Granted Patent B2

US 11,863,023 · App. 16/914,570 · Granted Jan 2, 2024

Inventor: Yuki Takahashi (Kariya, JP)

Assignee: DENSO CORPORATION

H02K1/2786H02K5/04H02K7/003H02K7/08

Abstract

Claims (63)

1. A rotating electrical machine comprising:

a magnetic field-producing unit equipped with a magnet unit including a plurality of magnetic poles whose magnetic polarities are arranged alternately in a circumferential direction; and

an armature which includes a multi-phase armature winding,

wherein one of the magnetic field-producing unit and the armature is engineered as a rotor whose rotating shaft is retained by a bearing to be rotatable,

the armature winding has conductor portions which are arranged at a given interval away from each other in the circumferential direction and face the magnet unit,

the armature has conductor-to-conductor members arranged between the conductor portions in the circumferential direction, the conductor-to-conductor members being made from a magnetic material which meets a relation of Wt×Bs≤Wm×Br where Wt is a width of the conductor-to-conductor members in the circumferential direction within one magnetic pole of the plurality of magnetic poles, Bs is a saturation magnetic flux density of the conductor-to-conductor members, Wm is a width equivalent to one magnetic pole of the plurality of magnetic poles in the circumferential direction, and Br is a remanent flux density in the magnet unit, and

the magnet unit is magnetically oriented to have an easy axis of magnetization, in a region located closer to a d-axis that is a center of a magnetic pole of the plurality of magnetic poles, aligned to be more parallel to the d-axis than that in a region located closer to a q-axis that is a boundary between magnetic poles.

2. The rotating electrical machine as set forth in claim 1 , wherein the magnet unit is magnetically oriented to create an arc-shaped magnet-produced magnetic path in which the easy axis of magnetization is directed parallel or near parallel to the d-axis in the region closer to the d-axis and also directed perpendicular or near perpendicular to the q-axis in the region closer to the q-axis.

3. The rotating electrical machine as set forth in claim 1 ,

wherein the magnet unit includes a plurality of permanent magnets which are arranged in the circumferential direction,

wherein each of the permanent magnets is shaped to have an armature-side outer peripheral surface facing the armature and a q-axis-side outer peripheral surface facing the q-axis in the circumferential direction, the armature-side outer peripheral surface and the q-axis-side outer peripheral surface functioning as magnetic flux input and output surfaces that are magnetic flux acting surfaces into and from which magnetic flux flows, and

wherein a magnetic path is created to connect between the armature-side outer peripheral surface and the q-axis-side outer peripheral surface.

4. The rotating electrical machine as set forth in claim 1 ,

wherein the magnet unit is made of a ring-shaped magnet that is a circular ring-shaped permanent magnet, and

wherein the ring-shaped magnet has defined therein an arc-shaped magnet-produced magnetic path in which a magnetic orientation is directed in a radial direction on the d-axis of each magnetic pole of the plurality of magnetic poles and a magnetic orientation is directed in the circumferential direction on the q-axis between the magnetic poles.

5. The rotating electrical machine as set forth in claim 1 ,

wherein the magnetic field-producing unit has a skew structure in which the magnetic poles of the magnet unit are arranged in an axial direction of the rotating shaft and are offset from each other in the circumferential direction, and

wherein a skew amount from a magnetic pole center line of each of the magnetic poles of the magnet unit in a first circumferential direction is identical with that in a second circumferential direction opposite the first circumferential direction.

6. The rotating electrical machine as set forth in claim 1 ,

wherein the armature has a skew structure in which conductor locations of the armature winding for each phase in an axial direction of the rotating shaft are offset in the circumferential direction, and

wherein a skew amount of each of phase windings of the armature winding in a first circumferential direction from an energized phase center line extending in the axial direction is identical with that in a second circumferential direction opposite the first circumferential direction.

7. The rotating electrical machine as set forth in claim 1 ,

wherein the rotating shaft is retained by a plurality of the bearings to be rotatable, and

wherein each of the bearings is offset from an axial center of the rotor to one of opposed ends thereof in an axial direction.

