Inverter-integrated motor

Abstract

An inverter-integrated motor has an inverter unit at an end portion in a direction of a rotational shaft of the motor, the motor has an electrically conductive member electrically connected to the inverter unit, the inverter unit has a control member connected to the electrically conductive member to control driving of the motor, the electrically conductive member is disposed extending along the rotational shaft in a state of being adjacent to the rotational shaft from the end portion of the motor, and the control member is disposed more radially outward than the electrically conductive member.

Description

Technical Field

[0001] This invention relates to an inverter-integrated motor. Background Technology

[0002] An inverter-integrated motor is known as a motor in which the motor and inverter are combined into one unit.

[0003] JP2015-089298A discloses an inverter-integrated motor in which the inverter is located near the motor and the motor housing and inverter housing are arranged adjacent to each other in the axial direction. Summary of the Invention

[0004] In existing technology, the motor coil wires (busbars) that electrically connect the motor and the inverter are located on the outer periphery of the inverter, while the inverter's components are located on the inner side of the busbars. This structure increases the limitations on the size of the inverter's components. For example, if the inverter is designed to achieve high output and high voltage withstand capability for the motor, the components become larger. However, the presence of the busbars prevents the components from expanding radially; instead, they expand along the rotational axis. Therefore, a problem arises: achieving high output for the motor makes miniaturization along the rotational axis difficult.

[0005] The present invention was proposed in view of this problem, and its purpose is to provide an inverter-integrated motor that can achieve high output while also miniaturizing in the direction of rotation.

[0006] One embodiment of the present invention applies to an inverter-integrated motor having an inverter unit at one end in the direction of the motor's rotation axis. The motor has a conductive component electrically connected to the inverter unit. The inverter unit has a control component connected to the conductive component to control the drive of the motor. The conductive component extends along the rotation axis from the end of the motor in a state adjacent to the rotation axis, and the control component is configured to be radially outward than the conductive component.

[0007] The effects of the invention

[0008] According to the present invention, the conductive component connecting the motor and the inverter is arranged adjacent to the rotating shaft, and the control component of the inverter unit is arranged radially outward, thereby enabling the control component to expand radially outward. For example, even if the size of the control component is increased to achieve high output and high voltage withstand capability for the motor, the expansion is radial, thereby suppressing expansion in the rotational axis direction. Thus, while achieving high output for the motor, miniaturization in the rotational axis direction is also possible. Attached Figure Description

[0009] Figure 1This is an explanatory diagram of an inverter-integrated motor according to an embodiment of the present invention.

[0010] Figure 2 yes Figure 1 Section II-II.

[0011] Figure 3 This is an explanatory diagram of an inverter-integrated motor, a variation of this embodiment.

[0012] Figure 4 These are explanatory diagrams of other variations of the inverter-integrated motor.

[0013] Figure 5 This is an illustration of another variation of an inverter-integrated motor.

[0014] Figure 6 This is a cross-sectional view of another variation of the inverter-integrated motor. Detailed Implementation

[0015] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings and other figures.

[0016] Figure 1 and Figure 2 This is an explanatory diagram of an inverter-integrated motor 1 according to an embodiment of the present invention. Figure 1 It is a cross-sectional view along the axis of rotation. Figure 2 yes Figure 1 Section II-II.

[0017] The inverter-integrated motor 1 consists of a motor 3 and an inverter unit 2 disposed at the axial end (coil end) of the motor 3. The inverter-integrated motor 1 is mounted in a vehicle, for example, and drives the vehicle by rotating the motor 3.

[0018] The motor 3 has a rotating shaft 11, as well as a rotor and stator (not shown). The motor 3 is powered by the inverter unit 2 to rotate the rotor, thereby driving the rotating shaft 11 to rotate.

[0019] At the axial end of the motor 3, the busbar 30 that electrically connects the inverter unit 2 and the motor 3 is erected and extended axially.

[0020] Inverter unit 2 converts the DC power supplied by the battery (not shown) into AC power and supplies it to motor 3, thereby driving motor 3. In addition, when the vehicle decelerates, the regenerative power of motor 3 is used to charge the battery. Inverter unit 2 consists of housing 20 and control components (smoothing capacitor 21, power component 22, control board 23, current sensor 24, etc.) housed in housing 20.

[0021] The housing 20 of the inverter unit 2 has a cylindrical shape whose outer periphery follows the outer periphery of the motor 3. The rotation shaft 11 of the motor 3 passes through the inner periphery of the housing 20. Therefore, the housing 20 is formed in an annular shape (donut shape).

[0022] The smoothing capacitor 21 smooths out the noise and pulsation of the DC current supplied to the power component 22. The smoothing capacitor 21 is configured to house a plurality of capacitor elements, such as film capacitors.

