Rotating electric machine with integrated control unit

Abstract

Rotating electric machine with integrated control device (1) with a rotating electric machine (2) which is equipped with a stator (21) and a rotor (22), and a power converter (3) which is equipped with a control board (30) and a plurality of power modules (33A to 33C), wherein the stator (21) has two sets of three-phase stator coils (21b, 21c), the control board (30) is equipped with electronic components that configure a control circuit for the rotating electric machine (2), the large number of power modules (33A to 33C) are equipped with a large number of switching elements (33Aa to 33Ad, 33Ba to 33Bd, 33Ca to 33Cd), and at least one of the power modules (33A) is provided with switching elements (33Aa to 33Ad) that control two different sets of the stator coils, and with a sensing element (33Af) that detects a state of the power module, wherein: the power converter (3) is equipped with the power modules (33A, 33B, 33C) which are subdivided into a first power module (33A) and second power modules (33B, 33C), The first power module (33A) controls two different sets of stator coils (21b, 21c), and the second power modules (33B, 33C) control the same set of stator coils (21b, 21c).

Description

BACKGROUND OF THE FINDING Technical field

[0001] The present invention relates to a rotating electric machine with an integrated control device. State of the art

[0002] US 2014 / 0346910A1 discloses a condensed permanent magnet motor, wherein the number of magnetic poles is M, a stator has N teeth around which coils are condensed and arranged at equal intervals around the circumference, wherein M is equal to (18 ± 4)n and N is equal to 18n, an armature winding has m parallel connections, and a 1-phase circuit of the parallel connections is configured to have 6n / m coils connected in series.

[0003] WO 2015 / 003970 A1 discloses an electric drive device for an electric power steering system, comprising an electric motor with a motor housing and a motor shaft with a drive end, an electronic control unit arranged coaxially to the motor shaft which controls the drive of the motor and comprises a power board and a control board, and a heat sink which absorbs and dissipates the heat generated by the power board, wherein the motor, the heat sink, the power board and the control board are arranged in this order with respect to the drive end, the power board covering the cross-section of the motor housing.

[0004] US Patent 2012 / 0 229 005 A1 discloses an electric drive device comprising an electric motor, a control device arranged coaxially to the axis of the electric motor's rotating shaft and responsible for controlling the electric motor's drive, a motor terminal whose end extends from the electric motor towards the control device, and an output terminal whose end extends from the control device towards the electric motor; wherein a section of the motor terminal including its end and a section of the output terminal including its end are each configured such that they extend parallel to an axial direction of the electric motor and are connected to each other in an overlapping manner.

[0005] US Patent 2011 / 0273042A1 discloses a dynamoelectric machine with an integrated control device, comprising: a metal housing with a front and a rear support, a rotor rotatably arranged in the housing by being attached to a shaft rotatably supported by the front and rear supports, a stator with a cylindrical stator core arranged to be held between the front and rear supports and surrounding the rotor, and a stator winding mounted on the stator core, and a control device comprising a DC-AC conversion circuit section that supplies electric current to the stator winding, and a control circuit section that controls the DC-AC conversion circuit section, the control device being located inside the rear support.

[0006] Traditionally, there are rotating electric machines with integrated control devices, each consisting of a rotating electric machine and a control device.

[0007] The rotating electric machine with integrated control device comprises a rotating electric machine and a control device (also referred to as an inverter assembly). The control device includes a power module, a heat sink, a connection terminal, a busbar, and an insulator. The power module is attached to the heat sink by an adhesive that exhibits thermal conductivity and electrical insulating properties. The connection terminal and the busbar, which has an inner wall section, an outer wall section, and a flat wall section, are embedded in an insulator that forms a housing element. The insulator is attached to the heat sink by the adhesive. The power module is housed in a concave section formed by the insulator and the heat sink.One terminal of the power module is connected to the terminal block and the busbar. The concave section formed by the insulator and the heat sink is filled with a filler that has electrical insulating properties. An example of a conventional rotating electric machine with an integrated control device is disclosed in JP 2014-45629A and JP 2011-243909A.

