on the axial inside, and a front surface portion 174 on the radial inside. In addition, in the insulating cover 162, the pair of side portions 171 are provided with semicircular recesses 177 at positions that are both circumferential ends of the front surface portion 174, and a pair of protrusions 178 are provided on the outer surface portion 172. As a difference from the insulating cover 161, the insulating cover 162 is configured not to have an opening for pulling out the winding ends 154, 155 of the first partial winding 151A.

The insulating covers 161 and 162 have different axial height dimensions (i.e., axial width dimensions at the pair of side portions 171 and the front portion 174). Specifically, as shown in FIG. 17, the axial height dimension W11 of the insulating cover 161 and the axial height dimension W12 of the insulating cover 162 are W11>W12. In other words, when winding the conductor CR in multiple layers, it is necessary to switch (change lanes) the winding stages of the conductor CR in a direction perpendicular to the winding direction (circumferential direction), and it is considered that the winding width becomes larger due to the switching. To supplement, the insulating cover 161 of the insulating covers 161 and 162 is a portion that covers the first crossover portion 153A on the side including the winding start and winding end of the conductor CR, and by including the winding start and winding end of the conductor CR, the winding allowance (overlap allowance) of the conductor CR becomes larger than other portions, which may result in a larger winding width. Taking this into consideration, the axial height dimension W11 of the insulating cover 161 is greater than the axial height dimension W12 of the insulating cover 162. This prevents the insulating covers 161, 162 from limiting the number of turns of the conductor wire CR, as opposed to a case in which the height dimensions W11, W12 of the insulating covers 161, 162 are the same.

Next, we will explain the second coil module 150B.

Figure 22(a) is a perspective view showing the configuration of the second coil module 150B, and Figure 22(b) is a perspective view showing the components of the second coil module 150B disassembled. Also, Figure 23 is a cross-sectional view taken along line 23-23 in Figure 22(a).

22(a) and (b), the second coil module 150B has a second partial winding 151B formed by multiple windings of conductive wire CR, similar to the first partial winding 151A, and insulating covers 163, 164 attached to one and the other axial ends of the second partial winding 151B. The insulating covers 163, 164 are made of an insulating material such as synthetic resin.

The second partial winding 151B has a pair of intermediate conductor parts 152 arranged parallel to each other and linearly, and a pair of second bridge parts 153B that connect the pair of intermediate conductor parts 152 at both axial ends, and is formed into a ring shape by the pair of intermediate conductor parts 152 and the pair of second bridge parts 153B. In the second partial winding 151B, the pair of intermediate conductor parts 152 has the same configuration as the intermediate conductor part 152 of the first partial winding 151A. In contrast, the pair of second bridge parts 153B has a different configuration from the first bridge part 153A of the first partial winding 151A. The second bridge part 153B of the second partial winding 151B is arranged to extend linearly in the axial direction from the intermediate conductor part 152 without being bent in the radial direction. In FIG. 18, the difference between the partial windings 151A and 151B is clearly shown in comparison.

In the second partial winding 151B, an end of the conductor wire CR is pulled out from one of the second jumper portions 153B on both axial sides (the upper second jumper portion 153B in FIG. 22(b)), and this end serves as winding end portions 154, 155. Similarly to the first partial winding 151A, in the second partial winding 151B, one of the winding end portions 154, 155 is connected to a current input/output terminal, and the other is connected to a neutral point.

In the second partial winding 151B, similar to the first partial winding 151A, each intermediate conductor portion 152 is covered with a sheet-like insulating cover 157. The insulating cover 157 is provided by using a film material FM having an axial dimension of at least the length of the axial insulating cover range of the intermediate conductor portion 152 and winding the film material FM around the intermediate conductor portion 152.

The configuration of the insulating cover 157 is also generally similar for each partial winding 151A, 151B. That is, as shown in FIG. 23, the intermediate conductor portion 152 is covered with a film material FM with its circumferential end overlapped. The intermediate conductor portion 152 is provided with an insulating cover 157 so as to cover all of the two circumferential side surfaces and two radial side surfaces. In this case, the insulating cover 157 surrounding the intermediate conductor portion 152 is provided with an overlap portion OL where the film material FM overlaps the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., one of the two circumferential side surfaces of the intermediate conductor portion 152. In this embodiment, the overlap portion OL is provided on the same circumferential side of each of the pair of intermediate conductor portions 152.

In the second partial winding 151B, an insulating cover 157 is provided in the range from the intermediate conductor portion 152 to the portion of the second crossover portion 153B on both axial sides that is covered by the insulating covers 163, 164 (i.e., the portion inside the insulating covers 163, 164). In FIG. 17, the range AX2 in the second coil module 150B is the portion not covered by the insulating covers 163, 164, and the insulating cover 157 is provided in a range extending above and below the range AX2.

In each of the partial windings 151A, 151B, the insulating cover 157 is provided in an area that includes a portion of the jumper section 153A, 153B. That is, in each of the partial windings 151A, 151B, the insulating cover 157 is provided on the intermediate conductor section 152 and on the portion of the jumper section 153A, 153B that extends linearly beyond the intermediate conductor section 152. However, because the axial lengths of the partial windings 151A, 151B are different, the axial ranges of the insulating cover 157 are also different.

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

The insulating cover 163 is attached to the second crossover portion 153B on one axial side of the second partial winding 151B, and the insulating cover 164 is attached to the second crossover portion 153B on the other axial side of the second partial winding 151B. The configuration of the insulating cover 163 is shown in Figures 24(a) and (b). Figures 24(a) and (b) are perspective views of the insulating cover 163 viewed from two different directions.

24(a) and (b), the insulating cover 163 has a pair of side portions 181 that are circumferential side surfaces, an outer surface portion 182 on the axially outer side, a front surface portion 183 on the radially inner side, and a rear surface portion 184 on the radially outer side. Each of these portions 181 to 184 is formed in a plate shape and is connected to each other in a three-dimensional shape so that only the axially inner side is open. Each of the pair of side portions 181 is provided in a direction that extends toward the axis of the core assembly CA when assembled to the core assembly CA. Therefore, when a plurality of second coil modules 150B are arranged in a circumferential line, the side portions 181 of the insulating cover 163 of the adjacent second coil modules 150B face each other in abutment or close proximity. This allows the second coil modules 150B adjacent in the circumferential direction to be insulated from each other while being preferably arranged in an annular arrangement.

In the insulating cover 163, the front surface portion 183 is provided with an opening 185a for pulling out the winding end portion 154 of the second partial winding 151B, and the outer surface portion 182 is provided with an opening 185b for pulling out the winding end portion 155 of the second partial winding 151B.

The front surface 183 of the insulating cover 163 is provided with a protruding portion 186 that protrudes radially inward. The protruding portion 186 is provided at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163 so as to protrude radially inward from the second bridge portion 153B. The protruding portion 186 has a tapered shape that tapers toward the radially inner side in a plan view, and a through hole 187 extending in the axial direction is provided at its tip. Note that the protruding portion 186 may have any configuration as long as it protrudes radially inward from the second bridge portion 153B and has a through hole 187 at a position that is the center between one end and the other end of the circumferential direction of the insulating cover 163. However, assuming an overlapping state with the insulating cover 161 on the axial inner side, it is desirable to form the protruding portion 186 narrow in the circumferential direction to avoid interference with the winding ends 154, 155.

The protrusion 186 has a stepped axial thickness at its radially inner tip, and the thinned lower step 186a is provided with a through hole 187. This lower step 186a corresponds to a portion where the height from the axial end face of the inner tube member 81 is lower than the height of the second bridge portion 153B when the second coil module 150B is assembled to the core assembly CA.

23, the protrusion 186 is provided with a through hole 188 that penetrates in the axial direction. This makes it possible to fill the gap between the insulating covers 161 and 163 through the through hole 188 when the insulating covers 161 and 163 are overlapped in the axial direction.

Although detailed explanation using the drawings will be omitted, the other insulating cover 164 in the axial direction has a configuration generally similar to that of the insulating cover 163. Like the insulating cover 163, the insulating cover 164 has a pair of side portions 181, an outer surface portion 182 on the axial outside, a front surface portion 183 on the radial inside, and a rear surface portion 184 on the radial outside, and also has a through hole 187 provided at the tip of the protruding portion 186. Also, as a difference from the insulating cover 163, the insulating cover 164 is configured not to have an opening for pulling out the winding ends 154, 155 of the second partial winding 151B.

In the insulating covers 163 and 164, the radial width dimensions of the pair of side portions 181 are different. Specifically, as shown in FIG. 17, the radial width dimension W21 of the side portion 181 of the insulating cover 163 and the radial width dimension W22 of the side portion 181 of the insulating cover 164 are W21>W22. In other words, of the insulating covers 163 and 164, the insulating cover 163 is a portion that covers the second crossover portion 153B on the side including the winding start and winding end of the conductor material CR, and by including the winding start and winding end of the conductor material CR, the winding allowance (overlap allowance) of the conductor material CR is larger than other portions, and as a result, the winding width may be larger. Taking this into consideration, the radial width dimension W21 of the insulating cover 163 is larger than the radial width dimension W22 of the insulating cover 164. This prevents the number of turns of the conductive wire CR being limited by the insulating covers 163, 164, which is a disadvantage when the widths W21, W22 of the insulating covers 163, 164 are the same.

Figure 25 is a diagram showing the overlap position of the film material FM when the coil modules 150A, 150B are arranged in the circumferential direction. As described above, in each coil module 150A, 150B, the film material FM is covered around the intermediate conductor portion 152 so as to overlap the portion facing the intermediate conductor portion 152 in the partial winding 151 of the other phase, i.e., the circumferential side surface of the intermediate conductor portion 152 (see Figures 20 and 23). Then, when the coil modules 150A, 150B are arranged in the circumferential direction, the overlap portion OL of the film material FM is arranged on the same side (the right side in the circumferential direction in the figure) of both sides in the circumferential direction. As a result, the overlap portions OL of the film material FM in the intermediate conductor portions 152 of the partial windings 151A, 151B of different phases adjacent to each other in the circumferential direction do not overlap each other in the circumferential direction. In this case, a maximum of three sheets of film material FM overlap between each of the intermediate conductor portions 152 aligned in the circumferential direction.

