Electrical device

Abstract

Provided is an electrical device capable of suppressing generation of impact sound and reduction in charging efficiency caused by vibration of a rotor during AC charging. The electrical apparatus includes a power storage device, a rotating electrical machine, and a power control unit. The power control unit includes a third full-bridge circuit connected to both ends of a beta-phase first coil of the rotating electrical machine and a fourth full-bridge circuit connected to both ends of a beta-phase second coil. The beta-phase first coil and the beta-phase second coil form an AC input phase connected to the AC power supply connection member. The rotating electrical machine is provided with a stator core in which slots are formed, each coil is disposed in each slot, and the combination of the number of turns of each coil differs between a first pole and a second pole forming a pole pair.

Description

Technical Field

[0001] This invention relates to electrical equipment. Background Technology

[0002] In recent years, research and development have been conducted on charging and discharging of mobile vehicles equipped with secondary batteries to ensure that more people can afford, rely on, sustainably and advanced energy. These secondary batteries contribute to energy efficiency.

[0003] Conventionally, for example, an electric vehicle is known to convert AC power supplied from an external power source into DC power through a combination of multiphase stator windings of a motor and a multiphase bridge circuit based on switching elements (see, for example, Patent Document 1 below). In this electric vehicle, in order to suppress the torque generated on the motor during AC charging based on an external power source and to maximize the inductance, the rotor position (rotation angle) when the motor stops is controlled to be a predetermined position.

[0004] In addition, in the past, for example, a motor is known in which the number of turns of the two windings connected in series in the N and S poles of the stator magnetic poles is set to be the same (for example, see Patent Document 2 below).

[0005] Patent Document 1: Japanese Patent Application Publication No. 2009-65808

[0006] Patent Document 2: Japanese Patent Application Publication No. 2020-25377 Summary of the Invention

[0007] In technologies related to charging and discharging in mobile vehicles equipped with secondary batteries, the challenge lies in suppressing the decrease in charging efficiency caused by increased current distortion during AC charging based on an external power source, while simultaneously suppressing the generation of gear knocking noise, also known as grinding noise, caused by the torque generated by the motor. For example, in conventional electric vehicles, even when the rotor position at the motor's stop point is pre-controlled to a predetermined position, it may be difficult to properly control the rotor position due to the driver's intentions, the surrounding environment, and other vehicle controls. Furthermore, even when the rotor position is set to a predetermined position, the vibration of the rotor, generated according to the frequency of the charging current during AC charging, may also produce grinding noise from the gears connected to the rotor.

[0008] The present invention addresses the above-mentioned issues and aims to provide an electrical device capable of suppressing the generation of impact noise caused by rotor vibration during AC charging and reducing charging efficiency. Furthermore, it contributes to energy efficiency.

[0009] In order to solve the above-mentioned problems and achieve the relevant objectives, the present invention adopts the following solution.

[0010] (1): An electrical device according to one aspect of the present invention comprises: an energy storage device; a rotating electric machine having a rotor and a plurality of coils; a power control unit connected to the rotating electric machine and the energy storage device to control the power supply and receiving of the energy storage device and the rotating electric machine respectively; and an AC power connection member connecting the rotating electric machine to an external AC power source, the power control unit comprising a first full-bridge circuit connected to the ends of the first coil and a second full-bridge circuit connected to the ends of the second coil for a first coil and a second coil forming a predetermined phase connected to the AC power connection member among the plurality of coils, the rotating electric machine comprising a stator core having slots in which the first coil and the second coil are disposed, the combination of the number of turns of the first coil and the second coil being different in the first pole and the second pole forming the pole pair.

[0011] (2): Based on the above scheme (1), the first coil and the second coil may be disposed in the slots that are opposite each other in the stator core across the central shaft.

[0012] (3): Based on the above scheme (2), it is also possible that, for the first slot and the second slot which are opposite each other in the stator core across the central axis, the first coil is disposed in the first slot and the second coil is disposed in the second slot.

[0013] (4): Based on any one of the above schemes (1) to (3), it is also possible that, regarding the combination of the number of turns of the first coil and the second coil, the first pole and the second pole of all pole pairs of the stator core are the same.

[0014] (5): Based on the above scheme (4), the specified phase can also be the AC input phase that converts the input of AC power into the output of DC power.

[0015] (6): Based on the above scheme (5), the power control unit may also include: a first circuit breaker connected between one end of the first coil and the first full-bridge circuit; a second circuit breaker connected between one end of the second coil and the second full-bridge circuit; a third full-bridge circuit connected to the two ends of the third coil and a fourth full-bridge circuit connected to the two ends of the fourth coil for forming a DC-DC conversion phase among the plurality of coils; a third circuit breaker connected between the positive terminals of the third full-bridge circuit and the fourth full-bridge circuit; and a fourth circuit breaker connected between the negative terminals of the third full-bridge circuit and the fourth full-bridge circuit.

[0016] According to the above scheme (1), the combination of the number of turns of the first coil and the second coil connected to the external AC power supply forms a pole pair in the stator core where the first pole and the second pole are different from each other. Therefore, even when they are energized in reverse phase, for example, when connected in parallel, their magnetic flux is suppressed and canceled out. An inductance larger than the leakage inductance can be generated, and by suppressing current ripple and distortion, the charging efficiency can be improved.

[0017] In the above scheme (2), the first coil and the second coil are arranged in slots opposite each other in the stator core across the central shaft, so that even when energized in reverse phase, for example, in parallel connection, the rotor can generate a magnetic flux distribution that cancels out the torque. By suppressing the torque generation of the rotating motor during AC charging, the generation of impact noises such as gear grinding caused by torque pulsation can be suppressed.

[0018] In the above scheme (3), the first coil is configured in the first slot and the second coil is configured in the second slot, thereby increasing the inductance and further suppressing current ripple and distortion.

[0019] In the case of the above scheme (4), by adopting, for example, a correspondence in which the number of turns of each coil at the first pole and the second pole are reversed, the number of turns of the first coil and the second coil can be made the same as that of each other as a whole stator core. As a result, the torque generation of the rotary motor during AC charging can be suppressed, and the reverse waveform of each coil during the driving of the rotary motor can be made to be the same reverse waveform as when the number of turns of the first coil and the second coil at each of the first pole and the second pole are the same.

