Electric rotary machine with integrated control unit

Abstract

An electric rotary machine with an integrated control unit (100) comprising a power circuit section (20) provided between an external power source and a stator winding (300) of an electric rotary machine main body (102), the power circuit section (20) comprising: a positive-side power input / output terminal (11) and a negative-side power input / output terminal (71) electrically connected to the external power source; a power module (21) connected to the external power source via the positive-side power input / output terminal (11) and the negative-side power input / output terminal (71), further connected to the stator winding (300) and performing power conversion between the external power source and the stator winding (300); and a single cooling unit (23) which cools the power module (21), wherein the positive-side power input / output terminal (11) is attached to the single cooling unit (23) via an insulating material, the negative-side power input / output terminal (71) is directly attached to the single cooling unit (23), and either the positive-side power input / output terminal (11) or the negative-side power input / output terminal (71) is attached to a cable attachment provided with an even number of recesses arranged at approximately equal intervals, and the other terminal is attached to a cable attachment provided with at least three and an odd number of recesses arranged at approximately equal intervals.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention

[0001] The present invention relates to an electric rotary machine with an integrated control unit, in which an electric rotary machine and a control unit for controlling the electric rotary machine are integrated with each other. 2. Description of the state of the art

[0002] A rotary electric machine with an integrated control unit, installed in a vehicle such as a car, is provided with a power conversion circuit that performs power conversion between an armature winding of the rotary electric machine and a battery installed outside the rotary electric machine. This power conversion circuit typically includes multiple power modules containing switching elements made of semiconductors. The power conversion circuit operates as an inverter or rectifier by controlling a gate signal applied to each gate of these switching elements.

[0003] When the electric rotary machine is operated as a motor, the power conversion circuit operates as an inverter. The inverter converts the battery's direct current into alternating current and supplies the alternating current to the armature winding of the electric rotary machine.

[0004] When the electric rotary machine is operated as a generator, the power conversion circuit acts as a rectifier. The rectifier converts the alternating current induced by the armature winding of the electric rotary machine into direct current and supplies the direct current to the battery.

[0005] Such a conventional control unit-integrated rotary electric machine having the above-mentioned structure is provided with a positive-side power input / output terminal for the armature winding of the rotary electric machine. Furthermore, a negative-side power input / output terminal for the plurality of power modules is electrically connected to a rear bracket made of die-cast aluminum via a cooling unit made of die-cast aluminum, and is further electrically connected to the negative electrode terminal of the battery using one end of the rear bracket (see, for example, JP 2015-126602 A, DE 10 2016 219 938 A1, US 2010 / 0 308 700 A1, JP 5 840 282 B1, JP 2001-332 244 A, and JP 2001-102 042 A). SUMMARY OF THE INVENTION

[0006] Unfortunately, the current technology suffers from the following problems. The rear support, made of die-cast aluminum, is exposed to the outside in this conventional device, which also exposes the negative electrode section. Therefore, it is important to improve the vibration resistance of the positive-side power input / output terminal and the negative-side power input / output terminal.

[0007] The present invention has been devised to solve the above problems inherent in the conventional electric rotary machines, and an object thereof is to provide an electric rotary machine with an integrated control unit capable of ensuring vibration resistance.

[0008] An electric rotary machine with an integrated control unit according to the present invention has the features of claim 1 and in particular a power circuit section which is connected between an external or internal power supply.external power source and a stator winding of an electric rotary machine main body, the power circuit portion comprising: a positive-side power input / output terminal and a negative-side power input / output terminal electrically connected to the external power source; a power module connected to the external power source through the positive-side power input / output terminal and the negative-side power input / output terminal, further connected to the stator winding, and performing power conversion between the external power source and the stator winding; and a single cooling unit that cools the power module, the positive-side power input / output terminal being fixed to the single cooling unit via an insulation material, and the negative-side power input / output terminal being directly fixed to the single cooling unit.

