Control device integrated type rotating electric machine

Abstract

The present application does not need to set a hole for loading a brush holder in the central part of the control module, and can reduce the radial dimension of the control module. In the control device integrated type rotating electric machine (1) including a driving part (29) and an inverter assembly (30), a brush holder (16) holding an electric brush (16a) is detachably installed on either one of a rear bracket (5) side of the inverter assembly (30) and the inverter assembly (30) side of the rear bracket (5).

Description

TECHNICAL FIELD

[0001] The present application relates to a control device integrated rotary electric machine. BACKGROUND

[0002] According to the prior art, in order to install the brush holder from the rear side after the brush holder is installed in the radial center portion of the control substrate, a hole is formed in the center portion of the control substrate, and a hole portion is formed in the center portion of the housing in which the control substrate is housed, so that the brush holder can be attached and detached from the rear side.

[0003] PRIOR ART DOCUMENT

[0004] PATENT DOCUMENT

[0005] Patent Document 1: Japanese Patent Laid-Open No. 2019-205216 SUMMARY

[0006] According to the prior art described above, in order to load the brush holder from the rear side after the brush holder is installed in the inverter drive portion, since the space for loading the brush holder is arranged on the side of the central axis of the drive portion, a hole needs to be provided in the center portion of the control substrate, and components cannot be loaded in the center portion of the control substrate. In order to load the components on the control substrate while avoiding the hole, the housing in which the control substrate is housed also needs to be enlarged in the radial direction, so that the radial dimension of the inverter as a whole is increased, and there is a technical problem that the radial dimension of the control module in the control device integrated rotary electric machine is increased.

[0007] The present application discloses a technology that is completed in view of such a practical situation, and aims to reduce the radial dimension of the control module in the control device integrated rotary electric machine.

[0008] The control device integrated rotary electric machine disclosed in the present application includes a drive portion including a rotor having a field winding, a stator, and a rear bracket, and an inverter assembly provided on the rear side of the drive portion and having a field module, a heat sink, and a control module. The field module supplies a field current to the field winding via a collector ring provided on the outer periphery of the rotation axis of the rotor and an electric brush in sliding contact with the collector ring. The heat sink is thermally connected to the field module. The control module is provided on the rear side of the heat sink. The control module controls the field current by controlling the field module. A brush holder that holds the electric brush is detachably installed on either one of the rear bracket side of the inverter assembly and the inverter assembly side of the rear bracket.

[0009] In the control device integrated rotary electric machine of the present application, the brush holder holding the brush is detachably attached to either one of the rear bracket side of the inverter assembly and the inverter assembly side of the rear bracket, so that a hole for the insertion of the brush holder does not need to be provided in the central portion of the control module, and the radial dimension of the control module can be reduced. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1A is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 1 of the present application.

[0011] Figure 1B is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 1 of the present application. Figure 1A is an enlarged view of the portion A in

[0012] Figure 2 is a perspective view of the main portion before the brush holder is attached, as viewed from the front side, which is an example of Embodiment 1 of the present application.

[0013] is a perspective view of the main portion before the brush holder is attached, as viewed from the front side, which is an example of Embodiment 2 of the present application.

[0014] Figure 3B is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 2 of the present application. Figure 3A is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 2 of the present application.

[0015] Figure 4 is a perspective view of the main portion before the brush holder is attached, as viewed from the front side, which is an example of Embodiment 3 of the present application.

[0016] Figure 5 is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 3 of the present application.

[0017] Figure 6 is a perspective view of the main portion before the brush holder is attached, as viewed from the front side, which is an example of Embodiment 4 of the present application.

[0018] Figure 7 is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 4 of the present application.

[0019] Figure 8 is a perspective view of the main portion before the brush holder is attached, as viewed from the front side, which is an example of Embodiment 5 of the present application.

[0020] Figure 9FIG. 5 is a longitudinal sectional view illustrating a main part before the brush holder is mounted, which illustrates Embodiment 5 of the present application.

[0021] Figure 10 FIG. 6 is a perspective view of a main part viewed from the front side, which illustrates Embodiment 6 of the present application.

[0022] Figure 11 FIG. 7 is a perspective view of a main part viewed from the front side, which illustrates Embodiment 7 of the present application.

[0023] Figure 12 FIG. 8 is a perspective view of a main part viewed from the front side, which illustrates Embodiment 8 of the present application.

[0024] Figure 13 FIG. 9 is a perspective view of a main part viewed from the front side, which illustrates Embodiment 9 of the present application.

[0025] Figure 14 FIG. 10 is a front view of a main part viewed from the front side, which illustrates Embodiment 9 of the present application.

[0026] Figure 15 FIG. 11 is a perspective view of a brush holder viewed from the front side, which illustrates a part of a main part, which illustrates Embodiment 11 of the present application.

[0027] Figure 16 FIG. 12 is a longitudinal sectional view of a main part, which illustrates Embodiment 10 of the present application.

[0028] Figure 17 FIG. 13 is a perspective view of an oil baffle viewed from the front side, which illustrates a part of a main part, which illustrates Embodiment 11 of the present application.

[0029] Figure 18 FIG. 14 is a perspective view of an oil baffle viewed from the front side, which illustrates a part of a main part, which illustrates Embodiment 11 of the present application.

[0030] Figure 19 FIG. 15 is an assembly explanatory view of a main part, which illustrates Embodiment 11 of the present application, and is a perspective view of a state in which an oil baffle is fitted to a first step of a brush holder viewed from the front side.

[0031] Figure 20 FIG. 16 is a sectional view illustrating a state in which protrusion of a brush is suppressed by an oil baffle, which illustrates Embodiment 11 of the present application.

[0032] Figure 21is a drawing illustrating Embodiment 11 of the present application, which is an assembly view of a main portion, and is a perspective view of a state in which the oil shield is embedded into the brush holder second step from the front side.

[0033] Figure 22 is a drawing illustrating Embodiment 11 of the present application, which is a sectional view illustrating a state in which the brush protrusion is not suppressed by the oil shield.

[0034] Figure 23 is a drawing illustrating Embodiment 12 of the present application, which is a perspective view of a main portion from the front side.