[0020] In the above scheme (5), the generation of impact noise such as gear grinding noise caused by the torque pulsation of the rotating motor during AC charging is suppressed, and the current ripple and distortion are suppressed, thereby improving the charging efficiency.

[0021] In the above scheme (6), when the energy storage device drives the rotating motor, the power control unit can function as an inverter with a multi-bridge circuit. When the external AC power supply charges the energy storage device, the combination of the third and fourth coils with the third and fourth full-bridge circuits can function as an isolated bidirectional DC-DC converter. For example, in the case of boost operation during AC charging, the voltage of the energy storage device, which is higher than the charging voltage of the external AC power supply, can be charged rapidly. Attached Figure Description

[0022] Figure 1 This is a diagram showing the structure of an electrical device according to an embodiment of the present invention.

[0023] Figure 2This is a structural diagram of the full-bridge circuits and rotating motors of the electrical equipment according to an embodiment of the present invention.

[0024] Figure 3 This is a block diagram illustrating the functional structure of the electronic control unit during AC charging of an electrical device according to an embodiment of the present invention.

[0025] Figure 4 This is a circuit diagram illustrating an example of current flow in parallel mode during AC charging of an electrical device according to an embodiment of the present invention.

[0026] Figure 5 This is a structural diagram showing a model of a rotary electric motor representing a first modified embodiment of the present invention.

[0027] Figure 6 This is a structural diagram showing a model of a rotary electric motor according to a second variation of an embodiment of the present invention.

[0028] Figure 7 This is a structural diagram showing a model of a rotary electric motor according to a third variation of an embodiment of the present invention.

[0029] Figure 8 This is a structural diagram illustrating an example of the distributed winding of a rotary electric motor, a third variation of an embodiment of the present invention. Detailed Implementation

[0030] Hereinafter, the electrical equipment according to the embodiments of the present invention will be described with reference to the accompanying drawings.

[0031] Figure 1 This is a diagram showing the structure of the electrical device 10 according to the embodiment. Figure 2 This is a modeled structural diagram of the full-bridge circuits 12a, 12b, 13a, 13b of the electrical equipment 10 and the rotary motor 16 in the embodiment.

[0032] The electrical equipment 10 in the implementation method is, for example, mounted on electric vehicles, electric mobile bodies, electric machinery, and power supply devices. Electric vehicles include, for example, electric motor vehicles equipped with a rotary motor as a power source, motorcycles and scooters, hybrid vehicles based on a combination of a rotary motor and an internal combustion engine, and fuel cell vehicles based on a combination of an energy storage device and a fuel cell. Electric mobile bodies include, for example, robots, flying vehicles, and mobile bodies on or under water. Electric machinery includes, for example, construction machinery equipped with a rotary motor as a power source. Power supply devices include, for example, stationary or mobile power supply devices that discharge and charge energy storage devices.

[0033] (Electrical equipment)

[0034] like Figure 1 and Figure 2As shown, the electrical device 10 in this embodiment includes, for example, an energy storage device 11, a first power conversion unit 12 and a second power conversion unit 13, a DC power connection unit 14 and an AC power connection unit 15, a rotary motor 16(M), a gate drive unit 17, and an electronic control unit 18. It should be noted that, for example, the first power conversion unit 12 and the second power conversion unit 13, the DC power connection unit 14 and the AC power connection unit 15, the gate drive unit 17, and the electronic control unit 18 constitute a power control unit 10a.

[0035] The energy storage device 11 is connected to the first power conversion unit 12 and the second power conversion unit 13, which will be described later.

[0036] The energy storage device 11 may include multiple battery cells connected in series or parallel. Each battery cell may be a secondary battery such as a lead-acid battery, lithium-ion battery, nickel-metal hydride battery, or all-solid-state battery, a capacitor such as an electric double-layer capacitor, or a composite battery based on a combination of a secondary battery and a capacitor. Each battery cell is repeatedly charged and discharged. The energy storage device 11 receives and exchanges power with the rotary motor 16 via the power control unit 10a. The energy storage device 11 is charged by an external power source (external DC power source and external AC power source).

[0037] The first power conversion unit 12 includes a first full-bridge circuit 12a and a second full-bridge circuit 12b.

[0038] The first full-bridge circuit 12a and the second full-bridge circuit 12b each have, for example, a so-called H-bridge circuit formed by multiple switching elements connected by two-phase bridges. Each switching element is, for example, a transistor such as a MOSFET (Metal-Oxide Semiconductor Field Effect Transistor) or an IGBT (Insulated Gate Bipolar Transistor) made of SiC (Silicon Carbide). Each switching element is, for example, an N-channel MOSFET.

[0039] Multiple switching elements are, for example, each pair of transistors in element sections 21a and 21b that form pairs of high-side arms and low-side arms for each phase. Each pair of transistors in element sections 21a and 21b is connected in parallel, for example.

[0040] It should be noted that each full-bridge circuit 12a, 12b may also include rectifier elements such as freewheeling diodes that are connected in parallel from the emitter to the collector between the collector and emitter of each transistor.

[0041] The first power conversion unit 12 includes, for example, a first switch 22 connected between the midpoints Q2 and Q3 of the first full-bridge circuit 12a and the second full-bridge circuit 12b. The midpoint Q2 of the first full-bridge circuit 12a is, for example, the connection point between the element portion 21a (a2H) of the high-side arm and the element portion 21b (a2L) of the low-side arm, which are connected in series between the first phase and the second phase of the two phases of the first full-bridge circuit 12a. For example, the midpoint Q2 is the connection point between the source of the element portion 21a (a2H) of the high-side arm and the drain of the element portion 21b (a2L) of the low-side arm. The midpoint Q3 of the second full-bridge circuit 12b is, for example, the connection point between the element portion 21a (a3H) of the high-side arm and the element portion 21b (a3L) of the low-side arm, which are connected in series between the first phase and the first phase of the two phases of the second full-bridge circuit 12b. For example, midpoint Q3 is the connection point between the source of the high-side arm element section 21a (a3H) and the drain of the low-side arm element section 21b (a3L).