[0009] According to the present invention, the positive-side power input / output terminal and the negative-side power input / output terminal are configured to be attached to the same single cooling unit. Thus, a rotary electric machine with an integrated control unit capable of ensuring vibration resistance can be obtained. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a longitudinal sectional view of an electric rotary machine with an integrated control unit according to Embodiment 1 of the present invention; Fig. 2 is a circuit diagram of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention; Fig. 3 is a partially transparent rear side view showing a structure of a power circuit section of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention; Fig. 4 is a front view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention; Fig. 5 is a side view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention; Fig. 6 is a cross-sectional view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention; Fig. 7 is a side view of an electric rotary machine with an integrated control unit according to Embodiment 2 of the present invention; Fig. 8 is a front view of an electric rotary machine with an integrated control unit according to Embodiment 3 of the present invention; Fig. 9 is a side view of the control unit-integrated electric rotary machine according to Embodiment 3 of the present invention; Fig. 10 is a front view of an electric rotary machine with an integrated control unit according to Embodiment 4 of the present invention; and Fig. 11 is a front view showing a cable assembly installed in the control unit-integrated electric rotary machine according to Embodiment 4 of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, preferred embodiments of an electric rotary machine with an integrated control unit according to the present invention will be described with reference to the drawings. Embodiment 1

[0011] Fig. 1 is a longitudinal sectional view of an electric rotary machine with an integrated control unit according to Embodiment 1 of the present invention. As shown in Fig. As shown in Figure 1, the control unit-integrated electric rotary machine 100 for a vehicle includes a front carrier 1, a stator core 3 supported by a rear carrier 2, and a rotor core 4 housed in an interior of the stator core 3. The rotor core 4 has a plurality of rotor magnetic poles facing an inner peripheral surface of the stator core 3 with a gap therebetween.

[0012] A coil portion of a stator winding 300, an armature winding, is inserted into a slot of the stator core 3 and fixed to the stator core 3. In this embodiment 1, the stator winding 300 has a 6-phase connection.

[0013] A rotor winding 7, which functions as a field winding, is fixed to the rotor core 4. The stator core 3 and the stator winding 300 constitute a stator 5 of an electric rotary machine main body 102, and the rotor core 4 and the rotor winding 7 constitute a rotor 13 of the electric rotary machine main body 102.

[0014] The front bracket 1 and the rear bracket 2 are fastened to each other by means of a plurality of screws 101 in a direction in which these brackets come towards each other, with the stator core 3 being firmly held therebetween.

[0015] A rotor shaft 6 passing through the center of the rotor core 4 is rotatably supported by a front bearing 61 supported by the front bracket 1 and a rear bearing 62 supported by the rear bracket 2.

[0016] A front cooling fan 51 and a rear cooling fan 52 are fixed to a front end surface and a rear end surface of the rotor core 4, respectively, and rotate together with the rotor core 4, thereby introducing air from the outside with respect to the front bracket 1 and the rear bracket 2. As a result, the interior of the rotary electric machine main body 102 is cooled.

[0017] A pulley 12 is attached to a front end portion of the rotor shaft 6. A transmission belt (not shown), which moves in conjunction with a rotating shaft of an engine, is wound around the pulley 12. Two slip rings 8, which are attached to the peripheral surface of the rotor shaft 6, are in sliding contact with two brushes 9 held by a brush holder 90.

[0018] A magnetic pole position detection sensor 10 constructed by a synchronous resolver includes a sensor rotor 111 fixed to a rear end portion of the rotor shaft 6, a sensor stator 112 facing the sensor rotor 111 and fixed to the rear bracket 2, and a sensor coil 113 fixed to the sensor stator 112.

[0019] A control board 40 with a control circuit is housed in a resin-made board housing 41. The control circuit provided in the control board 40 controls the switching functions of the power modules 21, which are described below. The board housing 41 is attached to an outer surface portion of a cooling unit 23.