[0035] Figure 24 is a drawing illustrating Embodiment 13 of the present application, which is a perspective view of the oil shield as a part of a main portion from the front side.

[0036] (Symbol explanation)

[0037] 1 control device integrated type rotary electric machine; 2 rotor; 2a field winding; 2b field core; 3 stator; 3a three-phase stator winding; 4 front bracket; 5 rear bracket; 5a rear bracket rear hole; 6 magnetic pole position detection sensor; 6a sensor stator; 6b sensor rotor; 7 bearing; 8 bearing; 9 rectifier module; 10 field module; 11 rotating shaft; 12 pulley; 13 collector ring; 14 housing; 14a protrusion; 15 cover; 16 brush holder; 16a brush; 16b brush holder positioning protrusion; 16c brush holder waterproof protrusion; 16d limiting protrusion; 16e hole; 17 control module; 18 connecting plate; 20 fan; 21 fan; 22 screw; 23 oil shield; 23a oil shield protrusion; 23b oil shield flange portion; 23c limiting recess; 23d oil shield release portion; 23e brush retreat hole; 24 terminal-to-terminal insulation wall; 28 heat sink; 28a heat sink protrusion; 28ac surface contact portion; 28b heat sink positioning recess; 28c through hole; 29 driving portion; 30 inverter assembly; 31a first brush holder assembly; 31ah outer frame; 31b second brush holder assembly; 31bh outer frame; 31c second terminal; 32 spring; 33 first terminal. DETAILED DESCRIPTION

[0038] Hereinafter, based on the drawings, the embodiments of the control device integrated type rotary electric machine of the present application will be described. In addition, the present application is not limited to the following description, and can be appropriately changed within the scope of the gist of the present application. In the drawings shown below, in order to facilitate understanding, the scale of each member is sometimes different from the actual, and in addition, the illustration of the structure irrelevant to the characteristics of the present application is omitted.

[0039] Hereinafter, the embodiments of the present application will be described with reference to the drawings.

[0040] Embodiment 1

[0041] Figure 1A is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 1 of the present application. Figure 1B is a longitudinal sectional view of a control device integrated rotary electric machine, which is an example of Embodiment 1 of the present application. Figure 1A is an enlarged view of the portion A enclosed by the dotted line in FIG. 8. Figure 2 is a perspective view of a main portion before the brush holder is attached, which is an example of Embodiment 1 of the present application.

[0042] In Figure 1A and Figure 1B , a control device integrated rotary electric machine 1 is composed of a rotor 2 in which an excitation winding 2a is wound around an excitation core 2b, a stator 3 in which a three-phase stator winding 3a is wound, a front bracket 4 and a rear bracket 5 that house the rotor 2 and the stator 3, a magnetic pole position detection sensor 6 that detects the rotation state of the rotor 2, a rectifier module 9 that supplies electric power to the excitation winding 2a, an excitation module 10, and a control module 17 that controls them.

[0043] The control device integrated rotary electric machine 1 is composed of a driving portion 29 and an inverter assembly 30 as large structural members.

[0044] With regard to the detailed structure of the driving portion 29 and the inverter assembly 30, first, the driving portion 29 will be described, and then the inverter assembly 30 will be described.

[0045] First, the driving portion 29 will be described.

[0046] The rotor 2 includes a rotation shaft 11, both ends of which are rotatably supported to the front bracket 4 and the rear bracket 5 via bearings 7, 8, respectively. One end of the rotation shaft 11 protrudes to the front side from the front bracket 4, and a pulley 12 is attached to the front end thereof. The pulley 12 is used to transmit torque bidirectionally with respect to an internal combustion engine, which is not shown. The pulley 12 is connected to the internal combustion engine via a belt, which is not shown.

[0047] The excitation winding 2a of the rotor 2 has a collector ring 13 for supplying an excitation current, and the collector ring 13 protrudes to the rear side from the rear bracket 5. A brush 16a that is in sliding contact with the collector ring 13 for energizing the excitation winding 2a is built into the brush holder 16 in such a manner that it can move in the direction of the collector ring 13.

[0048] Fans 20, 21 for generating cooling air are attached to the end faces of the excitation core 2b of the rotor 2.

[0049] The magnetic pole position detection sensor 6 is disposed coaxially with the rotating shaft 11 between the collector ring 13 and the bearing 8 on the rear side of the rear bracket 5, and detects the magnetic pole position of the rotating shaft 11, i.e., the rotor 2. The magnetic pole position detection sensor 6 is composed of a sensor stator 6a and a sensor rotor 6b, and the sensor rotor 6b, which is only a core, is disposed on the rotating shaft 11, which rotates freely, on the inner side of the sensor stator 6a.

[0050] Next, the inverter assembly 30 will be described.

[0051] The inverter assembly 30 is composed of the rectifier module 9, which is a power module, the excitation module 10, which is composed of switching elements and peripheral circuits for controlling the excitation current, the heat sink 28 for cooling, the housing 14, which includes terminals for connecting to the terminals of the power systems of the respective modules, and the control module 17, which is composed of control circuits for controlling the rectifier module 9 and the excitation module 10.

[0052] The sensor stator 6a of the magnetic pole position detection sensor 6 is attached to the heat sink 28, and the signal wiring is connected to the control module 17.

[0053] The connection to the outside is not illustrated, and the signal terminal connector and the battery connection terminal are electrically connected to the housing 14 and the control module 17.

[0054] As illustrated in Figure 1A , Figure 1B and Figure 2 , the brush holder 16 is disposed on the drive side, i.e., the front side, of the inverter assembly 30. Furthermore, as illustrated in Figure 1A , Figure 1B and Figure 2 , the oil baffle 23 is attached to the brush holder 16 for the purpose of temporary holding during assembly of the brush 16a, waterproofing of the brush 16a and the collector ring 13, and prevention of intrusion of foreign matter from the outside, and is fixed to the inverter assembly 30 via the heat sink 18 by means of screws or the like in a state in which the oil baffle 23 is attached to the brush holder 16.