[0042] The first switch 22 is, for example, a bidirectional switch formed by two switching elements. Each switching element is a transistor such as a MOSFET or an IGBT, for example, an N-channel MOSFET. The first switch 22 has, for example, two transistors connected in reverse series. The two transistors are connected in series in reverse order by connecting their sources to each other. The first switch 22 switches the current between the midpoints Q2 and Q3 by turning the two transistors on (conducting) and off (cutting off).

[0043] It should be noted that each transistor may also have rectifier elements such as a freewheeling diode connected in parallel from the emitter to the collector between the collector and emitter.

[0044] The first power conversion unit 12 is connected to the α-phase first coil 23 (α1) and the α-phase second coil 24 (α2) of the rotary motor 16 described later. The α-phase first coil 23 is connected between the midpoints Q1 and Q2 of the first full-bridge circuit 12a. The α-phase second coil 24 (α2) is connected between the midpoints Q3 and Q4 of the second full-bridge circuit 12b. The midpoint Q1 of the first full-bridge circuit 12a is, for example, the connection point between the element portion 21a (a1H) of the high side arm and the element portion 21b (a1L) of the low side arm, which are connected in series in the first full-bridge circuit 12a. For example, the midpoint Q1 is the connection point between the source of the element portion 21a (a1H) of the high side arm and the drain of the element portion 21b (a1L) of the low side arm. The midpoint Q4 of the second full-bridge circuit 12b is, for example, the connection point between the element portion 21a (a4H) of the high-side arm and the element portion 21b (a4L) of the low-side arm, which are connected in series in the second full-bridge circuit 12b. For example, the midpoint Q4 is the connection point between the source of the element portion 21a (a4H) of the high-side arm and the drain of the element portion 21b (a4L) of the low-side arm.

[0045] The first power conversion unit 12 includes a first circuit breaker 25 connected between the positive terminals of the first full-bridge circuit 12a and the second full-bridge circuit 12b, and a second circuit breaker 26 connected between the negative terminals of the first full-bridge circuit 12a and the second full-bridge circuit 12b.

[0046] The first circuit breaker 25 and the second circuit breaker 26 are, for example, contactors, used to switch the connection between the first full-bridge circuit 12a and the second full-bridge circuit 12b between being connected (conducted) and disconnected (cut off).

[0047] The first power conversion unit 12 includes, for example, a capacitor 27 connected between the positive and negative terminals. The capacitor 27 smooths out voltage fluctuations caused by the switching operations of the switching elements of the first power conversion unit 12, such as when they are turned on (conducted) and off (cut off).

[0048] The first power conversion unit 12 includes, for example, a first current sensor 28a disposed between the first coil 23 (α1) of phase α and the midpoint Q2; a second current sensor 28b disposed between the second coil 24 (α2) of phase α and the midpoint Q4; and a third current sensor 28c disposed between the energy storage device 11 and the first power conversion unit 12.

[0049] For example, the first current sensor 28a detects the current flowing in the first coil 23 (α1) of phase α. The second current sensor 28b detects the current flowing in the second coil 24 (α2) of phase α.

[0050] The third current sensor 28c detects the current flowing between the first power conversion unit 12 and the energy storage device 11.

[0051] The second power conversion unit 13 includes a third full-bridge circuit 13a and a fourth full-bridge circuit 13b.

[0052] The third full-bridge circuit 13a and the fourth full-bridge circuit 13b each have, for example, a so-called H-bridge circuit formed by multiple switching elements connected by a two-phase bridge. Each switching element is, for example, a MOSFET of SiC or a transistor of IGBT. Each switching element is, for example, an N-channel MOSFET.

[0053] Multiple switching elements are, for example, each pair of transistors in element sections 31a and 31b that form the high-side arm and low-side arm of each phase. Each pair of transistors in element sections 31a and 31b is connected in parallel, for example.

[0054] It should be noted that each full-bridge circuit 13a, 13b may also include rectifier elements such as freewheeling diodes that are connected in parallel from the emitter to the collector between the collector and emitter of each transistor.

[0055] The second power conversion unit 13, for example, includes a second switch 32 connected between the midpoints R2 and R3 of the third full-bridge circuit 13a and the fourth full-bridge circuit 13b. The midpoint R2 of the third full-bridge circuit 13a is, for example, the connection point between the element portion 31a (b2H) of the high-side arm and the element portion 31b (b2L) of the low-side arm, which are connected in series between the first phase and the second phase of the two phases of the third full-bridge circuit 13a. For example, the midpoint R2 is the connection point between the source of the element portion 31a (b2H) of the high-side arm and the drain of the element portion 31b (b2L) of the low-side arm. The midpoint R3 of the fourth full-bridge circuit 13b is, for example, the connection point between the element portion 31a (b3H) of the high-side arm and the element portion 31b (b3L) of the low-side arm, which are connected in series between the first phase and the first phase of the two phases of the fourth full-bridge circuit 13b. For example, midpoint R3 is the connection point between the source of the element section 31a (b3H) of the high side arm and the drain of the element section 31b (b3L) of the low side arm.

[0056] The second switch 32 is, for example, a bidirectional switch formed by two switching elements. Each switching element is a transistor such as a MOSFET or an IGBT, for example, an N-channel MOSFET. The second switch 32 has, for example, two transistors connected in reverse series. The two transistors are connected in series in reverse order by connecting their sources to each other. The second switch 32 switches the current between the midpoints R2 and R3 by turning the two transistors on (conducting) and off (cutting off).

[0057] It should be noted that each transistor may also have rectifier elements such as a freewheeling diode connected in parallel from the emitter to the collector between the collector and emitter.

[0058] The second power conversion unit 13 is connected to the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) of the rotary motor 16 described later. The β-phase first coil 33 is connected between the midpoints R1 and R2 of the third full-bridge circuit 13a. The β-phase second coil 34 (β2) is connected between the midpoints R3 and R4 of the fourth full-bridge circuit 13b. The midpoint R1 of the third full-bridge circuit 13a is, for example, the connection point between the element part 31a (b1H) of the high side arm and the element part 31b (b1L) of the low side arm, which are connected in series in the first phase of the third full-bridge circuit 13a. For example, the midpoint R1 is the connection point between the source of the element part 31a (b1H) of the high side arm and the drain of the element part 31b (b1L) of the low side arm. The midpoint R4 of the fourth full-bridge circuit 13b is, for example, the connection point between the element portion 31a (b4H) of the high-side arm and the element portion 31b (b4L) of the low-side arm, which are connected in series in the second phase of the fourth full-bridge circuit 13b. For example, the midpoint R4 is the connection point between the source of the element portion 31a (b4H) of the high-side arm and the drain of the element portion 31b (b4L) of the low-side arm.