Next, the configuration for assembling each coil module 150A, 150B to the core assembly CA will be described.

The coil modules 150A, 150B have different axial lengths and different shapes of the bridge portions 153A, 153B of the partial windings 151A, 151B, and are configured to be attached to the core assembly CA with the first bridge portion 153A of the first coil module 150A facing axially inward and the second bridge portion 153B of the second coil module 150B facing axially outward. With regard to the insulating covers 161-164, the insulating covers 161, 163 are stacked in the axial direction at one axial end of each coil module 150A, 150B, and the insulating covers 162, 164 are stacked in the axial direction at the other axial end, and the insulating covers 161-164 are fixed to the core assembly CA.

26 is a plan view showing a state where multiple insulating covers 161 are arranged in the circumferential direction when the first coil module 150A is assembled to the core assembly CA, and FIG. 27 is a plan view showing a state where multiple insulating covers 161, 163 are arranged in the circumferential direction when the first coil module 150A and the second coil module 150B are assembled to the core assembly CA. Also, FIG. 28(a) is a vertical cross-sectional view showing a state before fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA, and FIG. 28(b) is a vertical cross-sectional view showing a state after fixing by the fixing pin 191 in the assembled state of each coil module 150A, 150B to the core assembly CA.

26, when multiple first coil modules 150A are assembled to the core assembly CA, multiple insulating covers 161 are arranged with their side portions 171 abutting or in close proximity to each other. Each insulating cover 161 is arranged so that the boundary line LB between the opposing side portions 171 coincides with the recess 105 in the axial end surface of the inner tube member 81. In this case, the side portions 171 of circumferentially adjacent insulating covers 161 abut or in close proximity to each other, so that a through hole extending in the axial direction is formed by each recess 177 of the insulating covers 161, and the positions of the through hole and the recess 105 coincide with each other.

27, the second coil module 150B is further assembled to the core assembly CA and the first coil module 150A. With this assembly, the insulating covers 163 are arranged with their side portions 181 in contact or in close proximity to each other. In this state, the transition portions 153A, 153B are arranged to intersect with each other on the circle on which the intermediate conductor portions 152 are arranged in the circumferential direction. Each insulating cover 163 is arranged such that the protrusion 186 overlaps with the insulating cover 161 in the axial direction and the through hole 187 of the protrusion 186 is axially connected to the through hole portion formed by each recess 177 of the insulating cover 161.

At this time, the protrusion 186 of the insulating cover 163 is guided to a predetermined position by a pair of protrusions 178 provided on the insulating cover 161, so that the position of the through hole 187 on the insulating cover 163 side matches the through hole portion on the insulating cover 161 side and the recess 105 of the inner tube member 81. In other words, when each coil module 150A, 150B is assembled to the core assembly CA, the recess 177 of the insulating cover 161 is located at the back side of the insulating cover 163, so it may be difficult to align the through hole 187 of the protrusion 186 with the recess 177 of the insulating cover 161. In this regard, the protrusion 186 of the insulating cover 163 is guided by the pair of protrusions 178 of the insulating cover 161, making it easier to align the insulating cover 163 with the insulating cover 161.

28(a) and (b), the insulating cover 161 and the protruding portion 186 of the insulating cover 163 are engaged with each other at the overlapping portion, and the fixing pin 191 is inserted into the recesses 105, 177 and the through hole 187 of the insulating cover 163 while aligning the recesses 105, 177 and the through hole 187 of the insulating cover 163. This allows the insulating covers 161 and 163 to be fixed together with the inner cylindrical member 81. According to this configuration, the coil modules 150A and 150B adjacent to each other in the circumferential direction are fixed to the core assembly CA at the coil end CE by the common fixing pin 191. The fixing pin 191 is preferably made of a material with good thermal conductivity, such as a metal pin.

As shown in FIG. 28B, the fixing pin 191 is attached to the lower step 186a of the protruding portion 186 of the insulating cover 163. In this state, the upper end of the fixing pin 191 protrudes above the lower step 186a, but does not protrude above the upper surface (outer surface 182) of the insulating cover 163. In this case, the fixing pin 191 is longer than the axial height dimension of the overlapping portion between the insulating cover 161 and the protruding portion 186 (lower step 186a) of the insulating cover 163, and has a margin for protruding upward, so that it is considered that the fixing pin 191 can be easily inserted into the recesses 105, 177 and the through hole 187 (i.e., when fixing the fixing pin 191). Furthermore, since the upper end of the fixing pin 191 does not protrude above the upper surface (outer surface portion 182) of the insulating cover 163, the inconvenience of the axial length of the stator 60 becoming longer due to the fixing pin 191 protruding can be suppressed.

After the insulating covers 161, 163 are fixed by the fixing pins 191, adhesive is filled through the through holes 188 provided in the insulating cover 163. This allows the insulating covers 161, 163, which overlap in the axial direction, to be firmly joined to each other. Note that in Figures 28(a) and (b), for convenience, the through holes 188 are shown in the range from the top to the bottom of the insulating cover 163, but in reality, the through holes 188 are provided in a thin plate portion formed by hollowing out or the like.

As shown in FIG. 28(b), the fixing position of each insulating cover 161, 163 by the fixing pin 191 is the axial end face of the stator holder 70 radially inward (left side of the figure) from the stator core 62, and the fixing pin 191 is fixed to the stator holder 70. In other words, the first bridge portion 153A is fixed to the axial end face of the stator holder 70. In this case, since the stator holder 70 is provided with a refrigerant passage 85, the heat generated in the first partial winding 151A is directly transferred from the first bridge portion 153A to the vicinity of the refrigerant passage 85 of the stator holder 70. In addition, the fixing pin 191 is inserted into the recess 105 of the stator holder 70, and the transfer of heat to the stator holder 70 side is promoted through the fixing pin 191. With this configuration, the cooling performance of the stator winding 61 is improved.

In this embodiment, 18 insulating covers 161, 163 are arranged in a stack on the inside and outside of the axial direction in the coil end CE, while 18 recesses 105 are provided on the axial end face of the stator holder 70, the same number as the insulating covers 161, 163. The 18 recesses 105 are then fixed by fixing pins 191.

Although not shown, the same is true for the insulating covers 162 and 164 on the opposite axial side. That is, when the first coil module 150A is assembled, the side portions 171 of the insulating covers 162 adjacent in the circumferential direction come into contact with or approach each other, so that the recesses 177 of the insulating covers 162 form through-holes extending in the axial direction, and the positions of the through-holes and the recesses 106 on the axial end surface of the outer tube member 71 are aligned. Then, when the second coil module 150B is assembled, the positions of the through-holes 187 on the insulating cover 164 side are aligned with the through-holes on the insulating cover 163 side and the recesses 106 of the outer tube member 71, and the fixing pins 191 are inserted into the recesses 106, 177, and the through-holes 187, so that the insulating covers 162 and 164 are fixed together with the outer tube member 71.

When assembling each coil module 150A, 150B to the core assembly CA, it is preferable to first attach all the first coil modules 150A to the outer periphery of the core assembly CA, and then assemble all the second coil modules 150B and fix them with the fixing pins 191. Alternatively, it is also possible to first fix two first coil modules 150A and one second coil module 150B to the core assembly CA with one fixing pin 191, and then repeatedly assemble the first coil modules 150A, assemble the second coil modules 150B, and fix them with the fixing pins 191 in this order.

Next, we will explain the busbar module 200.

The busbar module 200 is a winding connection member that is electrically connected to the partial windings 151 of each coil module 150 in the stator winding 61, connects one end of the partial windings 151 of each phase in parallel for each phase, and connects the other end of each partial winding 151 at a neutral point. Figure 29 is a perspective view of the busbar module 200, and Figure 30 is a cross-sectional view showing a part of a longitudinal section of the busbar module 200.

The busbar module 200 has an annular portion 201 having a circular ring shape, a plurality of connection terminals 202 extending from the annular portion 201, and three input/output terminals 203 provided for each phase winding. The annular portion 201 is formed in a circular ring shape from an insulating material such as resin.

As shown in FIG. 30, the annular portion 201 has laminated plates 204 that are approximately annular and laminated in multiple layers (five layers in this embodiment) in the axial direction, and four bus bars 211-214 are provided between the laminated plates 204. Each bus bar 211-214 is annular and consists of a U-phase bus bar 211, a V-phase bus bar 212, a W-phase bus bar 213, and a neutral bus bar 214. Each bus bar 211-214 is arranged in the annular portion 201 in the axial direction with the plate surfaces facing each other. Each laminated plate 204 and each bus bar 211-214 are bonded to each other with an adhesive. It is preferable to use an adhesive sheet as the adhesive. However, a liquid or semi-liquid adhesive may be applied. A connection terminal 202 is connected to each of the bus bars 211 to 214 so as to protrude radially outward from the annular portion 201 .

A protrusion 201a extending in a circular shape is provided on the upper surface of the annular portion 201, i.e., the upper surface of the laminate 204 which is the outermost layer of the five laminated layers 204.

The busbar module 200 may be one in which the busbars 211-214 are embedded in the annular portion 201, and the busbars 211-214 arranged at predetermined intervals may be integrally insert-molded. The arrangement of the busbars 211-214 is not limited to a configuration in which all are lined up in the axial direction and all of the plate surfaces face the same direction, but may be a configuration in which they are lined up in the radial direction, a configuration in which they are lined up in two axial rows and two radial rows, a configuration in which the plate surfaces extend in different directions, and the like.

29, the connection terminals 202 are arranged in the circumferential direction of the annular portion 201 and extend in the axial direction on the radially outer side. The connection terminals 202 include a connection terminal connected to the U-phase busbar 211, a connection terminal connected to the V-phase busbar 212, a connection terminal connected to the W-phase busbar 213, and a connection terminal connected to the neutral busbar 214. The connection terminals 202 are provided in the same number as the winding ends 154, 155 of each partial winding 151 in the coil module 150, and each of the connection terminals 202 is connected to one of the winding ends 154, 155 of each partial winding 151. As a result, the busbar module 200 is connected to the U-phase partial winding 151, the V-phase partial winding 151, and the W-phase partial winding 151.