[0055] The length and position in the axial direction of the cylindrical oil baffle 23 are as illustrated in Figure 1A and Figure 1BAs illustrated, the end surface of the front side is not in contact with the sensor rotor 6b, and the end surface of the rear side is not in contact with the housing 14. Further, the end surface of the axial rear side of the cylindrical oil baffle 23 is not in contact with the peripheral wall of the central hole of the heat sink 28, and is positioned further forward than the axial rear side end of the central hole of the heat sink 28. The space directly below the cylindrical oil baffle 23 communicates with the external space of the control device-integrated rotary electric machine 1 via the space between the heat sink 28 and the rear bracket 5. Salt water, water, or the like splashed on the outer peripheral surface of the cylindrical oil baffle 23 drips from the space directly below the cylindrical oil baffle 23 to the external space of the control device-integrated rotary electric machine 1 via the space between the heat sink 28 and the rear bracket 5.

[0056] After the inverter assembly is assembled, the inverter assembly 30 is fixed to the boss provided on the rear side of the rear bracket 5 of the drive section 29 on which the connection plate 18 is mounted by the screw 22.

[0057] Then, in order to protect the inverter assembly 30 mounted on the outer side of the rear side of the rear bracket 5 from splashing of salt water or the like, insulation of the inverter assembly 30 from engine peripheral components, and the like, the cover 15 is mounted to the housing 14 by screws not shown, and the inverter assembly 30 is built in and protected.

[0058] As described above, according to the embodiment 1, in the case where the brush holder 16 is loaded from the rear side by fixing the brush holder 16 to the housing 14 from the front side, in order to fit the brush holder 16 to the control module 17 and the housing 14, a space or a hole for fitting the brush holder 16 is required in the axial direction, but by fixing the brush holder 16 to the housing 14 from the front side, it is possible to configure without providing a space and a hole for fitting the brush holder 16 in the housing 14 and the control module 17, and it is possible to arrange the substrate mounting member and the substrate circuit in the center of the substrate, it is possible to reduce the size of the entire substrate, and it is also possible to make the housing 14 correspondingly smaller, and thus, it is possible to suppress the radial size of the entire inverter assembly.

[0059] Embodiment 2

[0060] The embodiment 2 of the present application will be described.

[0061] Figure 3A is a front view of a rotary electric machine according to the embodiment 2 of the present application. Figure 3B is a drawing illustrating the embodiment 2 of the present application, which is a partial cross-sectional view of a main part in Figure 3A .

[0062] However, in Figure 3A and Figure 3B , the same symbols are attached to elements similar to those of the structure of the embodiment 1.

[0063] Since the basic structure is the same as that of Embodiment 1, the description is omitted.

[0064] The brush holder 16 is divided into a brush holder fitting member 31a (the brush built-in side) as a first brush holder fitting member built in the power brush 16a and a brush holder fitting member 31b (the control module side) as a second brush holder fitting member fixed to the substrate in the control module 17 via the terminal and by soldering or the like, and the brush holder fitting member 31a and the brush holder fitting member 31b are fixed to each other by a coupling member such as a screw.

[0065] The second brush holder fitting member 31b is fixed to the control module 17 by soldering or the like and is threadedly fastened to the heat sink 28. The first brush holder fitting member 31a is fixed to the heat sink 28 and the second brush holder fitting member 31b by a detachable mounting member such as a screw in a manner that the first brush holder fitting member 31a can be detached from the heat sink 28.

[0066] The outer frame 31ah of the first brush holder fitting member 31a and the outer frame 31bh of the second brush holder fitting member 31b are each molded from a resin having good thermal conductivity and electrical insulation.

[0067] As described above, according to Embodiment 2, the brush holder 16 is divided into the first brush holder fitting member 31a built in the power brush 16a and the second brush holder fitting member 31b as the substrate connecting portion, and the first brush holder fitting member 31a built in the power brush 16a is configured in a structure that can be detached from the heat sink 28 by a screw or the like, so that when the power brush 16a makes an abnormal noise or wears, the first brush holder fitting member 31a in which the power brush 16a is built in can be easily replaced, and thus productivity and maintainability can be improved.

[0068] Embodiment 3

[0069] Embodiment 3 of the present application will be described.

[0070] Figure 4 is a front perspective view showing the rear bracket and the brush holder of Embodiment 3 of the present application, Figure 5 is a cross-sectional view showing the rear bracket and the brush holder of Embodiment 3 of the present application after installation.

[0071] The oil baffle 23 is embedded in the brush holder 16 on the rotation shaft side of the brush holder 16, which plays a role of controlling the protruding state of the power brush 16a or preventing foreign matter from intruding from the outside.

[0072] An oil baffle protruding portion 23a is provided on the front side of the oil baffle 23, and is formed in a structure in which the oil baffle protruding portion 23a is fitted to the rear bracket rear hole 5a as an installation portion provided on the center axis side of the rear bracket 5. In this case, the concave-convex relationship of the oil baffle 23 and the rear bracket 5 can also be reversed.

[0073] As described above, according to Embodiment 3, since the oil baffle 23, which is a cylindrical member that is freely rotatably fitted in the rear side end of the rotating shaft 11 in the inside thereof concentrically and whose inner circumferential surface surrounds the collector ring 13 with a gap, is fitted into the hole of the rear bracket 5 and the hole of the heat sink 28 in the rear side thereof, moisture that enters the control device-integrated rotating electric machine is less likely to enter the brush periphery, so that a decrease in electrical characteristics due to splashing can be prevented, and furthermore, the oil baffle 23 is fitted to the heat sink 28 that is freely attached and detached in the rear side of the rear bracket 5 with the housing 14 interposed therebetween, so that the accuracy of the radial position of the center axis of the rear bracket 5 and the center axis of the cylindrical oil baffle 23 is stable, and thus dimensional stability can be achieved in both the extending direction of the center axes and the radial direction.

[0074] Embodiment 4

[0075] Embodiment 4 of the present application will be described.

[0076] Figure 6 is a front perspective view showing the heat sink and the brush holder of Embodiment 4 of the present application, Figure 7 is a cross-sectional view showing the heat sink and the brush holder after installation of Embodiment 4 of the present application.

[0077] Since the basic structure is the same as that of Embodiment 3, the description will be omitted.

[0078] The oil baffle 23 is provided with an oil baffle flange portion 23b that is in surface contact with a front side end surface face contact portion 28ac of a heat sink protruding portion 28a provided on the front side of the heat sink 28, and is in a structure in which the heat sink protruding portion 28a is in contact with the oil baffle flange portion 23b when the oil baffle 23 is fixed from the front side.