[0059] The second power conversion unit 13 includes: a third circuit breaker 35 connected between one end of the β-phase first coil 33 (β1) and the third full-bridge circuit 13a; and a fourth circuit breaker 36 connected between one end of the β-phase second coil 34 (β2) and the fourth full-bridge circuit 13b.

[0060] The third circuit breaker 35 and the fourth circuit breaker 36 are, for example, contactors. The third circuit breaker 35 is connected, for example, between one end of the first coil 33 (β1) of phase β and the midpoint R1 of the first phase of the third full-bridge circuit 13a, and is used to switch the connection between the first coil 33 (β1) of phase β and the midpoint R1 to be connected (conducted) and disconnected (cut off). The fourth circuit breaker 36 is connected, for example, between one end of the second coil 34 (β2) of phase β and the midpoint R4 of the fourth phase of the fourth full-bridge circuit 13b, and is used to switch the connection between the second coil 34 (β2) of phase β and the midpoint R4 to be connected (conducted) and disconnected (cut off).

[0061] The second power conversion unit 13 includes, for example, a capacitor 37 connected between the positive and negative terminals. The capacitor 37 smooths out voltage fluctuations caused by the switching operations of the switching elements of the second power conversion unit 13, such as when they are turned on (conducted) and off (cut off).

[0062] The second power conversion unit 13 includes, for example, a fourth current sensor 38a disposed between the first coil 33 (β1) of the β phase and the midpoint R2; and a fifth current sensor 38b disposed between the second coil 34 (β2) of the β phase and the midpoint R4.

[0063] For example, the fourth current sensor 38a detects the current flowing in the first coil 33 (β1) of phase β. The fifth current sensor 38b detects the current flowing in the second coil 34 (β2) of phase β.

[0064] The DC power connection part 14 and the AC power connection part 15 are, for example, equipped with connectors for DC power and AC power of specified specifications. The DC power connection part 14 and the AC power connection part 15 are connected to an external DC power source (external DC power source) and an AC power source (external AC power source) obtained from, for example, a commercial power source connected to a power system.

[0065] The DC power supply connection 14 is connected, for example, to the negative terminal of the second power conversion unit 13, and to the midpoint of the first switch 22 and the second switch 32 (i.e., between the two transistors connected in reverse series).

[0066] The AC power connection 15 is connected, for example, to the first midpoint R1 and the fourth midpoint R4 of the second power conversion unit 13, and to the connection point between the first coil 33 (β1) of the β phase and the third circuit breaker 35, and to the connection point between the second coil 34 (β2) of the β phase and the fourth circuit breaker 36.

[0067] The rotary motor 16 (M) is, for example, a two-phase AC brushless DC motor. The rotary motor 16 includes, for example, an α-phase first coil 23 (α1) and an α-phase second coil 24 (α2), a β-phase first coil 33 (β1) and a β-phase second coil 34 (β2), a rotor 41, and a stator core 42.

[0068] The rotor 41 is equipped with a permanent magnet for excitation. The stator core 42 is equipped with coils α1, α2, β1, and β2 that generate a rotating magnetic field that causes the rotor 41 to rotate.

[0069] The first coil 23 (α1) of phase α and the second coil 24 (α2) of phase α, as well as the first coil 33 (β1) of phase β and the second coil 34 (β2) of phase β are so-called open-ended coils, with the ends of each coil α1, α2, β1, β2 not connected to each other (i.e., each coil α1, α2, β1, β2 is separated from each other) and led out to the outside of the rotating motor 16.

[0070] The α-phase first coil 23 (α1) and the α-phase second coil 24 (α2) are, for example, spatially phase-difference-zero and wound in the same direction around the teeth of the stator core 42 when viewed from the axial direction along the central axis O of the rotating motor 16 (M). The α-phase first coil 23 (α1) and the α-phase second coil 24 (α2) are, for example, configured to share or each occupy a portion of a slot 43 formed in the stator core 42 and are magnetically coupled to each other with the same polarity.

[0071] The β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) are, for example, spatially phase-difference-zero and are wound in the same direction around the teeth of the stator core 42 when viewed from the axial direction along the central axis O of the rotating motor 16 (M). The β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) are, for example, configured to share or each occupy a portion of the slot 43 formed in the stator core 42 and are magnetically coupled to each other with the same polarity.

[0072] The α-phase first coil 23 (α1) and the α-phase second coil 24 (α2) are configured to have a spatial phase difference of 90° with the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2), thus forming a non-magnetic interference configuration.

[0073] For example, each coil α1, α2, β1, β2 is assembled into the stator core 42 by concentrated winding or distributed winding.

[0074] In the coils α1, α2 of phase α and coils β1, β2 of phase β, at least the coils β1, β2 of phase β are configured such that the combination of their turns is different between the first and second poles of the pole pairs (N pole and S pole) constituting the stator core 42. The combination of turns is, for example, the case where the first coil 33 (β1) of phase β and the second coil 34 (β2) of phase β are respectively located at the first and second poles, and the case where the number of turns of the first coil 33 (β1) of phase β and the second coil 34 (β2) of phase β are respectively zero at the first and second poles. When each coil β1 and β2 is located at the first and second poles, the turns ratio (so-called relative ratio) of each coil β1 and β2 is defined by a value other than 1. The case where the number of turns becomes zero is, for example, the case where only the first coil 33 (β1) of phase β is present at the first pole and only the second coil 34 (β2) of phase β is present at the second pole, and the case where only the second coil 34 (β2) of phase β is present at the first pole and only the first coil 33 (β1) of phase β is present at the second pole.