The input/output terminals 203 are made of, for example, busbar material and are arranged to extend in the axial direction. The input/output terminals 203 include an input/output terminal 203U for the U phase, an input/output terminal 203V for the V phase, and an input/output terminal 203W for the W phase. These input/output terminals 203 are connected to the busbars 211 to 213 for each phase within the annular portion 201. Through these input/output terminals 203, power is input/output from an inverter (not shown) to the phase windings of each phase of the stator winding 61.

In addition, a current sensor for detecting the phase current of each phase may be integrally provided in the busbar module 200. In this case, a current detection terminal may be provided in the busbar module 200, and the detection result of the current sensor may be output to a control device (not shown) through the current detection terminal.

In addition, the annular portion 201 has a plurality of protrusions 205 protruding toward the inner circumference as fixed portions to the stator holder 70, and the protrusions 205 have through holes 206 extending in the axial direction formed therein.

Figure 31 is a perspective view showing the state in which the busbar module 200 is assembled to the stator holder 70, and Figure 32 is a vertical cross-sectional view of the fixing portion that fixes the busbar module 200. Please refer to Figure 12 for the configuration of the stator holder 70 before the busbar module 200 is assembled.

31, the busbar module 200 is provided on the end plate portion 91 so as to surround the boss portion 92 of the inner tube member 81. The busbar module 200 is positioned by assembly to the support portion 95 (see FIG. 12) of the inner tube member 81, and is fixed to the stator holder 70 (inner tube member 81) by tightening fasteners 217 such as bolts.

32, the end plate portion 91 of the inner tube member 81 is provided with a support portion 95 extending in the axial direction. The busbar module 200 is fixed to the support portion 95 by a fastener 217 with the support portion 95 inserted into the through holes 206 provided in the multiple protrusions 205. In this embodiment, the busbar module 200 is fixed using a retainer plate 220 made of a metal material such as iron. The retainer plate 220 has a fastened portion 222 having an insertion hole 221 through which the fastener 217 is inserted, a pressing portion 223 that presses the upper surface of the annular portion 201 of the busbar module 200, and a bend portion 224 provided between the fastened portion 222 and the pressing portion 223.

In the attached state of the retainer plate 220, the fastener 217 is inserted into the insertion hole 221 of the retainer plate 220 and screwed to the support portion 95 of the inner tube member 81. In addition, the pressing portion 223 of the retainer plate 220 is in contact with the upper surface of the annular portion 201 of the busbar module 200. In this case, as the fastener 217 is screwed into the support portion 95, the retainer plate 220 is pushed downward in the figure, and the annular portion 201 is pressed downward by the pressing portion 223 accordingly. The downward pressing force in the figure generated by the screwing of the fastener 217 is transmitted to the pressing portion 223 through the bend portion 224, so that the pressing force by the pressing portion 223 is performed in a state accompanied by the elastic force of the bend portion 224.

As described above, an annular protrusion 201a is provided on the upper surface of the annular portion 201, and the tip of the retainer plate 220 on the pressing portion 223 side can abut against the protrusion 201a. This prevents the downward pressing force of the retainer plate 220 from escaping radially outward. In other words, the pressing force generated by the screwing of the fastener 217 is properly transmitted to the pressing portion 223 side.

31, when the busbar module 200 is assembled to the stator holder 70, the input/output terminals 203 are provided at positions 180 degrees circumferentially opposite the inlet opening 86a and the outlet opening 87a leading to the refrigerant passage 85. However, the input/output terminals 203 and the openings 86a, 87a may be provided together at the same position (i.e., adjacent positions).

Next, we will describe the relay member 230 that electrically connects the input/output terminals 203 of the busbar module 200 to an external device of the rotating electric machine 10.

1, in the rotating electric machine 10, the input/output terminals 203 of the busbar module 200 are arranged to protrude outward from the housing cover 242 and are connected to the relay member 230 on the outside of the housing cover 242. The relay member 230 is a member that relays the connection between the input/output terminals 203 for each phase extending from the busbar module 200 and the power lines for each phase extending from an external device such as an inverter.

Figure 33 is a vertical cross-sectional view showing the state in which relay member 230 is attached to housing cover 242, and Figure 34 is a perspective view of relay member 230. As shown in Figure 33, a through hole 242a is formed in housing cover 242, and input/output terminal 203 can be pulled out through the through hole 242a.

The relay member 230 has a main body 231 fixed to the housing cover 242, and a terminal insertion portion 232 inserted into the through hole 242a of the housing cover 242. The terminal insertion portion 232 has three insertion holes 233 through which the input/output terminals 203 of each phase are inserted one by one. The three insertion holes 233 have an elongated cross-sectional opening, and are aligned so that the longitudinal directions of the three insertion holes 233 are all oriented in approximately the same direction.

Three relay bus bars 234, one for each phase, are attached to the main body 231. The relay bus bars 234 are bent into a generally L-shape and fixed to the main body 231 with fasteners 235 such as bolts, and are fixed to the tip of the input/output terminal 203 inserted into the insertion hole 233 of the terminal insertion portion 232 with fasteners 236 such as bolts and nuts.

Although not shown in the figure, the relay member 230 can be connected to power lines for each phase extending from an external device, making it possible to input and output power to the input/output terminal 203 for each phase.

Next, we will explain the configuration of the control system that controls the rotating electric machine 10. Figure 35 is an electrical circuit diagram of the control system for the rotating electric machine 10, and Figure 36 is a functional block diagram showing the control processing by the control device 270.

As shown in FIG. 35, the stator winding 61 is composed of a U-phase winding, a V-phase winding, and a W-phase winding, and an inverter 260 equivalent to a power converter is connected to the stator winding 61. The inverter 260 is configured as a full bridge circuit having the same number of upper and lower arms as the number of phases, and a series connection consisting of an upper arm switch 261 and a lower arm switch 262 is provided for each phase. Each of these switches 261, 262 is turned on and off by a driver 263, and the phase winding of each phase is energized by the on and off. Each of the switches 261, 262 is configured of a semiconductor switching element such as a MOSFET or an IGBT. In addition, a charge supply capacitor 264 for supplying the charge required during switching to each switch 261, 262 is connected in parallel to the series connection of the switches 261, 262 to the upper and lower arms of each phase.

One end of the U-phase winding, the V-phase winding, and the W-phase winding are connected to the intermediate connection point between the switches 261 and 262 of the upper and lower arms. These phase windings are star-connected (Y-connected), and the other ends of the phase windings are connected to each other at the neutral point.

The control device 270 is equipped with a microcomputer consisting of a CPU and various memories, and performs current control by turning on and off each switch 261, 262 based on various detection information in the rotating electric machine 10 and requests for power running and power generation. The detection information of the rotating electric machine 10 includes, for example, the rotation angle (electrical angle information) of the rotor 20 detected by an angle detector such as a resolver, the power supply voltage (inverter input voltage) detected by a voltage sensor, and the current of each phase detected by a current sensor. The control device 270 performs on/off control of each switch 261, 262, for example, by PWM control at a predetermined switching frequency (carrier frequency) or square wave control. The control device 270 may be an internal control device built into the rotating electric machine 10, or an external control device provided outside the rotating electric machine 10.

Incidentally, since the rotating electric machine 10 of this embodiment has a slotless structure (teethless structure), the inductance of the stator 60 is reduced and the electrical time constant is small. In a situation where the electrical time constant is small, it is desirable to increase the switching frequency (carrier frequency) and the switching speed. In this regard, the charge supply capacitor 264 is connected in parallel to the series connection of the switches 261 and 262 of each phase, thereby reducing the wiring inductance, and appropriate surge countermeasures are possible even in a configuration with a high switching speed.

The high-potential terminal of the inverter 260 is connected to the positive terminal of the DC power supply 265, and the low-potential terminal is connected to the negative terminal (ground) of the DC power supply 265. The DC power supply 265 is, for example, configured as a battery pack in which multiple single cells are connected in series. In addition, a smoothing capacitor 266 is connected in parallel to the DC power supply 265 to the high-potential terminal and the low-potential terminal of the inverter 260.

Figure 36 is a block diagram showing the current feedback control process that controls the phase currents of the U, V, and W phases.

36, the current command value setting unit 271 uses a torque-dq map to set a d-axis current command value and a q-axis current command value based on the powering torque command value or the power generation torque command value for the rotating electric machine 10, and the electrical angular velocity ω obtained by time-differentiating the electrical angle θ. Note that the power generation torque command value is a regenerative torque command value, for example, when the rotating electric machine 10 is used as a power source for a vehicle.

The dq conversion unit 272 converts the current detection values (three phase currents) detected by the current sensors provided for each phase into d-axis current and q-axis current, which are components of an orthogonal two-dimensional rotating coordinate system with the d-axis being the direction of an axis of a magnetic field, or field direction.

The d-axis current feedback control unit 273 calculates a d-axis command voltage as an operation amount for feedback-controlling the d-axis current to the d-axis current command value. The q-axis current feedback control unit 274 calculates a q-axis command voltage as an operation amount for feedback-controlling the q-axis current to the q-axis current command value. In each of these feedback control units 273, 274, a command voltage is calculated using a PI feedback method based on the deviation of the d-axis current and the q-axis current from the current command value.

The three-phase conversion unit 275 converts the d-axis and q-axis command voltages into command voltages for the U, V, and W phases. Each of the above units 271 to 275 is a feedback control unit that performs feedback control of the fundamental wave current according to the dq transformation theory, and the command voltages for the U, V, and W phases are the feedback control values.

The operation signal generating unit 276 generates an operation signal for the inverter 260 based on the three-phase command voltages using a well-known triangular wave carrier comparison method. Specifically, the operation signal generating unit 276 generates switch operation signals (duty signals) for the upper and lower arms in each phase by PWM control based on a comparison of the magnitude between a signal obtained by normalizing the three-phase command voltages with the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signals generated by the operation signal generating unit 276 are output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

Next, the torque feedback control process will be described. This process is mainly used for the purpose of increasing the output of the rotating electric machine 10 and reducing losses under operating conditions where the output voltage of the inverter 260 is large, such as in high rotation ranges and high output ranges. The control device 270 selects and executes either the torque feedback control process or the current feedback control process based on the operating conditions of the rotating electric machine 10.

Figure 37 is a block diagram showing the torque feedback control processing corresponding to the U, V, and W phases.