[0020] A power circuit section 20 is mounted outside the rear carrier 2 and includes a power conversion circuit that performs power conversion between the stator winding 300, which functions as an armature winding, and a battery (not shown). This power conversion circuit is constructed with six power modules 21, described below, and operates as a 6-phase inverter or a 6-phase rectifier.

[0021] Fig. 2 is a circuit diagram of the electric rotary machine with integrated control unit according to Embodiment 1 of the present invention. As shown in Fig. 2, according to Embodiment 1, each of the power modules 21 includes two series-connected semiconductor switching elements and two diodes connected in anti-parallel to the semiconductor switching elements, respectively, and these switching elements and the diodes are sealed with a resin as a package.

[0022] The two semiconductor switching elements, which are sealed in each power module 21, are connected in series as described above. One of these semiconductor switching elements and the diode connected in antiparallel to it form a positive-pole arm corresponding to one phase of a 6-phase bridge circuit. The other semiconductor switching element and the diode connected in antiparallel to it form a negative-pole arm corresponding to one phase.

[0023] Each series connection point between the two semiconductor switching elements is connected to the stator winding 300 corresponding to one phase of a six-phase stator winding. Thus, the six power modules 21 constructed as described above are respectively connected to terminals 22a, which are connected to a B terminal 24, described below.

[0024] Fig. Fig. 3 is a partially transparent rear side view showing a structure of the power circuit section with integrated control unit according to Embodiment 1 of the present invention. As shown in Fig. 3, the power circuit section 20 comprises the six power modules 21, which form the 6-phase Construct a power conversion circuit and control the conduction of the stator winding 300, the cooling unit 23 to which these power modules 21 are mounted with insulation layers (not shown) therebetween, a positive-side power input / output terminal screw 11 electrically connected to the positive side of the battery, the B terminal 24 and a B bus bar 30 electrically connected to the positive-side power input / output terminal screw 11, and a power circuit case 25.

[0025] As it is in Fig. As shown in Figure 1, the cooling unit 23 is made of metal, such as die-cast aluminum, and has a through-hole 231 in the center. On the front surface of the cooling unit 23, a plurality of cooling fins 23a extending in an axial direction are integrally formed on the stator side of the rotary electric machine main body 102. The rotor shaft 6 passes through the through-hole 231 of the cooling unit 23.

[0026] As it is in Fig. As shown in Figure 3, the power circuit housing 25 is made of resin and includes an annular outer housing portion 251 and an annular inner housing portion 252. The inner housing portion 252 has an inner wall 255 surrounding a through-hole 254 of the inner housing portion 252. The inner wall 255 constitutes the inner wall of the power circuit housing 25.

[0027] The power circuit case 25 is fixed to a rear front surface of the cooling unit 23, thereby constructing a power module receiving portion 257 surrounded by the outer case portion 251 and the inner case portion 252 of the power circuit case 25 and the rear front surface of the cooling unit 23.

[0028] As it is in Fig. As shown in Figure 3, the six power modules 21 described above are housed in the power module housing section 257 and arranged to form an inverted C-shape with gaps between them. Furthermore, control board connectors 260 connected to the control board 40 are inserted into the power module housing section 257.

[0029] The control board connectors 260 each apply a gate signal sent from the control circuit of the control board 40 to the gates of the semiconductor switching elements of each power module 21.

[0030] A waterproof power circuit resin 28 is sealed into the power module receiving portion 257, in which the power modules 21 and the control board connectors 260 are housed. The power modules 21 and the control board connectors 62 are thus embedded in the waterproof power circuit resin 28 and protected from water by the waterproof power circuit resin 28.

[0031] The B terminal 24, which functions as a terminal electrically connected to the positive electrode of the external battery, is molded into the inner case portion 252 of the power circuit case 25 and a case coupling portion 253.

[0032] The B terminal 24 is electrically or mechanically connected to the terminals 22a of the six power modules 21 and terminals 260a of the control board connectors 260 by welding or soldering. Note that the B terminal 24 is exposed on an upper surface of the housing coupling portion 253 of the power circuit housing 25.