[0008] A rotating electric machine with an integrated control device, as defined in JP 2014-45629A, comprises two distinct power modules, each equipped with an identical switching element, such as an internal circuit, and an essentially symmetrical external appearance. The two power modules are combined as a pair with a heat sink. In this configuration, because the two distinct power modules are combined with the heat sink, a front end of at least one terminal of each power module, exposed beyond the resin element, is arranged in series to project at an equal distance from each other, i.e., from a surface end of both power modules. As a result, miniaturization of the rotating electric machine is achieved, while cooling characteristics and reliability can also be improved.

[0009] JP 2011-243909A discloses that when using a control device, a semiconductor device (power module) is required as a switching element for the upper and lower branches of an inverter for a rotating electric machine in a vehicle. Consequently, the number of wires and signal connections associated with a temperature sensing element increases, as does the number of signal connections of a control device (controlled by an IC).With regard to the problems described above, it is also disclosed that by using a power module configured with an upper and lower branch switching element and by connecting either the upper or the lower branch of a temperature sensing port to the signal port, the number of control IC ports can be reduced and miniaturization of the control device can be achieved.

[0010] However, an integrated control device disclosed in JP 2014-45629A applies a module that controls the upper and lower branches using two switching elements to the module of a rotating electric machine configured from two sets of three-phase stator coils, disclosed in JP 2011-243909A. That is to say, JP 2014-45629A discloses a rotating electric machine that uses a total of six modules.

[0011] In the integrated control device described above, it is necessary to monitor the temperature of the six power modules to detect anomalies in all phases of the stator coils. Consequently, increasing the number of connections to the control device (control IC), to which the temperature monitoring results (measured results) are sent, can be problematic. In particular, increasing the number of connections leads to a bulkier control device (control IC), which in turn results in a bulkier integrated control device. With regard to the above, the present disclosure aims to provide a rotating electrical machine with an integrated control device that can detect an operational anomaly of interest, such as an abnormal temperature of a stator coil, and to achieve miniaturization of this device. SUMMARY

[0012] To solve the problems described above, a rotating electric machine with an integrated control device is provided, as specified in claim 1.

[0013] Advantageous embodiments are specified in the dependent patent claims.

[0014] A rotating electric machine with an integrated control device according to a first embodiment of the disclosure comprises a rotating electric machine (2) having a stator (21) and a rotor (22), and a power converter (3) provided with a control board (30) and a plurality of power modules (33A to 33C). The stator (21) has two sets of three-phase stator coils (21b, 21c), and the control board (30) is equipped with electronic components that configure a control circuit of the rotating electric machine. The multiple power modules (33A to 33C) are equipped with multiple switching elements (33Aa to 33Ad, 33Ba to 33Bd, 33Ca to 33Cd), and at least one of the modules (33A) is equipped with switching elements (33Aa to 33Ad) that control two different sets of stator coils, and a sensing element (33Af) that detects a state of the module.

[0015] In this configuration, at least one of the modules controls two different sets of stator coils. An anomaly in the two sets of stator coils (for example, an abnormally high temperature) can be detected by sensing the state (for example, temperature) of at least one module using the sensing element. This means that the anomaly in the two sets of stator coils can be detected by sensing the state of at least one module, thus reducing the number of sensing elements required for the entire rotating electrical machine. Furthermore, the number of connections on the control device (IC controller) that receive a sensing result sent from the sensing element can also be reduced, which in turn reduces the size of the rotating electrical machine.

[0016] The rotating electric machine with integrated control unit is equipped with a power converter comprising a first module (33A) that controls the two different sets of stator coils, and second modules (33B, 33C) that control the same set of stator coils. According to this configuration, if an anomaly occurs in one of the two sets of stator coils, the stator coil in which the anomaly occurred can be identified based on the results obtained from the first and second modules.

[0017] The rotating electric machine with integrated control device according to a second embodiment of the disclosure is provided with the first module, which has a temperature sensing element (33Af) that detects the temperature of the first module. In this configuration, the state of the first module can be detected using the temperature.

[0018] The rotating electric machine with integrated control device according to a third embodiment of the disclosure is provided with the second modules, which have the temperature sensing elements as the sensing elements that detect a temperature of the second modules. In this configuration, a state of the second modules can be detected.