[0079] In addition, by the contact, the oil baffle 23 that is positioned in the axial direction is indirectly attached to the attachment portion of the heat sink 28 via the brush holder 16, for example, by a screw or the like, or is directly attached to the attachment portion of the heat sink 28 without passing through the brush holder 16, or is attached to the central portion of the heat sink 28 by fitting into a through-hole 28c that is provided concentrically with the oil baffle 23 and the rotating shaft 11 as the attachment portion.

[0080] As described above, according to Embodiment 4, since the oil shield flange portion 23b, which is provided protruding at the front side of the outer peripheral surface of the oil shield 23, is in surface contact with the face contact portion 28ac of the end surface of the axial protruding portion of the heat sink 28 at the front side in the axial direction, the positional deviation of the oil shield 23 in the drawing height direction (axial direction) is alleviated, the positional deviation of the oil shield 23 in the drawing height direction (axial direction) is reduced, the positional accuracy of the oil shield 23 and the brush holder 16 in the drawing height direction (axial direction) is stabilized, and thus the axial and radial dimensional stability of the assembled assembly of the heat sink 28, the oil shield 23, and the brush holder 16 can be achieved.

[0081] Embodiment 5

[0082] Embodiment 5 of the present application will be described.

[0083] Figure 8 is a front perspective view showing the heat sink and the brush holder of Embodiment 5 of the present application, Figure 9 is a cross-sectional view showing the heat sink and the brush holder of Embodiment 5 of the present application before installation.

[0084] Since the basic structure is the same as that of Embodiment 3, the description is omitted.

[0085] The brush holder 16 is provided with one or more brush holder positioning protrusions 16b with respect to the heat sink 28, and the heat sink 28 is provided with one or more heat sink positioning recesses 28b into which the brush holder positioning protrusions 16b are fitted. The structure is such that the brush holder positioning protrusions 16b are fitted into the heat sink positioning recesses 28b.

[0086] In this case, the concave-convex relationship of the brush holder 16 and the heat sink 28 can also be reversed.

[0087] As described above, according to Embodiment 5, the relative position of the brush holder 16 and the heat sink 28 is stabilized by the concave-convex fitting by the heat sink positioning recesses 28b and the brush holder positioning protrusions 16b, and the accuracy of the relative position of the inverter assembly 30 and the brush holder 16 is stabilized via the heat sink 28, and thus the radial and axial dimensional stability of the structure including the inverter assembly 30 and the brush holder 16 can be achieved.

[0088] Embodiment 6

[0089] Embodiment 6 of the present application will be described.

[0090] Figure 10 is a front perspective view showing the brush holder of Embodiment 6 of the present application.

[0091] The first brush holder assembly (brush built-in side) 31a and the second brush holder assembly (control module side) 31b are fixed to each other by a pair of screws or the like as the first terminals 33, 33, one of which is at "+" potential and the other of which is at "-" potential. The potentials of the pair of first terminals 33, 33 are different, and the pair of first terminals 33, 33 are disposed on both sides in the horizontal direction of the first brush holder assembly 31a as illustrated above. Figure 10 A terminal-to-terminal insulation wall 24 for securing a creepage distance is provided as illustrated above. In addition, the terminal-to-terminal insulation wall 24 is integrally injection-molded with the outer frame 31bh of the second brush holder assembly (control module connection side) 31b.

[0092] In addition, as the power supply path, current flows from the excitation module 10 via the control module 17, then via the second terminal 31c of the second brush holder assembly (control module connection side) 31b, and through the first terminals 33, 33 to the brush 16a built in the first brush holder assembly (brush built-in side) 31a, and current flows from the brush 16a to the driving section 29.

[0093] As described above, according to Embodiment 6, the possibility of salt water or the like falling on the pair of fixed connection members can be reduced, and since a creepage distance can be secured between the pair of fixed connection members at the time of splashing, a decrease in electrical reliability due to electrical corrosion or the like at the time of splashing can be prevented, and an improvement in electrical reliability of the product can be achieved.

[0094] Embodiment 7

[0095] Embodiment 7 of the present application will be described.

[0096] Figure 11 is a front perspective view of a brush holder according to Embodiment 7 of the present application.

[0097] Since the basic structure is the same as that of Embodiment 6, the description will be omitted.

[0098] The first brush holder assembly 31a and the second brush holder assembly 31b are integrally coupled to each other by a pair of screws or the like as the first terminals 33, 33, one of which is at "+" potential and the other of which is at "-" potential. The pair of first terminals 33, 33 are electrically connected to the brush 16a, and current flowing from the excitation module 10 via the control module 17 to a part of the second terminal 31c built in the second brush holder assembly 31b flows to the brush 16a via the pair of first terminals 33, 33. As illustrated above, Figure 7 In the case where the long side direction of the brush 16a (see, for example, FIG. 1) is the vertical direction, the pair of first terminals 33, 33 are disposed on both sides in the horizontal direction of the first brush holder assembly 31a as illustrated above.

[0099] As described above, according to Embodiment 7, in the case where the first brush holder fitting 31a built in the power supply brush 16a is arranged with the long side direction of the power supply brush 16a (the long side direction of the first brush holder fitting 31a built in the power supply brush 16a) as the vertical direction, by arranging the first terminals 33, 33 different in electric potential on both sides in the horizontal direction of the first brush holder fitting 31a, the influence of splashing between different electric potentials in an environment where splashing is likely to occur can be mitigated, a decrease in electric reliability due to galvanic corrosion or the like between the first terminals 33, 33 can be prevented, and an improvement in electric reliability of the product can be achieved.

[0100] Embodiment 8

[0101] Embodiment 8 of the present application will be described.

[0102] Figure 12 is a front perspective view showing the brush holder of Embodiment 8 of the present application.

[0103] Since the basic structure is the same as that of Embodiment 6, the description will be omitted.