The voltage amplitude calculation unit 281 calculates a voltage amplitude command, which is a command value for the magnitude of a voltage vector, based on a powering torque command value or a power generation torque command value for the rotating motor 10 and the electrical angular velocity ω obtained by time-differentiating the electrical angle θ.

The dq conversion unit 282 converts the current detection values by the current sensors provided for each phase into d-axis current and q-axis current, similar to the dq conversion unit 272. The torque estimation unit 283 calculates torque estimation values corresponding to the U, V, and W phases based on the d-axis current and the q-axis current. The torque estimation unit 283 calculates the voltage amplitude command based on map information that correlates the d-axis current, the q-axis current, and the voltage amplitude command.

The torque feedback control unit 284 calculates a voltage phase command, which is a command value for the phase of the voltage vector, as an operation amount for feedback control of the torque estimate value to the powering torque command value or the power generation torque command value. In the torque feedback control unit 284, the voltage phase command is calculated using a PI feedback method based on the deviation of the torque estimate value from the powering torque command value or the power generation torque command value.

The operation signal generating unit 285 generates an operation signal for the inverter 260 based on the voltage amplitude command, the voltage phase command, and the electrical angle θ. Specifically, the operation signal generating unit 285 calculates three-phase command voltages based on the voltage amplitude command, the voltage phase command, and the electrical angle θ, and generates switch operation signals for the upper and lower arms in each phase by PWM control based on a comparison of the magnitude between a signal obtained by normalizing the calculated three-phase command voltages with the power supply voltage and a carrier signal such as a triangular wave signal. The switch operation signal generated by the operation signal generating unit 285 is output to the driver 263 of the inverter 260, and the driver 263 turns on and off the switches 261 and 262 of each phase.

Incidentally, the operation signal generating unit 285 may generate a switch operation signal based on pulse pattern information, which is map information in which a voltage amplitude command, a voltage phase command, an electrical angle θ, and a switch operation signal are associated, a voltage amplitude command, a voltage phase command, and an electrical angle θ.

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

- The magnet configuration in magnet unit 22 may be changed as follows. In magnet unit 22 shown in Figure 38, the magnet easy axis of magnet 32 is oriented at an angle to the radial direction, and a linear magnetic flux path is formed along the direction of the easy axis of magnetization. Even in this configuration, the magnetic flux path length of magnet 32 can be made longer than the radial thickness dimension, making it possible to improve permeance.

-It is also possible to use Halbach array magnets in the magnet unit 22.

In each partial winding 151, the bending direction of the crossover portion 153 may be either radially inward or outward, and in terms of its relationship with the core assembly CA, the first crossover portion 153A may be bent toward the core assembly CA, or the first crossover portion 153A may be bent toward the opposite side of the core assembly CA. The second crossover portion 153B may be bent either radially inward or outward, as long as it is axially outside the first crossover portion 153A and circumferentially spans a portion of the first crossover portion 153A.

・The partial winding 151 may have only one type of partial winding 151, instead of two types of partial winding 151 (first partial winding 151A, second partial winding 151B). Specifically, the partial winding 151 may be formed to have an approximately L-shape or an approximately Z-shape in side view. When the partial winding 151 is formed to have an approximately L-shape in side view, the crossover portion 153 is bent radially inward or outward at one axial end, and the crossover portion 153 is not bent radially at the other axial end. When the partial winding 151 is formed to have an approximately Z-shape in side view, the crossover portion 153 is bent radially in opposite directions at one axial end and the other axial end. In either case, the coil module 150 may be fixed to the core assembly CA by an insulating cover that covers the crossover portion 153 as described above.

- In the above-mentioned configuration, all partial windings 151 for each phase winding in the stator winding 61 are connected in parallel, but this may be changed. For example, all partial windings 151 for each phase winding may be divided into multiple parallel connection groups, and the multiple parallel connection groups may be connected in series. In other words, all n partial windings 151 in each phase winding may be divided into two parallel connection groups of n/2 pieces each, or three parallel connection groups of n/3 pieces each, and these may be connected in series. Alternatively, the stator winding 61 may be configured such that multiple partial windings 151 for each phase winding are all connected in series.

The stator winding 61 in the rotating electric machine 10 may be configured to have two-phase windings (a U-phase winding and a V-phase winding). In this case, for example, in the partial winding 151, a pair of intermediate conductor portions 152 are provided one coil pitch apart, and one intermediate conductor portion 152 in the partial winding 151 of the other phase is disposed between the pair of intermediate conductor portions 152.

-Instead of the outer rotor type surface magnet type rotating electric machine, the rotating electric machine 10 can also be embodied as an inner rotor type surface magnet type rotating electric machine. Figures 39(a) and (b) are diagrams showing the configuration of the stator unit 300 in the case of an inner rotor structure. Of these, Figure 39(a) is a perspective view showing the state in which the coil modules 310A and 310B are assembled to the core assembly CA, and Figure 39(b) is a perspective view showing the partial windings 311A and 311B included in each coil module 310A and 310B. In this example, the core assembly CA is configured by assembling the stator holder 70 to the radial outside of the stator core 62. In addition, a configuration is configured in which multiple coil modules 310A and 310B are assembled to the radial inside of the stator core 62.

The partial winding 311A has a configuration similar to that of the first partial winding 151A described above, and includes a pair of intermediate conductor parts 312 and a bridge part 313A formed by bending the bridge part 313A toward the core assembly CA side (radially outward) on both axial sides. The partial winding 311B has a configuration similar to that of the second partial winding 151B described above, and includes a pair of intermediate conductor parts 312 and a bridge part 313B provided on both axial sides so as to straddle the bridge part 313A in the circumferential direction on the axially outer side. An insulating cover 315 is attached to the bridge part 313A of the partial winding 311A, and an insulating cover 316 is attached to the bridge part 313B of the partial winding 311B.

The insulating cover 315 has semicircular recesses 317 extending in the axial direction on both circumferential side surfaces. The insulating cover 316 has a protruding portion 318 protruding radially outward from the transition portion 313B, and a through hole 319 extending in the axial direction at the tip of the protruding portion 318.

Figure 40 is a plan view showing the state in which coil modules 310A, 310B are assembled to core assembly CA. In Figure 40, a plurality of recesses 105 are formed at equal intervals in the circumferential direction on the axial end face of stator holder 70. Stator holder 70 also has a cooling structure using liquid refrigerant or air, and for example, as an air-cooled structure, a plurality of heat dissipation fins may be formed on the outer circumferential surface.

In Figure 40, the insulating covers 315 and 316 are arranged so as to overlap in the axial direction. In addition, a recess 317 provided on the side of the insulating cover 315 and a through hole 319 provided in the protruding portion 318 of the insulating cover 316 at a position that is central between one end and the other end of the circumference of the insulating cover 316 are connected in the axial direction, and are fixed at each of these portions by fixing pins 321.

In addition, in Fig. 40, the fixing position of each insulating cover 315, 316 by the fixing pin 321 is the axial end face of the stator holder 70 radially outward of the stator core 62, and the fixing pin 321 is fixed to the stator holder 70. In this case, since the stator holder 70 is provided with a cooling structure, heat generated in the partial windings 311A, 311B is easily transferred to the stator holder 70. This improves the cooling performance of the stator winding 61.

The stator 60 used in the rotating electric machine 10 may have protrusions (e.g., teeth) extending from the back yoke. In this case, it is sufficient that the coil module 150 and the like are attached to the stator core by the back yoke.

- The rotating motor is not limited to star-connected ones, but can also be delta-connected ones.

-As the rotating electric motor 10, instead of a rotating field type rotating electric motor in which the field element is the rotor and the armature is the stator, it is also possible to adopt a rotating armature type rotating electric motor in which the armature is the rotor and the field element is the stator.

(Variation 2)
In the above embodiment or the above modified examples, the configuration may be modified as follows. In the following, in Modification 2, differences from the configurations described in the above embodiments and modified examples will be mainly described. In addition, in Modification 2, the basic configuration of the rotating electric machine 10 will be described using the first embodiment as an example. The following will mainly describe in detail the configuration of the magnet unit 1000 as the magnet section in Modification 2.

As shown in Figures 41 and 42, the magnet unit 1000 has a plurality of magnets 1001, 1002 arranged in a circumferential direction, and a magnet yoke 2000 that holds these magnets 1001, 1002. The magnets 1001, 1002 are fixed to the magnet yoke 2000 via an adhesive or the like. In this variant example 2, the inner peripheral surface of the magnet yoke 2000 corresponds to the magnet fixing surface.

First, the shape of each magnet 1001, 1002 will be described. Each magnet 1001, 1002 is provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent in the circumferential direction to the d-axis, which is the magnetic pole center. The magnets 1001 and 1002 are provided symmetrically in the circumferential direction with the d-axis, which is the magnetic pole center, or the q-axis, which is the magnetic pole boundary, as the center. In this modification example 2, the magnet on the left side of the d-axis, which is the magnetic pole center, in Figures 41 and 42 is shown as magnet 1001, and the magnet on the right side is shown as magnet 1002. The magnet unit 1000 is provided in a circular ring shape by arranging the magnets 1001 and 1002 side by side in the circumferential direction.

As shown in FIG. 41, each magnet 1001, 1002 has a stator side circumferential surface 1003 (armature side circumferential surface) on the radial inside (stator 60 side), a non-stator side circumferential surface 1004 (non-armature side circumferential surface) on the radial outside (magnet yoke 2000 side), and a circumferential end surface 1005 which is a flat surface along the radial direction at both circumferential ends. Each magnet 1001, 1002 is provided to have a predetermined height dimension in the axial direction. The cross-sectional shape of each magnet 1001, 1002 is the same at every point in the axial direction. Also, since each magnet 1001, 1002 is symmetrical, the following description will focus on magnet 1001.

Each circumferential end face 1005 is provided to connect the circumferential end of the stator side circumferential surface 1003 and the circumferential end of the anti-stator side circumferential surface 1004. Each magnet 1001, 1002 has a d-axis side end face 1005a which is the circumferential end face 1005 on the d-axis side which is the magnetic pole center, and a q-axis side end face 1005b which is the circumferential end face 1005 on the q-axis side which is the magnetic pole boundary.

The stator side peripheral surface 1003 of each magnet 1001 is formed in an approximately arc shape along the circumferential direction.