[0023] The power unit 22 converts the DC power supplied from the battery into three-phase high-frequency power (U, V, W), which is then supplied to the motor 3 via the bus 30. The power unit 22 is configured to have multiple switching elements corresponding to each of the three phases. The power unit 22 includes a cooler such as a cooling fan for cooling the switching elements.

[0024] The power assembly 22 has a motor-side bus 221 and a capacitor-side bus 222. The motor-side bus 221 is connected to the bus 30 of the motor 3 by bolting, welding, etc., and outputs AC power to the bus 30. The capacitor-side bus 222 is connected to the terminals of the smooth capacitor 21 by bolting, welding, etc. The capacitor-side bus 222 is also connected to a battery (not shown) to supply DC power.

[0025] The control board 23 receives instructions from a vehicle control unit (not shown) to control the operation of the power component 22 and adjust the power supplied to the motor 3. The control board 23 is electrically connected to the power component 22 and the current sensor 24. The control board 23 acquires the current value of the bus 30 obtained by the current sensor 24 and outputs control signals to the switching elements of the power component 22. A microcomputer and various electrical components are mounted on the control board 23.

[0026] The busbar 30 has a current sensor 24, which acquires the current value supplied to the motor 3 and outputs a signal corresponding to the acquired current value to the control board 23. The current sensor 24 is, for example, composed of a Hall element that detects the current flowing in the busbar 30.

[0027] Next, the configuration of the control components of the inverter-integrated motor 1 will be explained.

[0028] Current inverter-integrated motors have a busbar extending axially from near the outer periphery of the motor end, and a current sensor is located on this busbar. Regarding this structure, for example, in order to achieve high output of the motor, the control components become larger in order to achieve high voltage withstand and high output of the inverter unit. However, due to the busbar and current sensor located on the outer periphery, the radial expansion of the control components is limited, and they must be expanded in the direction of the rotation axis.

[0029] Therefore, currently, in order to achieve high output of the motor, it is unavoidable to increase the size of the inverter-integrated motor in the direction of rotation axis.

[0030] On the other hand, in this embodiment, according to the structure described below, the motor 3 is configured to achieve high output while also being miniaturized in the direction of rotation axis.

[0031] like Figure 1 As shown, a busbar 30 is vertically mounted at the axial end of motor 3, i.e., on the side where inverter unit 2 is located. Figure 2 As shown, the busbar 30 consists of three busbars 30 corresponding to U, V, and W, which are arranged close to the rotation shaft 11 and at equal intervals, extending axially from the end of the motor 3 along the rotation shaft 11.

[0032] like Figure 1 As shown, current sensors 24 are provided near the portion of busbar 30 that extends from motor 3. The current sensors 24 are arranged along the extension direction of busbar 30 in a manner that surrounds busbar 30, and detect the current value flowing in busbar 30. The current sensors 24 are connected to control board 23 using wiring harnesses or the like, and output a signal indicating the current value to control board 23.

[0033] A smoothing capacitor 21 is disposed on the outer periphery of busbar 30 and current sensor 24. For example... Figure 2 As shown, the smoothing capacitor 21 is formed with an approximately annular cross-section when viewed from the axial direction. The power component 22 and the control substrate 23 are also formed in annular shape.

[0034] like Figure 1 As shown, the inverter unit 2 is stacked in the order of smoothing capacitor 21, power component 22 and control board 23, starting from the end of motor 3.

[0035] The busbar 30 extending from the end of the motor 3 and the current sensor 24 disposed along the busbar 30 are located in the hollow portion of the inner periphery of the smoothing capacitor 21, the power component 22 and the control board 23.

[0036] With this structure, the limitations on the dimensions of the smoothing capacitor 21, power component 22, and control board 23, which are control components of the inverter unit 2, are reduced. That is, the dimensions can be expanded to the extent that they can be housed within the housing 20 (the outer diameter of the motor 3).

[0037] This allows for a radial increase in the size of the control components, thereby increasing the number and size of capacitor elements housed within the smoothing capacitor 21. Regarding the power assembly 22, the size of the switching elements and the wiring connected to the power elements can be increased. Furthermore, the size of the cooler used to cool the switching elements can be increased. Regarding the control board 23, the mounted components and wiring can also be increased.

[0038] Therefore, while increasing the size of the control components of the inverter unit 2 in line with the high output of the motor 3, it is also possible to increase its size in the outer diameter direction, and to minimize the increase in the rotation axis direction.