[0104] In a state where the second brush holder fitting 31b having the second terminal 31c connected to the control module 17 is fixed to the heat sink 28 by a fixing member such as a screw, an adhesive, or the like not shown, the first brush holder fitting 31a built in the power supply brush 16a is fixed to the second brush holder fitting 31b having the second terminal 31c connected to the control module 17 only by the pair of first terminals 33, the first brush holder fitting 31a built in the power supply brush 16a does not have a fixing portion to the heat sink 28, and in a state where the oil baffle protrusion portion 23a of the oil baffle 23 into which the first brush holder fitting 31a is fitted and fixed is in contact with the heat sink 28 in the height direction as shown in Embodiment 4, the first brush holder fitting 31a built in the power supply brush 16a is fixed to the heat sink 28 via the oil baffle 23 and the second brush holder fitting 31b. Figure 6 、 Figure 7 In a state where the oil baffle protrusion portion 23a of the oil baffle 23 into which the first brush holder fitting 31a is fitted and fixed is in contact with the heat sink 28 in the height direction as shown in Embodiment 4, and in a state where the first brush holder fitting 31a is not directly fixed to the heat sink 28 by a fixing member such as a screw or the like, the first brush holder fitting 31a is fixed to the heat sink 28 via the oil baffle 23 and the second brush holder fitting 31b.

[0105] As described above, according to Embodiment 8, in a state where the second brush holder fitting 31b is fixed to the heat sink 28 by a fixing member such as a screw, an adhesive, or the like, and the first brush holder fitting 31a is not directly fixed to the heat sink 28 but is indirectly fixed to the heat sink 28 via the first terminal 33 serving as a fixing member to the second brush holder fitting 31b and the oil baffle flange portion 23b of the oil baffle. By not adopting a structure in which the first brush holder fitting 31a built in the power supply brush 16a is directly fixed to the heat sink 28 but adopting a structure in which the first brush holder fitting 31a is indirectly fixed to the heat sink 28, the number of screws can be reduced, and a reduction in the cost of the product can be achieved. Furthermore, by reducing the number of live fixing screws, a decrease in electric reliability due to galvanic corrosion or the like can be prevented.

[0106] Embodiment 9

[0107] Embodiment 9 of the present application will be described.

[0108] Figure 13 is a front perspective view showing a case of Embodiment 9 of the present application, Figure 14 is a front view showing a case and a brush grip of Embodiment 9 of the present application.

[0109] On the front side of the case 14 in the inverter assembly 30, a protruding portion 14a protruding convexly toward the brush grip 16 side is provided integrally with the case 14 (see also Figure 1A and Figure 1B ). The width of the protruding portion 14a is formed larger than the width of the brush grip 16. In a state where the control device-integrated rotary motor is loaded, the protruding portion 14a is located on the top side of the brush grip 16 and covers the brush grip 16, and is convex on the side opposite to the brush grip 16. The convex portion shape of the protruding portion 14a is formed in a circular arc or a "H" character shape.

[0110] As described above, according to Embodiment 9, the salt water or the like flowing down from the top side along the case 14, the heat sink 28, and the like contacts the wall provided to the case 14 to fall in the ground direction along the wall, and therefore, by making the width in the horizontal direction of the protruding portion 14a larger than the width in the horizontal direction of the brush grip 16, it is possible to reduce the possibility of splashing on the brush grip 16, and furthermore, by being formed in a circular arc or a "H" character shape to have good water separation property at the time of splashing, it is possible to prevent the electrical reliability under the influence of the electric corrosion or the like.

[0111] Embodiment 10

[0112] Embodiment 10 of the present application will be described.

[0113] Figure 15 is a rear perspective view showing a brush grip of Embodiment 10 of the present application, Figure 16 is a sectional view showing a case and a brush grip of Embodiment 10 of the present application.

[0114] Since the basic structure is the same as Embodiment 9, the description will be omitted.

[0115] A convex brush grip waterproof protruding portion 16c is provided on the case 14 side of the brush grip 16.

[0116] The above brush grip waterproof protruding portion 16c forms a labyrinth structure with the protruding portion 14a of the case 14 on the front side as a part of the wall shown in Embodiment 9 (see Figure 16 ).

[0117] As described above, according to Embodiment 10, due to the fact that the front side protrusion 14a as a part of the housing 14 and the brush grip waterproof protrusion 16c are configured to have a difference in height, the possibility of moisture adhering to the electrified portion of the brush grip 16 and the like can be reduced when the salt water, water, or the like sprayed from the top side flows down, and thus the improvement of the electrical reliability can be achieved.

[0118] Embodiment 11

[0119] Embodiment 11 of the present application will be described.

[0120] Figure 17 is a rear perspective view of a brush grip of Embodiment 11 of the present application, Figure 18 is a rear perspective view of an oil retaining ring of Embodiment 11 of the present application, Figure 19 is a rear perspective view of an oil retaining ring embedded into a first stage step of a brush grip of Embodiment 11 of the present application, Figure 20 is a cross-sectional view of a brush protrusion suppressed by an oil retaining ring of Embodiment 11 of the present application, Figure 21 is a rear perspective view of an oil retaining ring embedded into a second stage step of a brush grip of Embodiment 11 of the present application, Figure 22 is a cross-sectional view of an armature protrusion not suppressed by an oil retaining ring of Embodiment 11 of the present application.

[0121] The oil retaining ring 23 is a structure in which a groove located in the axial direction of the brush grip 16 is embedded into the guide, and the oil retaining ring 23 has two or more limiting recesses 23c with respect to the brush grip. The limiting recesses 23c of the oil retaining ring 23 are arranged in parallel in the axial direction, and the brush grip 16 has one or more limiting protrusions 16d. The limiting protrusions 16d of the brush grip 16 are configured to be embedded into the limiting recesses 23c of the oil retaining ring 23. That is, the symbol 16d is a limiting protrusion of the brush grip 16 with respect to the oil retaining ring 23.

[0122] For example, in a case where the oil retaining ring 23 is provided with two limiting recesses 23c, 23c and the brush grip 16 is provided with one limiting protrusion 16d, if the brush grip 16 is fixed, when the brush grip 16 is installed by moving along the axial direction in the oil retaining ring 23, the first stage limiting recess 23c of the oil retaining ring 23 is embedded into the limiting protrusion 16d of the brush grip 16, and the oil retaining ring 23 is temporarily fixed.