The radially outermost surface of the anti-stator side peripheral surface 1004 of each magnet 1001 is formed in an approximately arc shape along the circumferential direction and abuts against the inner peripheral surface of the magnet yoke 2000.

In addition, the anti-stator side q-axis recess 1004b is provided at the end of the anti-stator side circumferential surface 1004 of each magnet 1001 on the q-axis side, which is the magnetic pole boundary. Due to the anti-stator side q-axis recess 1004b, the corner between the anti-stator side circumferential surface 1004 and the q-axis side end face 1005b is recessed radially inward. The anti-stator side q-axis recess 1004b is approximately trapezoidal in shape, with its opening (radially outer portion) being wider than its bottom (radially inner portion), and its side surface being an inclined surface that is inclined radially. The extent to which the anti-stator side q-axis recess 1004b is provided will be described later.

As described above, the anti-stator side peripheral surface 1004 of each magnet 1001, 1002 is formed with a radially uneven shape. In this embodiment, the anti-stator side q-axis recess 1004b is formed on the q-axis side, which is the magnetic pole boundary, with the inner peripheral surface of the magnet yoke 2000 as the reference, but the bottom of the anti-stator side q-axis recess 1004b may also be used as the reference. In other words, when the bottom of the anti-stator side q-axis recess 1004b is used as the reference, it can be said that the magnet 1001 has a d-axis side protrusion formed thereon that protrudes radially toward the d-axis side, which is the magnetic pole center.

Next, the magnetic flux paths in each magnet 1001, 1002 will be described with reference to FIG. 42. The magnetization easy axis in these magnets 1001, 1002 is oriented so that its direction is parallel to the d-axis, which is the magnetic pole center, on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary, and the magnetic flux paths are formed along the magnetization easy axis. Specifically, in each magnet 1001, 1002, multiple arc-shaped magnetic flux paths are formed with a center point (orientation center) set on the q-axis as shown in FIG. 42 as the center. The shape of the magnetic flux path may be an arc shape that is a part of a perfect circle, or an arc shape that is a part of an ellipse. In addition, although the center of the arc is on the q-axis, it does not have to be on the q-axis as long as it is on the q-axis side of the d-axis. Furthermore, the center of the arc may be set radially on the stator side peripheral surface 1003 of the multiple magnets 1001, 1002, or on the stator 60 (armature) side of the stator side peripheral surface 1003 of the multiple magnets 1001, 1002.

Therefore, the axis of easy magnetization of each magnet 1001, 1002 is parallel to the d-axis, which is the magnetic pole center, or nearly parallel to the d-axis, which is the magnetic pole center, in the portion closer to the d-axis, which is the magnetic pole center, and is perpendicular to the q-axis, which is the magnetic pole boundary, or nearly perpendicular to the q-axis, which is the magnetic pole boundary, in the portion closer to the q-axis, which is the magnetic pole boundary.

The magnetic flux path of magnet 1001 is formed symmetrically in the circumferential direction around the d-axis, which is the magnetic pole center, with respect to the magnetic flux path of magnet 1002, which is adjacent in the circumferential direction around the d-axis, which is the magnetic pole center. Here, magnet 1001 and magnet 1002, which is adjacent in the circumferential direction to magnet 1001 around the d-axis, which is the magnetic pole center, are referred to as a pair of magnets 1001, 1002.

The magnet unit 1000 has the magnetization directions (magnetization directions) of the magnets 1001 and 1002 opposite each other for each pair of magnets 1001 and 1002 so that the polarity of the d-axis, which is the center of the magnetic poles adjacent to each other in the circumferential direction, is different. That is, as shown in FIG. 42, the magnetization directions (magnetization directions) of the pair of magnets 1001 and 1002 are set so that the magnetic flux lines converge toward the d-axis, which is the center of the magnetic poles, where the polarity is positive (N pole). On the other hand, the magnetization directions (magnetization directions) of the pair of magnets 1001 and 1002 are set so that the magnetic flux lines expand in the opposite direction from the d-axis, which is the center of the magnetic poles, where the polarity is negative (S pole).

Next, an outline of the manufacturing method of the magnets 1001, 1002 will be described. Each magnet 1001, 1002 is a sintered magnet manufactured by a sintering method. That is, the raw materials such as neodymium, boron, and iron produced are melted and alloyed (step 1). Next, the alloy obtained in step 1 is crushed into particles (step 2). Then, the powder obtained in step 2 is placed in a metal mold and pressure-molded in a magnetic field (step 3). After pressure molding, the molded product is sintered (step 4), and after sintering is completed, it is heat-treated (step 5). In the heat treatment, heating and cooling are performed several times. Then, after mechanical processing such as grinding and surface processing are performed (step 6), the magnets are magnetized (step 7), and each magnet 1001, 1002 is completed.

Next, the magnet yoke 2000 will be described with reference to FIG. 41. The magnet yoke 2000 is made of a soft magnetic material and is formed into a cylindrical shape. The inner peripheral surface of the magnet yoke 2000 is provided with engagement portions 2001 that protrude radially inward at regular intervals in the circumferential direction. The engagement portions 2001 are formed integrally with the magnet yoke 2000 and are made of a soft magnetic material.

The engaging portion 2001 is formed to fill the anti-stator side q-axis recess 1004b in accordance with the shape of the anti-stator side q-axis recess 1004b so that it can be accommodated in the anti-stator side q-axis recess 1004b of each magnet 1001, 1002. That is, the engaging portion 2001 is formed in a substantially trapezoidal shape such that its bottom side (the radially outer part) is wider than its top side (the radially inner part), and is configured so that a gap is minimized between the magnets 1001, 1002, that is, so that they abut. The engaging portion 2001 engages with the side of the anti-stator side q-axis recess 1004b at its side, restricting the circumferential movement of the magnets 1001, 1002. Therefore, it functions as a positioning member for the magnets 1001, 1002 and also functions as a rotation stopper.

Here, the arrangement interval of the engagement portion 2001 will be explained. As described above, the magnetization easy axis of each magnet 1001, 1002 is oriented so that its orientation is parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis. In order to easily manufacture magnets 1001, 1002 having such a magnetic flux path, it is desirable to arrange each magnet 1001, 1002 between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent to the d-axis, which is the magnetic pole center. In other words, it is preferable to manufacture the magnet by dividing it at the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary. On the other hand, when magnets 1001 and 1002 are arranged between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent to the d-axis, which is the magnetic pole center, in order to improve the magnetic flux density at the d-axis, which is the magnetic pole center, while making the surface magnetic flux density closer to a sinusoidal wave, it is preferable to arrange the magnets in the circumferential direction with the gap in the circumferential direction as small as possible.

However, as mentioned above, due to the manufacturing method of magnets 1001 and 1002, it is difficult to manufacture magnets 1001 and 1002 to the exact dimensions, and some gaps occur. Also, when magnets 1001 and 1002 are provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary, the adjacent d-axis side end faces 1005a have the same polarity and tend to repel each other, so gaps are more likely to form than with the q-axis side end faces 1005b.

Therefore, the interval between adjacent engagement portions 2001 in the circumferential direction is set so that the gap between the d-axis end faces 1005a of the magnets 1001 and 1002 is narrower than the gap between the q-axis end faces 1005b. Specifically, the distance L21 from the side of the anti-stator side q-axis recess 1004b (the engagement position with the engagement portion 2001) to the d-axis, which is the magnetic pole center, is set to be the same as half the interval L20 of the engagement portion 2001 or slightly smaller. In other words, it can be said that the shape of the magnets 1001 and 1002 (the anti-stator side q-axis recess 1004b or the d-axis end face 1005a) is adjusted so that the distance L21 from the side of the anti-stator side q-axis recess 1004b to the d-axis, which is the magnetic pole center, is the same as half the interval L20 of the engagement portion 2001 or slightly smaller. For example, the gap between the d-axis side end faces 1005a may be ¼ or less of the gap between the q-axis side end faces 1005b.

Even if a gap occurs on the q-axis side, which is the magnetic pole boundary, magnetic flux leakage can be suppressed by the engagement portion 2001, which is made of a soft magnetic material. Even if the magnetic flux density decreases on the q-axis side, which is the magnetic pole boundary, the impact on performance is small compared to when the magnetic flux density decreases on the d-axis side, which is the magnetic pole center. For this reason, a certain degree of gap is tolerated on the q-axis side, which is the magnetic pole boundary, compared to the d-axis side, which is the magnetic pole center.

As shown in Fig. 41, the distance between adjacent engaging portions 2001 in the circumferential direction is narrower the further outward in the radial direction. Therefore, when the rotating electric machine 10 rotates, part of the centrifugal force acting radially outward on the magnets 1001, 1002 is converted by the engaging portions 2001 into stress toward the circumferential d-axis side. In other words, a force is applied in the direction in which the magnets 1001, 1002 approach the d-axis side, which is the magnetic pole center, and the gap between the d-axis side end faces 1005a can be prevented from widening.

The magnetization easy axis of each magnet 1001, 1002 is oriented so that its direction is parallel to the d-axis, which is the magnetic pole center, on the d-axis side, which is the magnetic pole center, compared to the q-axis side, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis. Therefore, compared to forming a magnetic flux path linearly along the radial direction, it is possible to reduce leakage magnetic flux between the magnetic poles and make the surface magnetic flux density of the magnets 1001, 1002 closer to a sine wave (a sine wave with an extreme value at the d-axis, which is the magnetic pole center). In other words, when a magnetic flux path is formed in an arc shape as in this embodiment, it is possible to reduce leakage magnetic flux between the magnetic poles and make the surface magnetic flux density of the magnets 1001, 1002 closer to a sine wave.

However, due to the manufacturing process of magnets 1001, 1002, it is difficult to fine-tune the shape of the magnet magnetic path, such as its length and direction, which are closely related to the magnetic flux density, and even when configured as described above, there is a problem that it is difficult to make the surface magnetic flux density perfectly sinusoidal when the thickness dimension of magnets 1001, 1002 in the radial direction is constant. Therefore, in this embodiment, the shape of magnets 1001, 1002 is configured as follows, as explained below.