[0075] The correspondence between the combination of the number of turns of each coil β1 and β2 at the first pole and the combination of the number of turns of each coil β1 and β2 at the second pole is, for example, an inverse correspondence, where the turns ratios are mutually inverse. The correspondence between the first and second poles related to the combination of the number of turns of each coil β1 and β2 is, for example, two inverse correspondences formed by alternating first and second pole pairs set with the same number of turns along the circumference of the stator core 42.

[0076] Regarding the combination of the number of turns of each coil β1 and β2, the first and second poles of all pole pairs of the stator core 42 are the same. In each of the first and second poles of the stator core 42 as a whole, the number of turns of the first coil 33 (β1) of phase β is the same as the number of turns of the second coil 34 (β2) of phase β.

[0077] Table 1 below shows that in Figure 2 Examples of the number of turns of coils α1, α2, β1, β2 corresponding to the N and S poles at the first and second pole pairs in the rotary electric motor 16(M) of the illustrated embodiment. As shown in Table 1 below, in each of the first and second pole pairs, the correspondence between the combination of the number of turns of coils β1, β2 at the N pole and the combination of the number of turns of coils β1, β2 at the S pole are reversed. Regarding the combination of the number of turns of each coil β1, β2, the correspondence between the N and S poles at the first pole pair and the correspondence between the N and S poles at the second pole pair are reversed.

[0078] It should be noted that, as shown in Table 1 below, in Figure 2In the rotary motor 16(M) of the illustrated embodiment, the coils α1, α2 of the α phase and the coils β1, β2 of the β phase are similarly configured as combinations of turns, and the first and second poles of the pole pairs (N pole and S pole) forming the stator core 42 are different from each other.

[0079]

[0080] In example Figure 2 In the rotary motor 16(M) of the illustrated embodiment, for the slots 43 (opposite between the first slot SL1 and the second slot SL2 and the third slot SL3 and the fourth slot SL4) that are opposed to each other in the stator core 42 across the central axis O, the β-phase first coil 33 (β1) is disposed in the first slot SL1 and the second slot SL2, and the β-phase second coil 34 (β2) is disposed in the third slot SL3 and the fourth slot SL4. Similarly, in the α-phase, for the slots 43 (opposite between the second slot SL2 and the third slot SL3 and the first slot SL1 and the fourth slot SL4) that are opposed to each other in the stator core 42 across the central axis O, the α-phase first coil 23 (α1) is disposed in the second slot SL2 and the third slot SL3, and the α-phase second coil 24 (α2) is disposed in the first slot SL1 and the fourth slot SL4.

[0081] The rotary motor 16(M) generates rotational power by performing a traction operation using electricity supplied from the first power conversion unit 12 and the second power conversion unit 13. For example, when connected to the wheels of a vehicle, the rotary motor 16(M) generates driving force using electricity supplied from the first power conversion unit 12 and the second power conversion unit 13. The rotary motor 16(M) can also generate electricity through a regenerative operation using rotational power input from the wheel side of the vehicle. For example, when connected to the internal combustion engine of a vehicle, the rotary motor 16(M) can also generate electricity using the power of the internal combustion engine.

[0082] The gate drive unit 17 switches the switching elements of the first power conversion unit 12 and the second power conversion unit 13, as well as the circuit breakers 25, 26, 35, and 36, on and off based on the control signals obtained from the electronic control unit 18. For example, the gate drive unit 17 outputs gate signals generated by amplifying and level shifting the control signals for each switching element of each full-bridge circuit 12a, 12b, 13a, and 13b, thereby switching them on and off.

[0083] The electronic control unit 18 comprehensively controls the operation of both the power control unit 10a and the rotary motor 16(M). For example, the electronic control unit 18 is a software functional unit that functions by executing a predetermined program by a processor such as a CPU (Central Processing Unit). This software functional unit is an ECU (Electronic Control Unit) that includes a processor such as a CPU, ROM (Read Only Memory) for storing programs, RAM (Random Access Memory) for temporarily storing data, and electronic circuits such as timers. It should be noted that at least a portion of the electronic control unit 18 may also be an integrated circuit such as an LSI (Large Scale Integration).

[0084] The electronic control unit 18 generates control signals indicating the timing for driving each switching element of the first power conversion unit 12 and the second power conversion unit 13, as well as each circuit breaker 25, 26, 35, 36, to be turned on (on) and off (off). The electronic control unit 18 inputs the generated control signals to the gate drive unit 17.

[0085] (Control actions of electrical equipment)

[0086] When the rotating motor 16(M) is in power traction or regenerative operation, the electronic control unit 18 sets the first circuit breaker 25 and the second circuit breaker 26 to the on (conducting) state. The electronic control unit 18 switches the series connection of each α-phase coil α1, α2 and the series connection of each β-phase coil β1, β2, as well as the parallel connection of each α-phase coil α1, α2 and the parallel connection of each β-phase coil β1, β2 by switching the first switch 22 and the second switch 32 between on (conducting) and off (cutting off).

[0087] The electronic control unit 18 generates control signals that instruct the driving of each switching element of the first power conversion unit 12 and the second power conversion unit 13, for example, by performing current feedback control using the current detection value of the rotating motor 16 (M) and the current target value corresponding to the torque command value of the rotating motor 16 (M).

[0088] In the case of power traction or regenerative operation of the rotary motor 16(M), for example, current flows in the same direction (in phase) through each coil α1, α2, β1, β2. The reverse waveforms of each coil α1, α2, β1, β2 are the same as when the number of turns of each coil α1, α2, β1, β2 is the same at each of the first and second poles. Even if the combination of the number of turns of each coil α1, α2 at the first and second poles of the stator core 42, as in the rotary motor 16(M) of the embodiment, is different, the performance of power traction and regeneration is the same as when the number of turns is the same.

[0089] When DC charging occurs, i.e., when the energy storage device 11 is charged by an external DC power supply connected to the DC power connection section 14, the electronic control unit 18 sets the first circuit breaker 25 and the second circuit breaker 26 to the ON (ON) state. For example, for an external DC power supply with a voltage lower than that of the energy storage device 11, the electronic control unit 18 enables the combination of each α-phase coil α1, α2 and the first power conversion section 12, and the combination of each β-phase coil β1, β2 and the second power conversion section 13 to function as non-isolated DC-DC converters that perform boost operation based on so-called chopper control.