[0123] By further pressing the oil retaining ring 23 from the temporarily fixed position, the oil retaining ring 23 is moved to a structure in which the second stage limiting recess 23c of the oil retaining ring 23 is embedded into the limiting protrusion 16d of the brush grip 16. The brush 16a built in the brush grip 16 is always urged toward the center axis side by the spring 32 or the like.

[0124] The concave-convex relationship of the brush grip 16 and the oil retaining ring 23 can also be reversed.

[0125] Since the brush 16a is always pressed toward the center axis side by the spring 32 or the like, the protruding state of the brush 16a toward the center axis side changes depending on the positional relationship between the oil baffle 23 and the brush retreat hole 23e provided in the oil baffle in the circumferential direction.

[0126] In addition, in Figure 17 , the symbol 31c is a second terminal that becomes a connection portion of the second brush holder assembly (control module connection side) 31b and the control module 17 (refer to Figure 1A ).

[0127] As described above, according to the embodiment 11, the oil baffle can be temporarily positioned in stages in the brush holder, and the protruding state of the brush housed in the brush holder is limited when the oil baffle moves in stages, for example, the brush is in contact with the oil baffle without protruding in the first stage of positioning, and the protruding state of the brush is limited depending on the positional relationship with the hole provided in the oil baffle in the second stage of positioning.

[0128] Embodiment 12

[0129] The embodiment 12 of the present application will be described.

[0130] Figure 23 is a rear perspective view showing the oil baffle and the brush holder of the embodiment 12 of the present application.

[0131] The brush holder 16 has a hole 16e provided in the axial direction for pressing the brush 16a when assembled.

[0132] When the brush 16a and the oil baffle 23 are fitted into the brush holder 16, first, in order to press the brush 16a from the center axis side, pressing is applied by a jig such as a pin, which becomes a state of being housed in the hole 16e for the brush holder assembly.

[0133] In the state where the pin or the like is housed in the hole 16e for the brush holder assembly, the oil baffle 23 is fitted into the brush holder 16, and the state of the brush 16a is limited by performing the multi-stage positioning as in the embodiment 11.

[0134] In the state where the position of the brush 16a is limited by the oil baffle 23, by pulling out the jig such as a pin housed in the hole 16e for the brush holder assembly, an assembled structure of the brush holder 16 and the oil baffle 23 in a state where the brush 16a does not protrude is obtained.

[0135] As described above, according to Embodiment 12, since the brush 16a can be constructed in the brush holder in the state where the brush 16a does not protrude, by restricting the multi-stage position posture of the oil retaining ring at the time of press-fitting into the inverter, press-fitting into the driving section in this state, the protrusion of the brush 16a at the time of press-fitting can be controlled by only the height relationship (displacement of the relative position in the height direction) between the first brush holder fitting 31a built in the brush 16a and the oil retaining ring 23 press-fitted into the first brush holder fitting 31a, and the protrusion state of the brush 16a can be controlled without a jig or the like for suppressing the protrusion state of the brush, and the protrusion state of the brush can be controlled without using a member other than the oil retaining ring.

[0136] Embodiment 13

[0137] Embodiment 13 of the present application will be described.

[0138] Figure 24 is a rear perspective view showing the oil retaining ring of Embodiment 13 of the present application.

[0139] The oil retaining ring 23 is formed with an oil retaining ring release portion 23d on the rear side in the axial direction as exemplified, and is open on the rear side in the axial direction. Figure 24

[0140] In addition, in the corresponding views of the other embodiments 1 to 12 described above, the oil retaining ring release portion can be clearly formed according to the drawing, but the reference numeral 23d is not shown.

[0141] As described above, according to Embodiment 13, the brush 16a built in the brush holder 16 is in contact with the collector ring 13 in the state where the brush 16a is always pressurized by the spring 32 at the time of operation of the rotary electric machine.

[0142] The main component of the brush 16a is copper powder, and when the rotor 2 rotates, a small amount of powder is generated from the brush 16a due to sliding in the pressurized state with the collector ring, but if the powder is accumulated between different potential portions in the vicinity of the brush 16a, an electric short circuit or the like can occur, and since the oil retaining ring release portion 23d is formed on the rear side in the axial direction of the oil retaining ring 23, the rear side in the axial direction of the oil retaining ring 23 is open, and in the case where the brush powder is generated, the powder is scattered into the space or the like on the housing 14 side, and thus, the electric short circuit between the different potential portions in the vicinity of the brush 16a is less likely to occur, and thus, the powder accumulation of the brush can be prevented, and thus, the electric reliability can be improved.

[0143] Hereinafter, technical feature points of each of the embodiments described above will be listed.

[0144] Feature Item 1-1:

[0145] ​A control device integrated type rotating electric machine includes: a rotor freely rotatably held, the rotor having a field winding, a field core covering the field winding, and a collector ring for supplying a field current to the field winding; a stator having an armature winding, the stator being provided with centrifugal fans on both sides of the rotor and being disposed around the rotor; a pulley for transmitting torque between the rotor and an internal combustion engine; a bearing for holding the rotor so as to be freely rotatable; a front housing and a rear housing holding the bearing and the stator from both sides of the rotor shaft; an inverter assembly composed of a power module in which switching elements for energizing the stator are mounted on a lead frame for electric wiring and molded with a resin material, a field module in which switching elements for supplying a field current are mounted on a lead frame for electric wiring and molded with a resin material, a control module having a control circuit for controlling the switching elements, and a heat sink for cooling the power module and the field module; a rotation sensor composed of a sensor rotor fixed to the rotor shaft of the rotor and a rotation detection portion for detecting a rotation position, for detecting the rotation position of the rotor; and a cover having a brush holder holding a brush for supplying a current to the collector ring and protecting the inverter assembly, characterized in that the inverter assembly has no hole in the central portion of the control module and the housing, and the brush holder is mounted to the heat sink from the front side by screws or the like.

[0146] Feature 1-2:

[0147] The inverter assembly is characterized in that the brush holder is divided into a brush holder assembly in which the power brush is built in and a brush holder assembly fixed to the substrate via a terminal by soldering or the like, each of the brush holder assemblies is fixed by screws or the like, the brush holder assembly fixed to the control module by soldering or the like is fixed together with the heat sink and the housing or the like, and the brush holder assembly in which the power brush is built in is detachably fixed to the heat sink by a detachable member such as a screw.