When the permeance coefficient Pc in the circumferential direction (more specifically, the stator side circumferential surface 1003) of the above-mentioned magnets 1001, 1002 is calculated, it is found to be proportional to the length of the magnetic flux path. The permeance coefficient Pc is the ratio of magnetic flux density to magnetic field strength (magnetic field inside the magnet). If the material of the magnet is known, it can be calculated from the magnet shape (length in the magnetization direction and cross-sectional area). In general, it is known that as the length in the magnetization direction (length of the magnetic flux path) becomes longer, the permeance coefficient Pc becomes larger, making it less likely to self-demagnetize and making it easier for the magnetic flux density to increase.

In other words, if we assume that the magnets 1001 and 1002 are a collection of thin magnets along the magnetic flux path, as shown in FIG. 43, the permeance coefficient Pc of the magnets 1001 and 1002 in a state in which the anti-stator side q-axis recess 1004b is not provided is approximately proportional to the length of the magnetic flux path. For this reason, as shown in FIG. 43, in the magnets 1001 and 1002 in a state in which the anti-stator side q-axis recess 1004b is not provided, the permeance coefficient Pc becomes larger in the circumferential direction as it approaches the d-axis side, which is the magnetic pole boundary. Note that the above assumption is based on the premise that the magnets 1001 and 1002 are uniformly magnetized and have the same cross-sectional area (here, the axial cross-sectional area) perpendicular to the magnetization direction (direction of the magnetic flux path). In addition, when calculating the permeance coefficient Pc, it is advisable to use the average value of the predetermined thickness (radial width) of the magnets 1001 and 1002.

As shown by the dashed lines in Figure 43, the permeance coefficient Pc contour lines L11 to L13 can be virtually drawn for magnets 1001 and 1002 in a state where the anti-stator q-axis recess 1004b is not provided. The permeance coefficient Pc contour lines L11 to L13 refer to lines along which the permeance coefficient Pc has the same value. Note that due to the difference in length of the magnetic flux path, the contour line L13 closer to the anti-stator side has a higher permeance coefficient Pc than the contour line L11 closer to the stator side. In this embodiment, the permeance coefficient Pc is lowest for the contour line L11 in Figure 43, followed by the contour line L12 and the contour line L13 in order.

As shown by contour lines L11 to L13 in Figure 43, when the magnetic flux path is formed in an arc shape as in this embodiment, the radial thickness dimension of magnets 1001, 1002 needs to be thick on the d-axis side, which is the magnetic pole center, while it can be thin on the q-axis side, which is the magnetic pole boundary.

In addition, when the surface magnetic flux density of the magnet unit 1000 is made to approach a sinusoidal wave, it is desirable to increase the permeance coefficient Pc as it approaches the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. Therefore, referring to the contour lines L11 to L13, in order to increase the permeance coefficient Pc as it approaches the d-axis, which is the magnetic pole center, from the q-axis, which is the magnetic pole boundary, it is sufficient to adjust the length of the magnetic flux path as shown by the dashed line in FIG. 44. In other words, it is necessary to make the thickness dimension on the d-axis side, which is the magnetic pole center, thicker, while it is possible to increase the permeance coefficient Pc as it approaches the d-axis side, which is the magnetic pole center, by further reducing the thickness dimension on the q-axis side, which is the magnetic pole boundary.

In this embodiment, as shown in Figures 41 and 44, the permeance coefficient Pc of each magnet 1001, 1002 calculated based on the length of the magnetic flux path is increased in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. In other words, the length of the magnetic flux path is adjusted by providing irregularities on the circumferential surface 1004 on the stator side, so that the permeance coefficient Pc of each magnet 1001, 1002 is increased as it approaches the d-axis, which is the magnetic pole center, from the q-axis, which is the magnetic pole boundary. It is desirable to provide the q-axis recess 1004b on the stator side so that it completely matches the broken line in Figure 44, but because it is difficult to completely match it due to manufacturing reasons, the q-axis recess 1004b on the stator side is provided so as to approximate it.

Here, the dimensions of magnets 1001, 1002 will be explained. The maximum radial thickness dimension of magnets 1001, 1002 is dimension Ta (see Figure 41). This dimension Ta corresponds to the dimension from the radially innermost part of stator side peripheral surface 1003 to the radially outermost part of anti-stator side peripheral surface 1004. Note that in the case where anti-stator side d-axis recess 1004a is not provided, this corresponds to the thickness dimension on the d-axis side, which is the magnetic pole center of magnets 1001, 1002.

In addition, in the radial thickness dimension of magnets 1001, 1002, the thickness dimension on the q-axis side, which is the magnetic pole boundary, is dimension Tb (see Figure 41). This dimension Tb corresponds to the dimension from the radially innermost part of the stator side peripheral surface 1003 to the bottom of the anti-stator side q-axis recess 1004b. When dimensions Ta and Tb are set in this way, each thickness dimension is set so that Ta/Tb = 1.3 to 2.0.

Next, the operation when unevenness is provided on the counter-stator side peripheral surface 1004 as in this embodiment will be described. As a comparative example, a magnet 3000 having a shape as shown in FIG. 45 is assumed. The magnetic flux path of the magnet 3000 shown in FIG. 45 is assumed to be formed in an arc shape as in this embodiment. The shape of the stator side peripheral surface 1003 is also assumed to be the same. On the other hand, the counter-stator side q-axis recess 1004b is not provided on the q-axis side, which is the magnetic pole boundary, on the counter-stator side peripheral surface. In other words, the radial thickness of the magnet 3000 is assumed to be uniform. However, the radial thickness of the magnet 3000 is assumed to be thinner than the dimension Ta on the d-axis side, which is the magnetic pole center of the magnets 1001 and 1002, and thicker than the dimension Tb on the q-axis side, which is the magnetic pole boundary.

The surface magnetic flux density of a magnet unit composed of magnets 3000 formed in this manner is shown by the solid line in Figure 46. It can be seen that, compared to a magnet with a linear magnetic flux path along the radial direction, it is closer to a sine wave, but there is still room for improvement.

Here, by providing a q-axis recess 1004b on the anti-stator side as in magnets 1001 and 1002 shown in Figures 41 and 42, the surface magnetic flux density near the q-axis side, which is the magnetic pole boundary, can be reduced and made closer to a sine wave (shown by a dashed line) as shown by arrow Y1 in Figure 46. Also, by making the dimension Ta on the d-axis side, which is the magnetic pole center, larger than the dimension Tb on the q-axis side, which is the magnetic pole boundary, as in magnets 1001 and 1002 shown in Figure 41, the surface magnetic flux density near the d-axis side, which is the magnetic pole center, can be improved and made closer to a sine wave as shown by arrow Y2 in Figure 46.

The advantageous effects of variant example 2 configured as described above are explained below.

In the above-mentioned modified example 2, as shown in FIG. 42, the permeance coefficient Pc of the multiple magnets 1001, 1002 calculated based on the length of the magnetic flux path is increased in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. In other words, the length of the magnetic flux path of the magnet is adjusted by providing irregularities on the circumferential direction of the q-axis, which is the magnetic pole boundary, so that the permeance coefficient Pc is increased in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. This makes it easier to make the surface magnetic flux density of the magnet unit 1000 closer to a sine wave than when adjusting the direction or length of the easy magnetization axis.

As shown in Figure 42, on the anti-stator side circumferential surface 1004 of the multiple magnets 1001, 1002, on the q-axis side, which is the magnetic pole boundary, an engagement portion 2001 made of a soft magnetic material is provided that circumferentially engages with the anti-stator side q-axis recess 1004b of the anti-stator side circumferential surface 1004 and transmits and receives magnetic flux between the magnetic poles of different polarities of the magnets 1001, 1002. This makes it possible to suppress magnetic flux leakage between magnets of different polarities (between magnetic poles). In addition, the magnets 1001, 1002 can be appropriately fixed and prevented from rotating.

As shown in FIG. 42, the magnets 1001 and 1002 have easy magnetization axes oriented in an arc shape, and the center of the easy magnetization axes oriented in an arc shape is closer to the q-axis, which is the magnetic pole boundary, than the d-axis, which is the magnetic pole center, in the circumferential direction, and is set on the stator side circumferential surface 1003 of the magnets 1001 and 1002, or on the stator 60 side of the stator side circumferential surface 1003 of the magnets 1001 and 1002 in the radial direction. This makes it possible to suppress magnetic flux leakage between the magnet poles, improve the magnetic flux density, and make it closer to a sine wave. In addition, the average thickness dimension of each magnet 1001 and 1002 can be suppressed, and the amount of magnets used can be reduced.

As shown in Figure 42, by integrating the engaging portion 2001 with the magnet yoke 2000, it is possible to form the engaging portion 2001 with high precision, and the positioning precision can be improved. Furthermore, by integrating them, it is possible to improve the rigidity of the engaging portion 2001 and the magnet yoke 2000.

As shown in Figures 41 and 42, when the magnets 1001 and 1002 are provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary, the d-axis side end face 1005a has the same polarity and repels, so that a gap is more likely to be formed than the q-axis side end face 1005b. Therefore, the interval L20 between the adjacent engagement parts 2001 in the circumferential direction is set so that the gap between the d-axis side end faces 1005a of the magnets 1001 and 1002 is narrower than the gap between the q-axis side end faces 1005b. In other words, the interval L20 between the engagement parts 2001 that engage with the magnets 1001 and 1002 in the circumferential direction is adjusted so that the gap between the d-axis side end faces 1005a of the magnets 1001 and 1002 in the circumferential direction is narrower than the gap between the q-axis side end faces 1005b. This makes it possible to easily and accurately position the magnets 1001 and 1002. Furthermore, since the gap between the d-axis side end faces 1005a can be reduced, sudden changes in magnetic flux density caused by the gap can be reduced, and torque pulsation and cogging torque can be reduced.

As shown in Figure 42, the magnetization easy axis of magnets 1001, 1002 is oriented so that it is parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis. Therefore, it is possible to improve the magnetic flux density at the d-axis, which is the magnetic pole center, while making the surface magnetic flux density closer to a sinusoidal wave. In order to easily manufacture magnets 1001, 1002 having such a magnetic flux path, it is desirable to provide magnets 1001, 1002 between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent to the d-axis, which is the magnetic pole center.