[0033] The bus bar (hereinafter referred to as "B-bus bar") 30 electrically connected to the positive electrode of the external battery is electrically connected to the positive-side power input / output terminal screw 11 and fixed to the cooling unit 23 through the power circuit case 25 provided as an insulating material.

[0034] Fig. 4 is a front view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention. Fig. 5 is a side view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention. Fig. Fig. 6 is a cross-sectional view of the control unit-integrated electric rotary machine according to Embodiment 1 of the present invention, taken along AA' of Fig. 4.

[0035] The positive-side power input / output terminal screw 11 and a negative-side power input / output terminal screw 71 are in a positional relationship shown in the Fig. 4 and Fig. 5. As shown in Fig. 6, the negative-side power input / output terminal screw 71 is directly fixed to the cooling unit 23, whereas the positive-side power input / output terminal screw 11 is fixed to the cooling unit 23 via the power circuit case 25 provided as an insulating material.

[0036] In the control unit-integrated electric rotary machine 100 according to Embodiment 1 of the present invention having the above structure, the positive-side power input / output terminal screw 11 is electrically connected to the positive side of the battery provided outside the control unit-integrated electric rotary machine 100 via a battery cable assembly or the like (not shown).

[0037] The pulley 12 is connected via a belt to a pulley on an internal combustion engine (not shown) provided on the output shaft of the internal combustion engine.

[0038] When the rotary electric machine with integrated control unit 100 is operated as a motor, the power conversion circuit constructed by the power modules 21 operates as an inverter. Specifically, the power conversion circuit operates as an inverter by controlling the semiconductor switching elements of the power modules 21 as switches with a gate signal from the control circuit provided in the control board 40.

[0039] Thus, the direct current from the battery is input to the terminals 22a of the power modules 21 via the positive-side power input / output terminal screw 11, the B terminal 24, and the B bus bar 30. The input direct current is converted into a 6-phase alternating current by the inverter constructed by the power modules 21. Further, the resulting 6-phase alternating current is supplied to the winding of each phase of the 6-phase stator winding 300 via terminals 22b of the power modules 21.

[0040] As a result, the rotor 13 is driven by the interaction between a rotating magnetic field generated by the stator winding 300 and a magnetic field generated by the rotor winding (field winding) 7 provided in the rotor 13. Furthermore, by driving the rotor 13, power is transmitted from the pulley 12 to the engine via the belt.

[0041] In contrast, when the electric rotary machine with integrated control unit 100 is operated as a generator, the power of the internal combustion engine is transmitted via the belt to the pulley 12 to drive the rotor 13. In this case, the power conversion circuit constructed by the power modules 21 operates as a rectifier.

[0042] Specifically, the power conversion circuit operates as a rectifier by controlling the semiconductor switching elements of the power modules 21 as switches with a gate signal from the control circuit provided in the control board 40.

[0043] The alternating current induced by each phase winding of the stator winding 300 is applied to each of the power modules 21 via the terminals 22b of the power modules 21. As a result, the alternating current is converted into direct current by the rectifier constructed with the power modules 21. Further, the resulting direct current is supplied from the terminals 22a of the power modules 21 to the battery via the B busbar 30, the B terminal 24, an intermediate piece 42, and a nut 36.

[0044] In the control unit-integrated rotary electric machine 100 according to Embodiment 1 of the present invention, the positive-side power input / output terminal and the negative-side power input / output terminal each have a fixed structure, fixed to the same single cooling unit as described above. Thus, vibration resistance can be ensured.

[0045] The cooling effect of these terminals can be improved by providing these fixed or fixed structures. Thus, thermal expansion or contraction of the nut 36 during a thermal cycle can be easily prevented, thereby preventing loosening of the nut 36.

[0046] Furthermore, the control unit-integrated electric rotary machine 100 according to Embodiment 1 of the present invention has a space portion formed between the positive-side power input / output terminal and the negative-side power input / output terminal, as shown in Fig. 4. Thus, even if the electric rotary machine with integrated control unit 100 comes into contact with water, its insulation can always be ensured without water accumulating therein.