[0148] Feature 1-3:

[0149] The inverter assembly is characterized in that an oil baffle is built into the brush holder, a convex portion provided in the oil baffle is fitted into a concave portion provided in the rear bracket, and the concave-convex relationship can be reversed.

[0150] Feature 1-4:

[0151] The inverter assembly is characterized in that a flange portion is provided in the oil baffle, the heat sink has a protruding portion in contact with the oil baffle, and the heat sink is in surface contact with the oil baffle.

[0152] Feature 1-5:

[0153] The inverter assembly is characterized in that one or more protrusions for positioning are provided on the brush holder, and the heat sink has a recess for the protrusions of the brush holder to be inserted into.

[0154] Features 1-6:

[0155] The inverter assembly is characterized in that the connecting portions of the brush holder assembly with the power brushes built-in and the brush holder assembly fixed to the substrate via the terminal by soldering or the like have walls for insulating between the connecting portions.

[0156] Features 1-7:

[0157] The inverter assembly is characterized in that the connecting portions of the brush holder assembly with the power brushes built-in and the brush holder assembly fixed to the substrate via the terminal by soldering or the like have walls for insulating between the connecting portions.

[0158] Features 1-8:

[0159] The inverter assembly is characterized in that the brush holder is fixed only by the fixing of the detachable member such as a screw at the connecting portions of the brush holder assembly with the power brushes built-in and the brush holder assembly fixed to the substrate via the terminal by soldering or the like and the pressing in the height direction of the brush holder assembly fixed to the bracket via the oil baffle.

[0160] Features 1-9:

[0161] The inverter assembly is characterized in that it has a protrusion projecting toward the front side of the housing, the width of which is larger than the width of the brush holder, and the control device integrated with the rotary motor is arranged on the top side when loaded on a vehicle, and the protrusion is composed of a circular arc or a chevron shape.

[0162] Features 1-10:

[0163] The inverter assembly is characterized in that it has a protrusion on one side of the housing of the brush holder, and the protrusion forms a labyrinth structure with the wall provided on one side of the housing.

[0164] Features 1-11:

[0165] An inverter assembly is characterized in that the oil baffle has two or more recesses arranged parallel to the axial direction, the brush holder has one or more protrusions, the protrusions of the brush holder are inserted into the recesses of the oil baffle, the oil baffle is positioned in multiple stages, and at this time, the power brushes built-in the brush holder assembly are in a position relationship of being in contact with or not in contact with the oil baffle, and the protruding state can be limited according to the position of the oil baffle.

[0166] Features 1-12:

[0167] The inverter assembly is characterized in that the brush holder has a hole for housing a component used when assembling the brush.

[0168] Features 1-13:

[0169] The inverter assembly is characterized in that the oil baffle is open in the axial direction.

[0170] Hereinafter, more conceptual technical feature points of each of the aforementioned embodiments are listed.

[0171] Feature 2-1:

[0172] A control device integrated rotary electric machine includes a drive section including a rotor having a field winding, a stator, and a rear bracket, and an inverter assembly provided on a rear side of the drive section and having a field module, a heat sink, and a control module, the field module supplying a field current to the field winding via a collector ring provided on an outer periphery of a rotation shaft of the rotor and a brush in sliding contact with the collector ring, the heat sink being thermally connected to the field module, the control module being provided at a position further to the rear side than the heat sink, the field current being controlled by controlling the field module, characterized in that a brush holder that holds the brush is detachably attached to either one of the rear bracket side of the inverter assembly and the inverter assembly side of the rear bracket.

[0173] Feature 2-2:

[0174] The control device integrated rotary electric machine is characterized in that the brush holder is integrally combined by a fitting member by the first brush holder assembly for the brush built-in and the second brush holder assembly detachably attached.

[0175] Feature 2-3:

[0176] The control device integrated rotary electric machine is characterized in that an oil baffle in a cylindrical shape around the rotation shaft is fitted on a side where the brush of the brush holder protrudes, and the oil baffle is detachably fitted to either one of an attachment portion of the rear bracket side of the inverter assembly and the inverter side of the rear bracket.

[0177] Feature 2-4:

[0178] The control device integrated rotary electric machine is characterized in that an oil baffle in a cylindrical shape around the rotation shaft is fitted on a side where the brush of the brush holder protrudes, and the oil baffle is detachably fitted to an attachment portion of the rear bracket side of the inverter assembly, characterized in that a flange portion is provided on the oil baffle, and a protruding portion in surface contact with the flange portion is provided on the heat sink.

[0179] Features 2-5:

[0180] The control device integrated type rotary electric machine is characterized in that a brush holder limiting protrusion is provided in either of the brush holder and the heat sink, and a brush holder limiting recess is provided in the other, and the brush holder limiting protrusion is fitted in the brush holder limiting recess.

[0181] Features 2-6:

[0182] The control device integrated type rotary electric machine is characterized in that an inter-terminal insulation wall is provided in the brush holder, and the inter-terminal insulation wall insulates terminals that are connected to the control module from each other.

[0183] Features 2-7:

[0184] The control device integrated type rotary electric machine is characterized in that a pair of connection portions of the brush holder that are at different potentials from the control module are provided separately on both sides of a first brush holder fitting member in which the brush is built, with the long side direction of the brush as a reference.

[0185] Features 2-8:

[0186] The control device integrated type rotary electric machine is characterized in that the brush holder is composed of a first brush holder fitting member in which the brush is built and a second brush holder fitting member that is detachably attached, the first brush holder fitting member is combined with an oil baffle that is cylindrical and surrounds the rotation shaft, and the second brush holder fitting member is detachably attached to either of the rear bracket side of the inverter assembly and the inverter assembly side of the rear bracket.

[0187] Features 2-9:

[0188] The control device integrated type rotary electric machine is characterized in that a convex protrusion is provided on the top side of the brush holder and on the top side of the brush holder that prevents splashing.

[0189] Features 2-10:

[0190] The control device integrated type rotary electric machine is characterized in that a brush holder waterproof protrusion is provided on the control module side of the brush holder, a front side protrusion is provided on the housing that is provided toward the rear side of the brush holder and extends toward the front side, and the brush holder waterproof protrusion and the front side protrusion form a labyrinth structure.