8. The rotating electrical machine as set forth in claim 7 ,

wherein the rotating electrical machine is engineered as an outer-rotor type rotating electrical machine in which the rotor is arranged on a radially outer side,

wherein the magnetic field-producing unit includes a magnet holder which retains the magnet unit, and

wherein the magnet holder has an overhang which extends in a radial direction of the magnetic field-producing unit, the overhang being equipped with a contact avoider which extends in the axial direction and avoids physical contact with the armature.

9. The rotating electrical machine as set forth in claim 7 ,

wherein the rotating electrical machine is engineered as an outer-rotor type rotating electrical machine in which the rotor is arranged on a radially outer side,

wherein the rotating electrical machine further comprises:

a bearing retainer which surrounds the rotating shaft and retains the bearings,

a housing disposed to surround the magnetic field-producing unit and the armature, and

an armature holder which is disposed radially inside the armature to retain the armature,

wherein the bearing retainer is secured to a first end of the housing which is opposed to a second end of the housing through the magnetic field-producing unit in the axial direction, and

wherein the second end of the housing and the armature holder are joined together.

10. The rotating electrical machine as set forth in claim 7 , wherein the bearings have a non-conductive grease.

11. The rotating electrical machine as set forth in claim 1 ,

wherein the armature includes a ring-shaped base member which is disposed integrally with the armature winding and is secured to an armature holder, and

wherein the armature winding is covered with a molding material along with the base member.

12. The rotating electrical machine as set forth in claim 11 ,

wherein the base member is arranged radially inside or outside the armature winding on an opposite side of the armature winding to the magnet unit, and

wherein the base member has a surface which faces the armature winding and on which concavities and convexities are formed successively in at least one of the circumferential direction and an axial direction to define recesses filled with the molding material.

13. The rotating electrical machine as set forth in claim 11 ,

wherein the base member is an armature core made of a plurality of steel plates stacked on each other in an axial direction of the rotating shaft, and

wherein each of the steel plates has an end which faces the armature winding and has a cross-section tapered in a thickness-wise direction thereof.

14. The rotating electrical machine as set forth in claim 11 ,

wherein the base member is an armature core made from a conductive material, and

wherein an insulating layer is disposed between the armature winding and the armature core.

15. The rotating electrical machine as set forth in claim 11 , wherein the base member has holes which extend in an axial direction of the rotating shaft and are filled with the molding material.

16. The rotating electrical machine as set forth in claim 11 , wherein the armature winding is covered with the molding material except portions in axial and radial directions thereof.

17. The rotating electrical machine as set forth in claim 11 , wherein the armature holder is made from carbon fiber reinforced plastic.

18. The rotating electrical machine as set forth in claim 1 , further comprising

a power converter which includes switches and is electrically connected to the armature winding, and

a controller which controls on-off operations of the switches to energize the armature winding,

wherein the controller sets a switching frequency for the switches in a low current range in which a lower electrical current flows through the armature winding to be higher than that in a high current range which is higher in electrical current than the low current range and in which a higher electrical current flows through the armature winding.

19. A rotating electrical machine comprising:

a magnetic field-producing unit equipped with a magnet unit including a plurality of magnetic poles whose magnetic polarities are arranged alternately in a circumferential direction; and

an armature which includes a multi-phase armature winding, the armature winding being of a cylindrical shape having a longitudinal center line,

wherein one of the magnetic field-producing unit and the armature is engineered as a rotor whose rotating shaft is retained by bearings to be rotatable,

the armature includes a ring-shaped base member which is disposed integrally with the armature winding and secured to an armature holder, the base member being of a cylindrical shape coaxial with the longitudinal center line of the armature winding and having a peripheral surface in contact with a peripheral surface of the armature winding, the peripheral surfaces of the base member and the armature winding likewise being cylindrical in shape and coaxial with the longitudinal center line,

the armature winding is covered with a molding material along with the base member, and

the armature winding is comprised of a coated conductor in which a surface of a conductor body is covered with a coating.

Assignments (1)

Priority Claims (10)

Continuity (2)