On the other hand, when magnets 1001 and 1002 are provided between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent to the d-axis, which is the magnetic pole center, in order to improve the magnetic flux density on the d-axis, which is the magnetic pole center, while making the surface magnetic flux density closer to a sine wave, it is preferable to arrange magnets 1001 and 1002 in the circumferential direction with as small a gap as possible in the circumferential direction. Therefore, it is difficult to provide a rotation-stop member between magnets 1001 and 1002 that has sufficient width, i.e., strength.

Incidentally, if radially oriented magnets are arranged with no gaps in the circumferential direction, the magnetic flux density will change sharply near the q-axis, which is the magnetic pole boundary, as shown in Figure 9. For this reason, when radially oriented magnets are used, they are usually arranged with a certain amount of space between them.

Therefore, as shown in Figure 41, unevenness is formed on the anti-stator side peripheral surface 1004 of the magnets 1001, 1002, and the inner peripheral surface of the magnet yoke 2000 serving as the magnet fixing surface is provided with an engagement portion 2001 that has a shape corresponding to the anti-stator side peripheral surface 1004 and engages with the anti-stator side peripheral surface 1004. As a result, the anti-stator side peripheral surfaces 1004 of the magnets 1001, 1002 engage with the engagement portion 2001 in the circumferential direction, providing an excellent anti-rotation function.

In addition, the spacing between adjacent engaging portions 2001 in the circumferential direction is configured to become narrower the further radially outward. Therefore, when the rotating electric machine 10 rotates, part of the centrifugal force acting radially outward on the magnets 1001, 1002 is converted by the engaging portions 2001 into stress toward the d-axis side, which is the magnetic pole center, in the circumferential direction. In other words, a force is applied in the direction in which the magnets 1001, 1002 approach the d-axis side, which is the magnetic pole center, and the gap between the d-axis side end faces 1005a can be prevented from widening.

(Another example of Modification 2)
The magnet unit 1000 in the above-described modified example 2 may be modified as described below.

- In the above-mentioned variant 2, an outer rotor type rotor is used, but an inner rotor type rotor may also be used as shown in Fig. 47. The rotor will be described in detail below. The magnet unit 1000 shown in Fig. 47 has a plurality of magnets 1011, 1012 arranged in a circumferential direction, and a magnet yoke 2010 that holds these magnets 1011, 1012. The magnets 1011, 1012 are fixed to the outer peripheral surface of the magnet yoke 2010 via adhesive or the like.

As shown in Figure 47, each magnet 1011, 1012 is disposed between the d-axis, which is the magnetic pole center, and the q-axis, which is the magnetic pole boundary adjacent in the circumferential direction to the d-axis, which is the magnetic pole center, as in variant example 2. Magnets 1011 and 1012 are disposed symmetrically in the circumferential direction with the d-axis, which is the magnetic pole center, or the q-axis, which is the magnetic pole boundary, as the center. The magnet unit 1000 shown in Figure 47 is disposed in a circular ring shape by arranging magnets 1011, 1012 side by side in the circumferential direction.

As shown in FIG. 47, each magnet 1011, 1012 has a stator side circumferential surface 1003 (armature side circumferential surface) on the radially outer side (stator 60 side), a non-stator side circumferential surface 1004 (non-armature side circumferential surface) on the radially inner side (magnet yoke 2010 side), and a circumferential end surface 1005 which is a flat surface along the radial direction at both circumferential ends.

The stator side peripheral surface 1003 of each magnet 1011, 1012 is formed in an approximately arc shape along the circumferential direction. The radially innermost surface of the anti-stator side peripheral surface 1004 of each magnet 1011, 1012 is formed in an approximately arc shape along the circumferential direction and abuts against the outer circumferential surface of the magnet yoke 2010. In addition, the anti-stator side peripheral surface 1004 of each magnet 1011, 1012 has an anti-stator side q-axis recess 1004b at the end on the q-axis side, which is the magnetic pole boundary.

As in the second modification, the magnetization easy axis of magnets 1011 and 1012 is oriented so that its direction is parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axis. Specifically, in each of magnets 1001 and 1002, multiple magnetic flux paths are formed in an arc shape centered on a central point (orientation center) set on the q-axis, which is the magnetic pole boundary.

The magnet yoke 2010 is made of a soft magnetic material and is formed into a cylindrical shape. The outer peripheral surface of the magnet yoke 2010 is provided with engagement portions 2011 that protrude radially outward at regular intervals in the circumferential direction. The engagement portions 2011 are integrally formed with the magnet yoke 2010 and are made of a soft magnetic material.

This engagement portion 2011 is formed to fill the anti-stator side q-axis recess 1004b so as to be accommodated in the anti-stator side q-axis recess 1004b of each magnet 1011, 1012 and to match the shape of the anti-stator side q-axis recess 1004b.

Also, as in variant example 2, the spacing between adjacent engagement portions 2011 in the circumferential direction is set so that the gap between the d-axis side end faces 1005a of the magnets 1011 and 1012 is narrower than the gap between the q-axis side end faces 1005b.

Also, in Fig. 47, as in the second modification, the anti-stator q-axis recess 1004b is provided on the anti-stator side q-axis side of the anti-stator side circumferential surface 1004 so that the permeance coefficient Pc of the magnets 1011, 1012 increases in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. In other words, the thickness dimensions of the radial dimensions Ta and Tb of the magnets 1011, 1012 are set so that Ta/Tb = 1.3 to 2.0. In addition, in the inner rotor type rotor, as shown in Fig. 47, a cover member 2100 is provided to cover the stator side circumferential surface 1003 (outer surface) of the magnets 1011, 1012 to prevent the magnets 1011, 1012 from falling off.

Furthermore, compared to the outer rotor type, the inner rotor type rotor has less leakage flux between the magnet poles due to the geometric difference in magnet arrangement. For this reason, as shown in Figure 47, the q-axis side end face 1005b, which is the magnetic pole boundary of each magnet 1011, 1012, may be slightly separated from the q-axis. In other words, a predetermined circumferential gap may be provided on the q-axis side of the magnets 1011, 1012 with opposite polarity. This has the effect of reducing the amount of magnets without affecting torque reduction, and allows for magnet saving.

- In the above-mentioned modified example 2, the shape of the anti-stator side q-axis recess 1004b of magnets 1001, 1002 may be changed as desired. It may be concave in an arc shape, or may be formed in a stepped shape. Similarly, the side surface of the anti-stator side q-axis recess 1004b of magnets 1001, 1002 is an inclined surface, but may be changed as desired. For example, the side surface of the anti-stator side q-axis recess 1004b may be a curved surface, or may be a radial side surface and configured in a stepped shape.

- In the above variant 2, the direction and shape of the magnetic flux path may be changed. For example, as shown in FIG. 48, the magnetic easy axis in each magnet 1001, 1002 may be oriented in parallel so that its direction is linear and has a certain inclination angle with respect to the radial direction. In other words, multiple magnetic easy axes may be oriented in parallel so as to be oblique to the radial direction, and multiple magnetic flux paths may be formed in parallel along the magnetic easy axes so as to be oblique to the radial direction.

For example, as shown in FIG. 49, the magnetization easy axis of each magnet 1001, 1002 may be a linear magnetization easy axis having an inclination angle with respect to the radial direction, and the inclination angle may gradually change depending on the circumferential position. In this case, as shown in FIG. 49, the inclination angle of each linear magnetization easy axis may be set to become smaller with respect to the radial direction as it approaches the d-axis side, which is the magnetic pole boundary, in the circumferential direction, so that the linear magnetization easy axis becomes parallel to the d-axis, which is the magnetic pole center. In other words, the magnetization easy axis may be oriented radially around the d-axis, which is the magnetic pole center, and a magnetic flux path may be formed radially along the magnetization easy axis.

When changing the magnetic flux path in this way, it is desirable to form unevenness on the anti-stator side peripheral surface 1004 of the magnets 1001, 1002, as in the case of the modified example 2. In other words, it is desirable that the anti-stator side peripheral surface 1004 has a recess on the q-axis side, which is the magnetic pole boundary, or a protrusion on the d-axis side, which is the magnetic pole center, so that the permeance coefficient Pc of the magnets 1001, 1002 calculated based on the length of the magnetic flux path becomes larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center. Alternatively, it is desirable that the recess is provided on the q-axis side, which is the magnetic pole boundary, and the protrusion is provided on the d-axis side, which is the magnetic pole center.

- In both the outer rotor type and the inner rotor side of the above-mentioned variant example 2, the engagement portion 2001 may be provided separately from the magnet yoke 2000 and fixed to the magnet yoke 2000 by adhesive, screws, or the like. This allows the magnet yoke 2000 to be made of a material other than the engagement portion 2001, such as resin, making it possible to reduce weight. In this way, the magnet yoke of the present disclosure connects a magnet of a certain magnetic pole to a magnet of an adjacent magnetic pole, and the material is not limited to iron as a magnetic material.

- In the above-mentioned modified example 2, as shown in Fig. 50, a helical core 2200 formed into a cylindrical shape by spirally winding and stacking a long, thin, plate-like band member may be used as the magnet yoke. This can improve the yield of materials. It also makes it possible to easily change the axial length dimension of the magnet yoke.

In addition, the engagement portion 2001 may be integrally formed on the inner or outer peripheral surface of the helical core 2200. In this case, the helical core 2200 is also made of a soft magnetic material.

Here, the manufacturing method of the rotating motor 10, in particular the manufacturing method of the helical core 2200, will be explained based on Figure 51.

First, the method includes a bending step (step S101) in which a long, thin, plate-like strip material is bent to form a stacked cylindrical helical core 2200 by spirally winding it, and a fixing step (step S102) in which magnets 1001, 1002 are fixed to the helical core 2200.

Incidentally, when the engaging portion 2001 is integrally formed on the inner or outer peripheral surface of the helical core 2200, it is necessary to integrally form the engaging portion 2001 in advance so that it protrudes in the width direction of the plate member before performing the bending process step. However, when bending a linear plate member, distortion occurs due to deformation, and the shape of the engaging portion 2001 becomes distorted after processing, and it is possible that it will not properly abut against the magnets 1001, 1002.