[0039] The embodiments of the present invention described above are applied to an inverter-integrated motor 1 having an inverter unit 2 at one end of the motor 3 in the direction of the rotation shaft 11. The motor 3 has a busbar 30 as a conductive component electrically connected to the inverter unit 2. The inverter unit 2 has a control component connected to the busbar 30 and controlling the drive of the motor 3. The busbar 30 extends along the rotation shaft 11 adjacent to the rotation shaft 11 around the rotation shaft 11, and the control component is configured to be radially outward from the busbar 30.

[0040] Therefore, even though the control components of the inverter unit 2 are enlarged to achieve high voltage resistance and high output in order to increase the output of the motor 3, the control components can also be enlarged radially, thus suppressing enlargement in the rotational axis direction. Therefore, while achieving high output of the motor 3, it is also possible to achieve miniaturization in the rotational axis direction of the inverter-integrated motor 1.

[0041] In addition, in this embodiment, a current sensor 24 is provided on the bus 30, and the control unit is composed of the following components: a power component 22 that supplies power to the motor 3; a smoothing capacitor 21 that smooths the current of the power component 22; and a control board 23 that controls the operation of the power component 22. The control unit is disposed around the bus 30 and the current sensor 24.

[0042] Therefore, the power component 22, the smoothing capacitor 21, and the control board 23, which are the control components of the inverter unit 2, are arranged outside the bus 30 and the current sensor 24, so that the control components can be expanded in the radial direction.

[0043] In addition, in this embodiment, the control components are stacked in the order of smoothing capacitor 21, power component 22 and control board 23, starting from the end side of motor 3.

[0044] According to this structure, it is possible to configure the current sensor 24 disposed on the bus 30 to not interfere with the motor-side bus 221 of the power component 22, thereby expanding the control components in the radial direction.

[0045] Next, variations of the present invention will be described.

[0046] Figure 3 This is an explanatory diagram of an inverter-integrated motor 1, a modified example of the present invention, and is a cross-sectional view in the direction of the rotation axis.

[0047] exist Figure 3 In the variant example shown, with Figure 1 Compared to the structure described in the previous section, the stacking order of the control components in inverter unit 2 is different. Furthermore, other structural differences are also present. Figure 1 Since they are the same, they are marked with the same label and their descriptions are omitted.

[0048] like Figure 3 As shown, the inverter unit 2 is stacked in the order of control board 23, power component 22 and smoothing capacitor 21, starting from the end of motor 3.

[0049] In this configuration, it also corresponds to the aforementioned Figure 1 Similarly, the busbar 30 is arranged on the inner periphery of the inverter unit 2. In order to increase the output of the motor 3, the control components of the inverter unit 2 are made larger to achieve high voltage resistance and high output. The control components can be expanded radially.

[0050] In particular, when the smoothing capacitor 21 is disposed on the side separate from the motor 3, interference between the inner circumference of the smoothing capacitor 21 and the busbar 30 can be avoided, and the shape of the smoothing capacitor 21 can be enlarged on the inner circumference side.

[0051] In addition, such as Figure 3 As shown, when the control board 23 is brought close to the motor 3, it may be affected by noise caused by the driving of the motor 3. To prevent this, it is preferable to have a shielding component between the control board 23 and the motor 3 to shield electromagnetic waves, etc.

[0052] Figure 4 This is an explanatory diagram of an inverter-integrated motor 1, which is another variation of the present invention, and is a cross-sectional view in the direction of the rotation axis.

[0053] exist Figure 4 In the variant example shown, with Figure 1 Compared to the structure described in the previous section, the stacking order of the control components in inverter unit 2 is different. Furthermore, other structural differences are also present. Figure 1 Since they are the same, they are labeled with the same number and their descriptions are omitted.

[0054] like Figure 4 As shown, the current sensor 24 is mounted on the control board 23. More specifically, the current sensor 24 is configured such that a Hall element for detecting current is built into the housing. Terminals extending from the Hall element are fixed to the control board 23. That is, the control board 23 is configured to be radially outward than the Hall element for detecting current.

[0055] Based on this structure, in the aforementioned Figure 1 Based on the structural advantages, the elimination of wiring and other components required to connect the current sensor 24 to the control board 23 reduces the number of parts and manufacturing time, thereby reducing the manufacturing cost of the inverter-integrated motor 1.

[0056] Figure 5 This is an explanatory diagram of an inverter-integrated motor 1, which is another variation of the present invention, and is a cross-sectional view in the direction of the rotation axis.

[0057] exist Figure 5 In the variant example shown, with Figure 1 Compared to the structure described in the previous section, the stacking order of the control components in inverter unit 2 is different. Furthermore, other structural differences are also present. Figure 1 Since they are the same, they are labeled with the same number and their descriptions are omitted.

[0058] like Figure 5 As shown, the inverter unit 2 is stacked in the order of power component 22, control board 23 and smoothing capacitor 21, starting from the end of the motor 3.