[0019] In the rotating electric machine with integrated control device according to a fourth embodiment of the disclosure, each of the modules, each equipped with a heat sink (37A to 37C), is thermally insulated from another module below (33A to 33C). In this configuration, heat transfer to each module through the heat sink, which is arranged between adjacent modules, is suppressed. As a result, a reduction in the accuracy of the measured heat transfer results is also prevented.

[0020] The rotating electric machine with integrated control device according to a fifth embodiment of the disclosure is provided with the control board, which has an open circular shape. Each module is arranged around a circumferential direction (CIRC) of the open circular shape, and at least one of the modules is arranged diametrically opposite a section that is an open segment of the circle. In this configuration, the at least one of the modules is not in the immediate vicinity of the open segment of the circular shape. As a result, heat radiation from the at least one of the modules is suppressed, even if heat radiation occurs at the open segment. Consequently, a reduction in the detection accuracy of the detection element is prevented.It should be noted that a position that is diametrically opposite to the open section of the open circle is the position that is diametrically opposite in a direction of revolution therefrom, with reference to a center point of the circular shape of the circuit board.

[0021] Additionally, in the described configuration, modules other than the at least one module are arranged between the at least one module and the open section of the open circular shape. In this case, modules other than the at least one module can radiate heat to the open section of the open circular shape. As a result, the effect of heat transferred from other adjacent modules to the at least one module is suppressed.

[0022] The rotating electric machine with integrated control device according to a sixth embodiment of the disclosure is provided with the control board having the open circular shape which has an open section, wherein each of the modules is arranged around a circumferential direction (CIRC) of the open circular shape, and the first module is arranged diametrically opposite to the open section of the circular shape.

[0023] In this configuration, because the first module is positioned diametrically opposite the open section of the circular shape, heat radiation from the first module to the open section of the circular shape is suppressed. Specifically, the distance between the first module, which detects a state (anomaly) of the stator coil, and the open section of the circular shape is large, so that heat is only radiated from the open section of the circular shape with difficulty when the first module generates heat. The distance described above refers to the distance over which heat is transferred through the control board.

[0024] Additionally, because the second module is positioned between the open section of the circular shape and the first module, heat transfer through the interposed second module is blocked, even if heat is transferred to the open section of the circular shape when the first module radiates heat. As a result, a reduction in the detection accuracy with which a condition (anomaly) of the first module is detected is suppressed.

[0025] The rotating electric machine with integrated control device according to a seventh embodiment of the disclosure is provided with the control board, which has the open section of the circular shape, and connecting parts (31a, 31b) that connect the switching elements controlling the stator coils to an external connecting part provided on the open section of the circular shape. In this configuration, the connecting parts can also be used for heat dissipation to the open section of the circular shape. The connecting parts exhibit good heat dissipation properties. When a module generates heat, heat transfer occurs through the connecting part of the module. As a result, the heat dissipation capacity at the open section of the circular shape can be increased, thus suppressing the effect of heat from neighboring modules on the normally operating module.Additionally, suppression and a reduction in the detection accuracy of the detection element are also achieved.