Therefore, when the engagement portion 2001 is integrally formed on the inner or outer peripheral surface of the helical core 2200, as shown in FIG. 52(a), before the bending step is performed, the engagement portion 2001 is integrally formed in advance in the plate member 4001 so as to protrude in the width direction, and the engagement portion 2001 before processing is provided with unevenness 4002 that absorbs deformation due to bending. In other words, it has an inverse shape that incorporates the amount of deformation due to bending from the shape after bending into an annular shape. As a result, as shown in FIG. 52(b), when bending, the deformation due to bending is absorbed by the unevenness 4002, and the shape accuracy of the engagement portion 2001 can be stabilized. This makes it possible to reliably engage with the magnet and improve the positioning accuracy of the magnet.

- In the above variant example 2, it may be configured as follows.

A rotating electric machine (10) comprising a field element (20) having a magnet section (1000) including a plurality of magnetic poles whose polarities alternate in the circumferential direction, and an armature (60) disposed radially opposite the magnet section, wherein either the field element or the armature serves as a rotor,
The magnet section includes a plurality of magnets (1001, 1002) arranged in a circumferential direction, and a magnet yoke (2000) to which the plurality of magnets are fixed on an inner or outer peripheral surface,
Each of the magnets is provided between a d-axis and a q-axis adjacent to each other in the circumferential direction, and end faces are formed on the d-axis and the q-axis, respectively.
The peripheral surface (1004) of the magnet on the opposite armature side is provided with a concave portion (1004b) on the q-axis side, or a convex portion on the d-axis side, or a concave portion on the q-axis side and a convex portion on the d-axis side;
An engagement portion (2001) is provided on the q-axis side of the anti-armature side peripheral surface of the magnet, the engagement portion being engaged in a circumferential direction with the recess or the protrusion of the anti-armature side peripheral surface,
A rotating electric machine in which the spacing between adjacent engaging portions in the circumferential direction is set so that the gap between the d-axis side end faces of the magnets in the circumferential direction is narrower than the gap between the q-axis side end faces of the magnets.

- In the above embodiment and modified examples, the control unit and the method thereof described in the present disclosure may be realized by a dedicated computer provided by configuring a processor and memory programmed to execute one or more functions embodied in a computer program. Alternatively, the control unit and the method thereof described in the present disclosure may be realized by a dedicated computer provided by configuring a processor with one or more dedicated hardware logic circuits. Alternatively, the control unit and the method thereof described in the present disclosure may be realized by one or more dedicated computers configured by a combination of a processor and memory programmed to execute one or more functions and a processor configured with one or more hardware logic circuits. In addition, the computer program may be stored in a computer-readable non-transient tangible recording medium as instructions executed by the computer.

The disclosure in this specification is not limited to the exemplified embodiments. The disclosure includes the exemplified embodiments and modifications based thereon by those skilled in the art. For example, the disclosure is not limited to the combination of parts and/or elements shown in the embodiments. The disclosure can be implemented by various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes the omission of parts and/or elements of the embodiments. The disclosure includes the substitution or combination of parts and/or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some disclosed technical scopes are indicated by the description of the claims, and should be interpreted as including all modifications within the meaning and scope equivalent to the description of the claims.

Although the present disclosure has been described with reference to the embodiment, it is understood that the present disclosure is not limited to the embodiment or structure. The present disclosure also encompasses various modifications and modifications within the scope of equivalents. In addition, various combinations and forms, as well as other combinations and forms including only one element, more than one, or less than one, are also within the scope and concept of the present disclosure.

Claims (8)

A rotating electric machine (10) comprising a field element (20) having a magnet section (1000) including a plurality of magnetic poles whose polarities alternate in the circumferential direction, and an armature (60) disposed radially opposite the magnet section, wherein either the field element or the armature serves as a rotor,
The magnet section includes a plurality of magnets (1001, 1002) arranged in a circumferential direction, and a magnet yoke (2000) to which the plurality of magnets are fixed on an inner or outer peripheral surface,
The magnetization easy axes of the plurality of magnets are oriented so as to be parallel to the d-axis, which is the magnetic pole center, on the side of the d-axis, which is the magnetic pole center, compared to the side of the q-axis, which is the magnetic pole boundary, and a magnetic flux path is formed along the magnetization easy axes,
a recess (1004b) is provided on the anti-armature side peripheral surface (1004) of the plurality of magnets on the q-axis side, which is the magnetic pole boundary, so that a permeance coefficient of the plurality of magnets, which is calculated based on the length of the magnetic flux path, becomes larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center ;
On the anti-armature side circumferential surfaces of the plurality of magnets, an engagement portion (2001) is provided on the q-axis side, which is a magnetic pole boundary, that circumferentially engages with the recessed portion of the anti-armature side circumferential surface and is made of a soft magnetic material for transmitting and receiving magnetic flux between magnetic poles of different polarities of the plurality of magnets;
A rotating electric machine, wherein the recess provided in the magnet is provided so as to divide a contour line of a permeance coefficient where the permeance coefficient is the same in the magnet. The magnets have easy axes of magnetization oriented in an arc shape,
2. The rotating electric machine of claim 1, wherein the center of orientation of the arc-shaped easy magnetization axis is on the q-axis side, which is the magnetic pole boundary in the circumferential direction, and is set on the armature side peripheral surface (1003) of the plurality of magnets, or on the armature side of the armature side peripheral surface of the plurality of magnets in the radial direction. the magnetization easy axes of the magnets are linear magnetization easy axes having an inclination angle with respect to a radial direction, and the inclination angle gradually changes depending on a position in the circumferential direction;
2. A rotating electric machine as described in claim 1, wherein the inclination angle of each of the linear magnetization easy axes is set to become smaller relative to the radial direction in the circumferential direction as the linear magnetization easy axes approach from the q-axis side, which is the magnetic pole boundary, to the d-axis side, which is the magnetic pole center, so that the linear magnetization easy axes become parallel to the d-axis, which is the magnetic pole center. A rotating electric machine (10) comprising a field element (20) having a magnet section (1000) including a plurality of magnetic poles whose polarities alternate in the circumferential direction, and an armature (60) disposed radially opposite the magnet section, wherein either the field element or the armature serves as a rotor,
The magnet section includes a plurality of magnets (1001, 1002) arranged in a circumferential direction, and a magnet yoke (2000) to which the plurality of magnets are fixed on an inner or outer peripheral surface,
the magnetization easy axes of the magnets are oriented in parallel so that their directions are linear and have a constant inclination angle with respect to the radial direction, and a magnetic flux path is formed along the magnetization easy axes;
a concave portion (1004b) is provided on the anti-armature side peripheral surface (1004) of the plurality of magnets on the q-axis side which is the magnetic pole boundary, or a convex portion is provided on the d-axis side which is the magnetic pole center, so that the permeance coefficient of the plurality of magnets calculated based on the length of the magnetic flux path becomes larger in the circumferential direction from the q-axis which is the magnetic pole boundary to the d-axis which is the magnetic pole center, or a concave portion is provided on the q-axis side which is the magnetic pole boundary and a convex portion is provided on the d-axis side which is the magnetic pole center,
A rotating electric machine in which an engagement portion (2001) made of a soft magnetic material is provided on the anti-armature side circumferential surface of the multiple magnets, on the q-axis side which is the magnetic pole boundary, which circumferentially engages with the concave or convex portion of the anti-armature side circumferential surface and transmits and receives magnetic flux between magnetic poles of different polarities of the multiple magnets. The rotating electric machine according to any one of claims 1 to 4, wherein the engagement portion is integrally formed with the magnet yoke so as to protrude from the inner or outer peripheral surface of the magnet yoke. The rotating electric machine according to any one of claims 1 to 5, wherein the magnet yoke is a helical core (2200) formed into a cylindrical shape by spirally winding and stacking a thin, elongated strip member. Each of the magnets (1001, 1002) is provided between the d-axis, which is the center of the magnetic pole adjacent to each other in the circumferential direction, and the q-axis, which is the magnetic pole boundary, and end faces (1005) are formed at the d-axis, which is the magnetic pole boundary, and at the q-axis, which is the magnetic pole boundary, respectively.
A rotating electric motor as described in any one of claims 1 to 6, wherein the spacing between adjacent engaging portions in the circumferential direction is set so that the gap between the d-axis side end faces (1005a) of the magnets in the circumferential direction is narrower than the gap between the q-axis side end faces (1005b). A method for manufacturing a rotating electric machine (10) comprising: a field element (20) having a magnet portion (1000) including a plurality of magnetic poles whose polarities alternate in a circumferential direction; and an armature (60) disposed radially opposite the magnet portion, the method comprising the steps of:
The magnet portion includes a plurality of magnets (1001, 1002) arranged in a circumferential direction,
the magnetization easy axes of the plurality of magnets are oriented so as to be parallel to the d-axis on the side of the d-axis which is the magnetic pole center, compared to the side of the q-axis which is the magnetic pole boundary, or the magnetization easy axes are oriented in parallel so as to be linear at a certain inclination angle with respect to the radial direction, and a magnetic flux path is formed along the magnetization easy axes;
a recess (1004b) is provided on the anti-armature side peripheral surface (1004) on the q-axis side, which is the magnetic pole boundary, so that a permeance coefficient of the plurality of magnets, which is calculated based on the length of the magnetic flux path, becomes larger in the circumferential direction from the q-axis, which is the magnetic pole boundary, to the d-axis, which is the magnetic pole center ;
In a manufacturing method of a rotating electric machine, an engaging portion (2001) made of a soft magnetic material is provided on a q-axis side of a magnetic pole boundary on a peripheral surface of a counter-armature side of the magnet, the engaging portion (2001) engaging with the recessed portion of the peripheral surface of the counter-armature side in a circumferential direction and for transmitting and receiving magnetic flux between magnetic poles of different polarities of the plurality of magnets,
a bending step of bending an elongated, straight plate member (4001) to form a cylindrical magnet yoke (2200) by spirally winding an elongated, thin, plate-like band member;
and a fixing step of fixing the plurality of magnets to the magnet yoke,
Before the bending step is performed, the plate member is integrally formed with the engagement portion so as to protrude in the width direction thereof, and the engagement portion is provided with an unevenness (4002) that absorbs deformation due to the bending process;
A method for manufacturing a rotating electric machine, wherein the recess provided in the magnet is provided so as to divide a contour line of a permeance coefficient where the permeance coefficient is the same in the magnet.

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