[0191] Features 2-11:

[0192] The control device integrated type rotary electric machine is characterized in that a stopper protrusion is provided on one of the corresponding portion of the brush holder and the corresponding portion of the oil baffle to the outer circumferential surface of the oil baffle, and a stopper recess is provided on the other, and the brush holder and the oil baffle are positioned in stages by the stopper protrusion and the stopper recess.

[0193] Feature 2-12:

[0194] The control device integrated type rotary electric machine is characterized in that a hole for insertion and extraction of a jig that limits the position of the moving direction of the brush is provided on the opposite surface of the brush holder opposite to the outer circumferential surface of the oil baffle.

[0195] Feature 2-13:

[0196] The control device integrated type rotary electric machine is characterized in that the oil baffle is open in the axial direction.

[0197] In addition, in each drawing, the same symbols represent the same or equivalent parts.

[0198] In addition, various exemplary embodiments and examples are described in the present application, but the various features, modes, and functions described in one or more embodiments are not limited to the application of a specific embodiment, and can be applied to the embodiments alone or in various combinations.

[0199] Therefore, countless modifications that are not exemplified are assumed within the technical scope disclosed in the present application. For example, cases where at least one constituent element is modified, added, or omitted, and cases where at least one constituent element is extracted and combined with the constituent elements of other embodiments are included.

[0200] In addition, each embodiment can be appropriately combined, modified, or omitted.

Claims

1. A control device integrated rotary electric machine comprising: a drive unit including a rotor having a rotary shaft and a field winding, and a stator having an armature winding, both ends of the rotary shaft being supported to a front bracket and a rear bracket so as to be freely rotatable via a front-side bearing and a rear-side bearing, respectively; a collector ring provided to an outer periphery of a portion of the rotary shaft which protrudes toward a rear side from the rear bracket; a pole position detection sensor configured coaxially with the rotary shaft between the collector ring and the rear-side bearing on the rear side of the rear bracket, and composed of a sensor stator and a sensor rotor provided to the rotary shaft, the pole position detection sensor detecting a pole position of the rotor; a brush holder in which an electric brush in sliding contact with the collector ring is built so as to be movable in a direction of the collector ring; and an inverter assembly provided on a rear side of the drive unit, and having a field module which supplies a field current to the field winding via the collector ring and the electric brush, a heat sink which is thermally connected to the field module, and a control module which is provided at a position on the rear side of the heat sink, and which controls the field current by controlling the field module, characterized in that: the brush holder is composed of a first brush holder assembly in which the electric brush is built, and a second brush holder assembly which is fixed to the first brush holder assembly, the second brush holder assembly is fixed to the control module and is threadedly fastened to the heat sink, the first brush holder assembly is fixed to the heat sink and the second brush holder assembly by a detachable mount in a manner that the first brush holder assembly is detachable, the first brush holder assembly and the second brush holder assembly are fixed to each other by a pair of first terminals which are at different potentials from each other, the second brush holder assembly has a second terminal which is connected to the control module, as a power supply path, current flows from the field module via the control module, then via the second terminal of the second brush holder assembly, and through the first terminals to the electric brush built in the first brush holder assembly, and current flows from the electric brush to the drive unit.

2. The control device integrated rotary electric machine according to claim 1, characterized in that: the first brush holder assembly is provided on a front side of the heat sink.

3. The control device integrated rotary electric machine according to claim 1 or 2, characterized in that: a cylindrical oil baffle which surrounds the rotary shaft is fitted on a side of the brush holder from which the electric brush protrudes, the oil baffle is detachably fitted to a mounting portion of either one of the rear bracket side of the inverter assembly and the inverter side of the rear bracket.

4. The control device integrated rotary electric machine according to claim 1 or 2, characterized in that: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ In the control device integrated rotary electric machine, a side of the brush holder, on which the brush of the brush holder protrudes, is fitted with a cylindrical oil baffle that surrounds the rotary shaft, the oil baffle being detachably fitted to a mounting portion on one side of the rear support of the inverter assembly, A flange portion is provided on the oil baffle, A protruding portion that makes surface contact with the flange portion is provided on the heat sink.

5. The control device integrated rotary electric machine according to claim 4, wherein A brush holder positioning protruding portion is provided on either one of the brush holder and the heat sink, and a brush holder positioning recessed portion is provided on the other one, the brush holder positioning protruding portion being fitted into the brush holder positioning recessed portion.

6. The control device integrated rotary electric machine according to claim 1 or 2, wherein An inter-terminal insulation wall is provided on the brush holder, the inter-terminal insulation wall insulating the pair of first terminals of the brush holder from each other.

7. The control device integrated rotary electric machine according to claim 1 or 2, wherein The pair of first terminals of the brush holder are disposed on both sides of the brush holder with the long side direction of the brush as a reference.

8. The control device integrated rotary electric machine according to claim 1, wherein The first brush holder assembly is combined with a cylindrical oil baffle that surrounds the rotary shaft.

9. The control device integrated rotary electric machine according to claim 1 or 2, wherein A protruding portion that is positioned more on a top side than the brush holder and prevents the brush holder from being splashed is provided on one side of the inverter assembly.

10. The control device integrated rotary electric machine according to claim 1 or 2, wherein A brush holder waterproof protruding portion is provided on one side of the control module of the brush holder, A protruding portion that is provided on a position more on a rear side than the brush holder and extends toward a front side is provided, The brush holder waterproof protruding portion and the protruding portion form a labyrinth structure.

11. The control device integrated rotary electric machine according to claim 3, wherein A limiting protruding portion is provided on one of the corresponding portion of the brush holder and the corresponding portion of the oil baffle, and a limiting recessed portion is provided on the other one, the brush holder and the oil baffle being limited in stages by the limiting protruding portion and the limiting recessed portion.

12. The control device integrated rotary electric machine according to claim 3, wherein A hole for insertion and extraction of a jig that limits the position of the movement direction of the brush is provided on a surface of the brush holder that is opposite to the outer peripheral surface of the oil baffle.

13. The control device integrated rotary electric machine according to claim 3, wherein The oil baffle is open in the axial direction.

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