[0090] When the electronic control unit 18 is charging the energy storage device 11 via an external AC power source connected to the AC power connection 15, it sets the first circuit breaker 25 and the second circuit breaker 26 to the open (cut-off) state for insulation.

[0091] The electronic control unit 18, for example, makes the first α-phase coil 23 (α1) and the second α-phase coil 24 (α2) magnetically coupled to each other with the same polarity the coils of the α-phase, which are coils of the DC-DC conversion phase (α-phase) for the conversion between DC and DC power. The electronic control unit 18, for example, makes the combination of each α-phase coil α1, α2 and the first power conversion unit 12 function as an insulated bidirectional (boost and buck) converter, i.e., a DAB (Dual Active Bridge) type DC-DC converter.

[0092] The electronic control unit 18, for example, makes the first β-phase coil 33 (β1) and the second β-phase coil 34 (β2) magnetically coupled to each other with the same polarity as coils of the AC input phase (β phase) connected to an external AC power source. The electronic control unit 18, for example, makes the combination of each β-phase coil β1, β2 and the second power conversion unit 13 function as a so-called bridgeless (or bridgeless and totem-pole) power factor correction (PFC) circuit that converts AC power to DC power. A bridgeless PFC is a PFC that does not have a bridge rectifier implemented with multiple diodes based on a bridge connection, and a totem-pole PFC is a PFC that has a pair of switching elements of the same conductivity type connected in series in the same direction (totem-pole connection). The electronic control unit 18, for example, improves the power factor of the input voltage Vac and input current Iac while rectifying and boosting the AC power obtained from the external AC power source to DC power by controlling the switching operation of each switching element at each full-bridge circuit 13a, 13b of the second power conversion unit 13.

[0093] Figure 3 This is a block diagram illustrating the functional structure of the electronic control unit 18 during AC charging in the electrical equipment 10 of the embodiment.

[0094] like Figure 3 As shown, the second power conversion unit 13 includes, for example, an input voltage sensor 51 that detects the input voltage Vac of the external AC power supply; and an input current sensor 52 that detects the input current Iac of the external AC power supply.

[0095] The electronic control unit 18 includes, for example, a power supply voltage acquisition unit 61, a power supply current acquisition unit 62, a phase calculation unit 63, a target current calculation unit 64, a current control unit 65, a power calculation unit 66, and a PWM control unit 67.

[0096] The power supply voltage acquisition unit 61 outputs, for example, the input voltage Vac obtained from the input voltage sensor 51.

[0097] The power supply current acquisition unit 62 outputs, for example, the input current Iac obtained from the input current sensor 53.

[0098] The phase calculation unit 63 calculates, for example, the phase of the input voltage Vac output from the power supply voltage acquisition unit 61.

[0099] The target current calculation unit 64 calculates a target current that is synchronized with the input voltage Vac, for example, based on the target current amplitude relative to the input current Iac and the phase of the input voltage Vac output from the phase calculation unit 63.

[0100] The current control unit 65 outputs the duty cycle of the voltage command, for example, through PI (proportional-integral) control based on the current deviation obtained by subtracting the target current output from the target current calculation unit 64 and the input current Iac output from the power supply current acquisition unit 62. The duty cycle of the voltage command is defined as the ratio of the on-time to the switching cycle of the paired switching elements (i.e., the switching elements of the high-side arm and the low-side arm of each phase) in each phase of the full-bridge circuits 13a and 13b of the second power conversion unit 13.

[0101] The power calculation unit 66 outputs, for example, the power obtained by multiplying the input voltage Vac output from the power supply voltage acquisition unit 61 and the input current Iac output from the power supply current acquisition unit 62.

[0102] The PWM control unit 67 generates control signals indicating the timing for driving each switching element of the full-bridge circuits 13a and 13b of the second power conversion unit 13 to be turned on (conducted) and off (cut off), for example, by pulse width modulation operation based on the duty cycle of the voltage command output from the current control unit 65. The PWM control unit 67 sets the switching operation mode based, for example, on the power supply output from the power calculation unit 66. For example, Table 2 below shows the switching operation modes in parallel mode. Parallel mode is a mode in which the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) are connected in parallel.

[0103]

[0104] In the switching operation modes shown in Table 2 above, the first mode and the fourth mode are modes for charging the first coil 33 (β1) of phase β and the second coil 34 (β2) of phase β, while the second mode and the third mode are modes for discharging from each of the phase β coils 33 (β1) and 34 (β2).

[0105] In Table 2 above, for example, as the duty cycle (on-state ratio) of the element sections b2H and b3H of the high-side arms of the second and third arms in the second power conversion unit 13 decreases toward 0.5, the first and fourth modes of charging each β-phase coil 33 (β1) and 34 (β2) increase, and the second mode of discharging from each β-phase coil 33 (β1) and 34 (β2) decreases. For example, when the duty cycle (on-state ratio) of the element sections b2H and b3H of the high-side arms of the second and third arms is 0.5, only the first and fourth modes of charging each β-phase coil 33 (β1) and 34 (β2) become active. For example, as the duty cycle (on rate) of the element parts b2H and b3H of the high side arms of the second and third arms decreases from 0.5, the first and fourth modes of charging each β phase coil 33 (β1) and 34 (β2) decrease, and the third mode of discharging from each β phase coil 33 (β1) and 34 (β2) increases.

[0106] Figure 4 This is a circuit diagram illustrating an example of the current flow in parallel mode during AC charging in the electrical equipment 10 of the embodiment. Figure 4 The example shown corresponds to the third pattern in Table 2 above.

[0107] like Figure 4 As shown, in parallel mode during AC charging, the electronic control unit 18 is set to the open (cut-off) state for the third circuit breaker 35 and the fourth circuit breaker 36. In parallel mode, currents flowing in opposite directions (reverse phases) from the AC power connection 15 to each coil β1 and β2 flow. The currents flowing in the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) are reverse-phase currents that weaken each other's magnetic flux. The degree of weakening of the magnetic flux varies depending on the combination of the number of turns of each β-phase coil 33 (β1) and 34 (β2) at the first and second poles that form the pole pair (N pole and S pole) in the stator core 42 of the rotating motor 16 (M). For example, as the difference in the combination of the number of turns at the first and second poles increases, the degree of weakening of the magnetic flux decreases. As the degree of weakening of the magnetic flux decreases, the inductance of each β-phase coil 33 (β1), 34 (β2) increases compared to the leakage inductance caused by leakage flux, for example, when the magnetic fluxes of each other are canceled out. For example... Figure 2 In the model of the rotary motor 16 (M) shown, the magnetic flux waveform is 4 poles as shown by the magnetic flux line F.