[0047] When the electric rotary machine with integrated control unit needs to have a higher voltage (for example, approximately 50 volts), the above structure can prevent the risk of electric shock to a person who disconnects the electric rotary machine to maintain the vehicle.

[0048] The provision of such a space allows the positive-side power input / output terminal screw or a positive-side power supply cable assembly on the vehicle side to fall into the space in the event of a vehicle collision. Thus, the positive-side power input / output terminal screw or the positive-side power supply cable assembly on the vehicle side will not cause a short circuit with the negative-side power input / output terminal screw, thereby preventing destruction by fire and achieving a beneficial effect in collision safety.

[0049] As described above, Embodiment 1 provides a structure in which the positive-side power input / output terminal and the negative-side power input / output terminal are mounted on a single cooling unit. Thus, Embodiment 1 can realize a control-unit-integrated rotary electric machine capable of ensuring vibration resistance.

[0050] Embodiment 1 further provides a structure in which a space portion is formed between the positive-side power input / output terminal screw 11 and the negative-side power input / output terminal screw. Thus, even if the control unit-integrated rotary electric machine comes into contact with water, the control unit-integrated rotary electric machine can always ensure insulation without water accumulating therein.

[0051] Furthermore, the provision of such a space section not only avoids a short circuit between the positive side and the negative side, but also avoids destruction by fire even in the event of a collision of the vehicle, thereby contributing to improving collision safety. Embodiment 2

[0052] Fig. Fig. 7 is a side view of an electric rotary machine with an integrated control unit according to Embodiment 2 of the present invention. As shown in Fig. 7, in the control unit-integrated electric rotary machine 100 according to Embodiment 2 of the present invention, the positive-side power input / output terminal screw 11 is arranged at the rear side, unlike the structure according to Embodiment 1 described above, which is shown in Fig. 5 is shown.

[0053] As a result of such an arrangement of the positive-side power input / output terminal screw 11, the positive-side power input / output terminal screw 11 and the negative-side power input / output terminal screw 71 can be separated from each other in the axial direction of the rotor shaft of the electric rotary machine. As a result, the insulation between the positive and negative sides can be ensured even when foreign matter enters.

[0054] As described above, Embodiment 2 further has a structure in which the positive-side power input / output terminal and the negative-side power input / output terminal are separated in the axial direction. The structure of Embodiment 2 can thus realize a control unit-integrated electric rotary machine with improved insulation. Embodiment 3

[0055] Fig. 8 is a front view of an electric rotary machine with an integrated control unit according to Embodiment 3 of the present invention. Fig. 9 is a side view of the control unit-integrated electric rotary machine according to Embodiment 3 of the present invention.

[0056] A control unit-integrated rotary electric machine 100 according to Embodiment 3 of the present invention includes a positive-side power input / output terminal screw 11 extending in the axial direction and a negative-side power input / output terminal screw 71 extending in the radial direction of the rotary electric machine. Also in this arrangement, the positive-side power input / output terminal screw 11 and the negative-side power input / output terminal screw 71 are separated from each other in the radial direction. Thus, like the arrangement described with reference to Embodiment 2, the structure of Embodiment 3 can ensure insulation against any intrusion of foreign matter.

[0057] Although not shown, the same effects as in the Fig. 8 and Fig. 9 can be achieved with an arrangement that differs from that shown in the Fig. 8 and Fig. 9, in which the positive-side power input / output terminal screw 11 extends in the radial direction and the negative-side power input / output terminal screw 71 extends in the axial direction.

[0058] As described above, Embodiment 3 has a structure in which the positive-side power input / output terminal and the negative-side power input / output terminal extend in different directions and are separated from each other. Thus, the structure of Embodiment 3, like Embodiment 2, can realize a control unit-integrated rotary electric machine with improved insulation. Embodiment 4

[0059] Fig. 10 is a front view of an electric rotary machine with an integrated control unit according to Embodiment 4. Fig. 11 is a front view showing a cable assembly installed on the control unit-integrated electric rotary machine according to Embodiment 4 of the present invention.