[0059] In this configuration, it is also consistent with the aforementioned Figure 1 Similarly, in order to increase the output of motor 3, the control components of inverter unit 2 are made larger by increasing the voltage resistance and output, and the control components can also be expanded radially.

[0060] Specifically, when the power component 22 is brought close to the end of the motor 3, it can share the cooling of the power component 22 with the cooling of the motor 3. Specifically, the housing (or the end of the coil) of the motor 3 has a refrigerant flow path 3a for refrigerant to flow through. Therefore, by bringing the power component 22 close to the refrigerant flow path 3a present at the end of the motor 3, it is possible to configure the power component 22 to be cooled by the refrigerant in the refrigerant flow path 3a.

[0061] This improves the cooling efficiency of the power component 22, thus enabling the power component 22 to achieve higher voltage resistance.

[0062] Figure 6 This is an explanatory diagram of an inverter-integrated motor 1, which is another variation of the present invention, and is related to... Figure 2 The figure corresponding to section II-II.

[0063] exist Figure 6 The variation shown is Figures 1 to 5 The modified example of the structure described herein differs from the structure of the busbar 30 protruding from the motor 3. Furthermore, other structures are similar to... Figure 2 Since they are the same, they are labeled with the same number and their descriptions are omitted.

[0064] like Figure 6 As shown, the motor 3 has six busbars 30. The U, V, and W phases are each composed of two busbars 30. Each busbar 30 has a current sensor 24. Thus, the busbars 30 can be arbitrarily configured according to the structure of the motor 3.

[0065] In this configuration, it also corresponds to the aforementioned Figure 2 Similarly, the busbar 30 is arranged on the inner periphery of the inverter unit 2. In order to increase the output of the motor 3, the control components of the inverter unit 2 are made larger to achieve high voltage resistance and high output. The control components can also be expanded radially.

[0066] As described above, the embodiments of the present invention, the above-described embodiments, and the variations thereof merely illustrate a portion of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific structures of the above-described embodiments.

[0067] In this embodiment, the current sensor 24 is disposed on the busbar 30 near the end of the motor 3, but it is not limited to this. For example, the current sensor 24 can be disposed on the busbar 30 at a position separate from the motor 3, and the inner circumferential side of the smoothing capacitor 21 (or other control component) is configured in a shape close to that of the busbar 30 at a position closer to the end of the motor 3 than the current sensor 24.

[0068] The inverter-integrated motor 1 of this embodiment can be installed in an electric vehicle that uses power from a battery to drive the inverter-integrated motor 1, or in a series hybrid vehicle that has an engine and uses power generated by the engine to drive the inverter-integrated motor 1. Alternatively, it can be used for other driving power sources.

[0069] In this embodiment, the smoothing capacitor 21, power component 22, and control board 23, which are control components of the inverter unit 2, are configured in a circular shape, but are not limited to this. As long as the bus 30 and current sensor 24 can be arranged radially inward, they can be of any shape, including polygons and combinations of curved surfaces and polygons. Any suitable shape that corresponds to the shape of the components, wiring, etc., constituting each part is acceptable.

Claims

1. An inverter-integrated motor, wherein an inverter unit is provided at the end of the motor in the direction of its rotation axis, wherein, The motor has a bus that is electrically connected to the inverter unit. A current sensor is configured on the bus. The inverter unit has a control component connected to the bus to control the drive of the motor, and a housing that houses the control component. The busbar is positioned upright from the end of the motor and extends along the rotation axis adjacent to the rotation axis of the motor. The control component includes a smoothing capacitor, a power component, and a control board. The smoothing capacitor, the power component, and the control substrate each have a cross-section that is annular when viewed from the direction of the rotation axis. The busbar and the current sensor are disposed in the hollow portion of the smoothing capacitor, the power component, and the control board. The shell is cylindrical in shape. The rotating shaft of the motor passes through the inner circumference of the housing.

2. The inverter-integrated motor according to claim 1, wherein, The power component is configured to supply power to the motor. The smoothing capacitor is configured to smooth the current of the power component. The control board is configured to control the operation of the power components.

3. The inverter-integrated motor according to claim 2, wherein, The control components are stacked in the order of the smoothing capacitor, the power component, and the control board, starting from the end side of the motor.

4. The inverter-integrated motor according to claim 2, wherein, The control components are stacked in the order of the control board, the power components, and the smoothing capacitor, starting from the end side of the motor.

5. The inverter-integrated motor according to claim 4, wherein, The current sensor is mounted on the control board.

6. The inverter-integrated motor according to claim 2, wherein, The control components are stacked in the order of the power assembly, the control board, and the smoothing capacitor, starting from the end side of the motor. In the motor, a refrigerant flow path for refrigerant circulation is located adjacent to the power component.

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