[0108] As the number of turns of each coil β1 and β2 at the first and second poles of the stator core 42 is reversed, for example, the magnetic flux waveforms of each coil β1 and β2 become opposite shapes and cancel each other out. Therefore, the torque generated in the rotating motor 16(M) during AC charging is zero. For example, when the rotor 41 and stator core 42 of the rotating motor 16(M) have 8 poles, when the winding pattern shown in Table 1 above is energized in reverse phase, the magnetic flux waveform of the stator core 42 becomes 16 poles. The ratio of the number of magnetic poles between the rotor 41 and the stator core 42 is 1:2, forming a magnetic circuit that generates magnetic flux but does not generate torque.

[0109] As described above, in the electrical device 10 according to the embodiment, the combination of the number of turns of each coil β1 and β2 is different at the first and second poles of the stator core 42, so that even when they are connected in parallel and energized in reverse phase, the magnetic flux between them is suppressed from being canceled out. This generates an inductance larger than the leakage inductance, suppressing current ripple and distortion, thereby improving charging efficiency.

[0110] The turns ratios of the coils β1 and β2 at the first and second poles are reversed, thus ensuring that the turns ratios of each coil β1 and β2 are the same as those of the stator core 42 as a whole. This suppresses torque generation in the rotary motor 16 during AC charging and reduces impact noises such as gear grinding caused by torque pulsation. Furthermore, the reverse waveforms of the coils β1 and β2 during power traction and regeneration of the rotary motor 16 are the same as those in the case where the turns ratios of each coil β1 and β2 at the first and second poles are the same, ensuring consistent power traction and regeneration performance.

[0111] Each coil β1, β2 is positioned in a slot 43 in the stator core 42, facing each other across the central shaft O. This allows the rotor 41 to generate a flux distribution that counteracts torque, even when energized in reverse phase, for example, during parallel connection. By suppressing the torque generation of the rotating motor 16 during AC charging, the generation of impact noises such as gear grinding caused by torque pulsation can be suppressed.

[0112] The first coil 33 (β1) of the β phase is configured in the first slot SL1 and the second slot SL2, and the second coil 34 (β2) of the β phase is configured in the third slot SL3 and the fourth slot SL4, thereby increasing the inductance and further suppressing current ripple and distortion.

[0113] When the energy storage device 11 drives the rotating motor 16 (M), the power control unit 10a can function as an inverter with a quadruple full-bridge circuit. When the energy storage device 11 is DC charged by an external power source, the combination of each coil of the rotating motor 16 (M) with each full-bridge circuit can function as a non-isolated DC-DC converter. When the energy storage device 11 is AC charged by an external power source, the combination of each α-phase coil 23 (α1), 24 (α2) of the rotating motor 16 (M) with the first full-bridge circuit 12a and the second full-bridge circuit 12b can function as an isolated bidirectional DC-DC converter. The combination of each β-phase coil 33 (β1), 34 (β2) with the third and fourth full-bridge circuits 13a and 13b can function as a rectifier circuit. For example, in the case of boost operation during AC charging, rapid charging can be performed for the energy storage device 11 with a voltage higher than the charging voltage of the external power source.

[0114] (Modified example)

[0115] The following describes variations of the embodiments. It should be noted that the same reference numerals are used for the same parts as in the embodiments described above, and the descriptions are omitted or simplified.

[0116] In the above embodiment, the coils α1 and α2 of phase α and the coils β1 and β2 of phase β are configured such that the combination of the number of turns at the first and second poles constituting the pole pairs (N pole and S pole) in the stator core 42 is different, but not limited to this. For example, the number of turns of each coil α1 and α2 at each of the first and second poles can also be the same.

[0117] Figure 5 This is a structural diagram of the rotary motor 16A, a first variation of the implementation method.

[0118] Table 3 below shows the results in Figure 5 The first modified rotary motor 16A shown here is an example of the number of turns of each coil α1, α2, β1, β2 corresponding to the N pole and S pole in each of the first pole pair and the second pole pair.

[0119]

[0120] like Figure 5 As shown in Table 3 above, in the first modified rotary motor 16A, the combination of the number of turns of each coil β1, β2 at the first and second poles constituting the pole pair (N pole and S pole) in the stator core 42 is different, while the number of turns of each coil α1, α2 is the same.

[0121] In the above embodiment, the number of turns of the first phase first coil 33 (β1) or the second phase second coil 34 (β2) at each of the first and second poles constituting the pole pair (N pole and S pole) in the stator core 42 is zero, but it is not limited to this. For example, the first phase first coil 33 (β1) and the second phase second coil 34 (β2) may also be provided at each of the first and second poles.

[0122] Figure 6 This is a structural diagram of the rotary motor 16B, a second variation of the implementation method. It should be noted that... Figure 6 The number of turns of each coil α1, α2, β1, β2 shown is an illustrative example.

[0123] like Figure 6 As shown, in the second modified rotary motor 16B, there are coils α1 and α2 with different numbers of turns at the first pole and the second pole, and coils β1 and β2 with different numbers of turns at each other.

[0124] Table 4 below shows that in Figure 6 The second modified example shown is an example of the number of turns of each coil α1, α2, β1, β2 corresponding to the N pole and S pole in the first pole pair and the second pole pair of the rotary electric machine 16B.

[0125]

[0126] As shown in Table 4 above, in the second modified rotary motor 16B, the turns ratio of each coil β1 and β2 in the first and second poles is β1:β2=1:3 or β1:β2=3:1. Similarly, in the second modified rotary motor 16B, the turns ratio of each coil α1 and α2 in the α phase is α1:α2=1:3 or α1:α2=3:1, just as it is in the β phase.