[0060] A cable attachment of the positive-side power input / output terminal is provided with an odd number of recesses arranged at approximately equal intervals. On the other hand, a cable attachment of the negative-side power input / output terminal is provided with an even number of recesses arranged at approximately equal intervals. In the examples shown in the Fig. 10 and Fig. 11, the cable attachment of the positive-side power input / output terminal is provided with three grooves, and the cable attachment of the negative-side power input / output terminal is provided with two grooves.

[0061] These different installation structures of the two terminals prevent improper mechanical installation between them, for example, during market maintenance, thereby preventing incorrect battery connection. Consequently, smoke development and ignition can be prevented in advance.

[0062] Although not shown, the same effects as in the structure used in the Fig. 10 and Fig. 11 can be achieved by producing a structure different from that shown in the Fig. 10 and Fig.11, in which the cable attachment of the positive-side power input / output terminal is provided with an odd number of grooves arranged at approximately equal intervals, and the cable attachment of the negative-side power input / output terminal is provided with an odd number of grooves arranged at approximately equal intervals.

[0063] According to such a structure in which the cable attachments are each provided with recesses arranged at approximately equal intervals, the tightening torque generated when attaching the cables or cable assemblies can act substantially uniformly on the recesses, thereby preventing damage to the recesses.

[0064] According to Embodiment 4, as described above, the number of provided grooves for the cable attachments of the positive-side power input / output terminal and the negative-side power input / output terminal is different, and the grooves are arranged at approximately equal intervals. Thus, with the structure of Embodiment 4, incorrect connection of the battery and damage to the grooves caused by tightening torque can be prevented.

Claims

[1] An electric rotary machine with an integrated control unit (100) comprising a power circuit section (20) provided between an external power source and a stator winding (300) of an electric rotary machine main body (102), the power circuit section (20) comprising: a positive-side power input / output terminal (11) and a negative-side power input / output terminal (71) electrically connected to the external power source; a power module (21) connected to the external power source via the positive-side power input / output terminal (11) and the negative-side power input / output terminal (71), further connected to the stator winding (300) and performing power conversion between the external power source and the stator winding (300); and a single cooling unit (23) which cools the power module (21), wherein the positive-side power input / output terminal (11) is attached to the single cooling unit (23) via an insulating material, the negative-side power input / output terminal (71) is directly attached to the single cooling unit (23), and either the positive-side power input / output terminal (11) or the negative-side power input / output terminal (71) is attached to a cable attachment provided with an even number of recesses arranged at approximately equal intervals, and the other terminal is attached to a cable attachment provided with at least three and an odd number of recesses arranged at approximately equal intervals. [2] The control unit-integrated electric rotary machine (100) according to claim 1, wherein the positive-side power input / output terminal (11) and the negative-side power input / output terminal (71) are arranged separately from each other with a space portion therebetween. [3] The control unit-integrated electric rotary machine (100) according to claim 2, wherein a seating position for cable attachment of the positive-side power input / output terminal (11) and a seating position for cable attachment of the negative-side power input / output terminal (71) are separated from each other with the space portion therebetween in an axial direction. [4] The control unit-integrated electric rotary machine (100) according to claim 2 or 3, wherein a seating position for cable attachment of the positive-side power input / output terminal (11) and a seating position for cable attachment of the negative-side power input / output terminal (71) are separated from each other with the space portion therebetween in a radial direction. [5] The electric rotary machine with an integrated control unit (100) according to any one of the preceding claims, wherein one of the positive-side power input / output terminal (11) and the negative-side power input / output terminal (71) extends in an axial direction of the electric rotary machine, and the other of the positive-side power input / output terminal (11) and the negative-side power input / output terminal (71) extends in a radial direction of the electric rotary machine.

Images