[0127] It should be noted that in the second variation described above, for example, the number of turns of each coil α1 and α2 at the first pole and the second pole can also be the same.

[0128] Figure 7 This is a structural diagram of the rotary motor 16C, a third variation of the implementation method. It should be noted that... Figure 7 The number of turns of each coil α1, α2, β1, β2 shown is an illustrative example.

[0129] like Figure 7 As shown, in the rotary motor 16C of the third variation, there are coils α1 and α2 with the same number of turns at the first pole and the second pole respectively, and coils β1 and β2 with different numbers of turns.

[0130] Table 5 below shows that in Figure 7 The rotating electric machine 16C of the third modified example shown is an example of the number of turns of each coil α1, α2, β1, β2 corresponding to the N pole and S pole in the first pole pair and the second pole pair respectively.

[0131] Figure 8 This is a structural diagram showing an example of the distributed winding of the rotary motor 16C in the third variation of the embodiment, corresponding to Table 5 below.

[0132]

[0133] like Figure 8 As shown in Table 5 above, in the rotary electric machine 16C of the third modification, the turns ratio of the coils β1 and β2 in the first and second poles is β1:β2=1:3 or β1:β2=3:1. The turns of the coils α1 and α2 in the first and second poles are the same. For example, in the case that the rotor 41 and stator core 42 of the rotary electric machine 16C of the third modification have 8 poles, when the winding pattern shown in Table 5 above is energized in reverse phase, the magnetic flux waveform of the stator core 42 becomes 4 poles. The ratio of the number of magnetic poles between the rotor 41 and the stator core 42 is 2:1, forming a magnetic circuit that generates magnetic flux but does not generate torque.

[0134] In the above embodiment, the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) are configured to be magnetically coupled to each other with the same polarity, but this is not a limitation; the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2) may also be magnetically coupled to each other with opposite polarities. In this case, for example, a circuit breaker may be provided between one end of the β-phase first coil 33 (β1) and the midpoint R2 of the second phase of the third full-bridge circuit 13a, or between one end of the β-phase second coil 34 (β2) and the midpoint R3 of the third phase of the fourth full-bridge circuit 13b. In short, in the parallel mode during AC charging, a current flowing in a direction that weakens each other's magnetic flux is introduced according to the polarity of the magnetic coupling of the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2).

[0135] In the above-described embodiment, during AC charging, current flows from an external AC power source to the β-phase first coil 33 (β1) and the β-phase second coil 34 (β2), but this is not a limitation. For example, at least one of a circuit breaker that switches the connection between the AC power connection 15 and the β-phase first coil 33 (β1) and a circuit breaker that switches the connection between the AC power connection 15 and the β-phase second coil 34 (β2) may be included. In this case, it may also be configured to allow current to flow only to the β-phase first coil 33 (β1) or the β-phase second coil 34 (β2).

[0136] In the above embodiment, the DC power supply connection 14 is connected in parallel to the negative terminal of the second power converter 13 and the midpoints of the first switch 22 and the second switch 32 (i.e., between the two transistors connected in reverse series), but is not limited thereto. For example, the DC power supply connection 14 may also be connected in series to the negative terminal of the second power converter 13 and the midpoints Q4 and R4 of the first power converter 12 and the second power converter 13. For example, the DC power supply connection 14 may also be connected in other parallel patterns to the negative terminal of the second power converter 13 and the midpoints Q2, Q4 of the first power converter 12 and the midpoints R2, R4 of the second power converter 13.

[0137] In the above embodiments, in Figure 3 In the functional structure of the electronic control unit 18 for AC charging in the electrical device 10 shown, it may not be necessary to obtain the phase of the input voltage Vac of the external AC power supply. For example, it may be equipped with an output voltage sensor that detects the output voltage Vo across the two ends (between the positive and negative terminals) of the capacitor 37, and a voltage control unit that outputs a target value of the current amplitude of the input current Iac of the external AC power supply by means of PI (proportional-integral) control based on the output voltage Vo obtained from the output voltage sensor and the target voltage.

[0138] The embodiments described herein are illustrative examples and are not intended to limit the scope of the invention. These embodiments can be implemented in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included within the scope and spirit of the invention as well as within the scope of the invention described herein and its equivalents.

Claims

1. An electrical device, wherein, The electrical equipment includes: Energy storage devices; A rotary electric motor, which has a rotor and multiple coils; A power control unit is connected to the rotating motor and the energy storage device to control the power supply and reception of the energy storage device and the rotating motor respectively; as well as An AC power connection component connects the rotary motor to an external AC power source. The power control unit includes a first full-bridge circuit connected to the two ends of the first coil and a second full-bridge circuit connected to the two ends of the second coil, which are connected to the AC power connection member in a predetermined phase among the plurality of coils. The rotary motor has a stator core with slots in which the first coil and the second coil are disposed, and the combination of the number of turns of the first coil and the second coil is different for the first pole and the second pole forming the pole pair.

2. The electrical equipment according to claim 1, wherein, The first coil and the second coil are disposed in the slots opposite each other in the stator core across the central shaft.

3. The electrical equipment according to claim 2, wherein, For the first slot and the second slot, which are opposite each other in the stator core across the central axis, the first coil is disposed in the first slot and the second coil is disposed in the second slot.

4. The electrical equipment according to any one of claims 1 to 3, wherein, Regarding the combination of the number of turns of the first coil and the second coil, the first pole and the second pole are the same in all pole pairs of the stator core.

5. The electrical equipment according to claim 4, wherein, The specified phase is the AC input phase that converts the input of AC power into the output of DC power.

6. The electrical equipment according to claim 5, wherein, The power control unit includes: The first circuit breaker is connected between one end of the first coil and the first full-bridge circuit; The second circuit breaker is connected between one end of the second coil and the second full-bridge circuit; A third full-bridge circuit is connected to the two ends of the third coil and a fourth full-bridge circuit is connected to the two ends of the fourth coil for the DC-DC conversion phase formed by the formation of the DC-DC conversion phase among the plurality of coils. A third circuit breaker is connected between the positive terminals of the third and fourth full-bridge circuits; and The fourth circuit breaker is connected between the negative terminals of the third and fourth full-bridge circuits.

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