[0026] The rotating electric machine with integrated control device according to an eighth embodiment of the disclosure is provided with the power converter, which includes the connecting part and the heat sink connected to the external connecting part integrated into a resin container. The control board and the module are encapsulated in the resin container by potting with resin. In this configuration, the potted resin reduces the effect of the ambient temperature on the temperature sensing element of the module. Additionally, if a foreign body is present in the power converter (control device 3), the filler material prevents contact or collision of the foreign body with other components within it. As a result, a reduction in the sensing accuracy of the sensing element can also be prevented. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 shows a top view illustrating a rotating electric machine with an integrated control device according to a preferred embodiment. Fig. Figure 2 shows a cross-section along a line II-II according to Fig. 1 is taken, Fig. Figure 3 shows a top view illustrating a container part, viewed from a side opposite a side containing the rotating electric machine, according to the preferred embodiment. Fig. Figure 4 shows a cross-sectional view along a line IV-IV according to Fig. 3 is taken, Fig. Figure 5 shows a top view illustrating the container part as seen from the side, in which the rotating electric machine is mounted. Fig. Figure 6 shows a top view illustrating a fastening part viewed from the side opposite the side containing the rotating electrical machine. Fig. Figure 7 shows a side view illustrating the fastening part. Fig. Figure 8 shows a top view illustrating the mounting part as seen from the side, in which the rotating electric machine is mounted. Fig. Figure 9 shows a top view illustrating the fastening part as seen from the side opposite the side containing the rotating electric machine. Fig. Figure 10 shows a representation illustrating a side view of a second fastening part, Fig. Figure 11 shows a top view illustrating the second mounting part as seen from the side in which the rotating electric machine is mounted. Fig. Figure 12 shows a top view illustrating a heat sink for a power module viewed from the side opposite the side containing the rotating electric machine. Fig. Figure 13 shows a side view of the heat sink for the power module, Fig. Figure 14 shows a top view illustrating the heat sink for the power module as seen from the side in which the rotating electric machine is mounted. Fig. Figure 15 shows a top view illustrating the container part with the power module arranged on it, viewed from the side opposite the side containing the rotating electric machine. Fig. Figure 16 shows a cross-sectional view along a line XVI-XVI according to Fig. 15 taken, Fig. Figure 17 shows a cross-sectional view illustrating the container part with a wiring board attached to it, viewed from the side opposite the side containing the rotating electrical machine. Fig. 18 shows a cross-sectional view between an arrow XVIII-XVIII according to Fig. 17, Fig. Figure 19 shows a cross-sectional view illustrating a magnetic circuit mounted on a wiring board and the surrounding area of ​​the heat sink for the magnetic circuit IC. Fig. Figure 20 shows a cross-sectional view illustrating a microcomputer mounted on the wiring board and the area around the heat sink for the microcomputer. Fig. Figure 21 shows a cross-sectional view illustrating a control device of a charging unit in a charged state. Fig. Figure 22 shows a diagram illustrating a circuit of a rotating electric machine with integrated control device according to a preferred embodiment. Fig. Figure 23 shows a diagram illustrating a circuit of a rotating electric machine with integrated control device according to a modified form 1, and Fig. Figure 24 shows a diagram illustrating a circuit of a rotating electric machine with integrated control device according to a modified form 2. DETAILED DESCRIPTION OF THE PREFERRED EXECUTION EXAMPLE

[0027] A preferred embodiment of the present disclosure is described with reference to the accompanying drawings. A rotating electric machine with an integrated control device according to the preferred embodiment is shown as an example of a rotating electric machine with an integrated control device mounted in a vehicle. Preferred embodiments

[0028] The rotating electric machine with integrated control device 1 according to the preferred embodiment is described with reference to Fig. 1 to 22 described.

[0029] The rotating electric machine with integrated control device 1 according to the preferred embodiment is a device that generates motive power for propelling a vehicle using electrical power supplied from a battery B mounted in the vehicle (which is omitted in a number of drawings). The device also generates electrical power for charging the battery B by supplying motive power from a motor of the vehicle. The rotating electric machine with integrated control device 1 (hereinafter also referred to as the integrated rotating electric machine 1) is provided with a rotating electric machine and a control device 3.

[0030] Fig. Figure 1 shows a top view of the rotating electric machine with integrated control device 1 according to the preferred embodiment, viewed from a side opposite a side containing a rotating electric machine. The side containing the rotating electric machine (specifically the side in which the rotating electric machine is mounted) is referred to as “2a”, and the opposite side is referred to below as “2b”. Fig. 2 shows a cross-sectional view along a line II-II in Fig. 1 is taken. (Rotating electric machine)

[0031] The rotating electric machine 2 generates the driving force to propel a vehicle via the electrical power supply. The rotating electric machine also generates the electrical power to charge the battery via a driving force supplied by the power unit. The rotating electric machine 2 is equipped with a housing 20, a stator 21, a slip ring 23, a brush 24, and a magnet for detecting the angle of rotation 25.

[0032] The housing 20 accommodates the stator 21 and one rotor 20 and also supports the rotor 22 in a rotatable position. The control device 3 is fixed. The housing 20 is provided with an arc-shaped engagement element 20a that engages with the control device 3 when the control device 3 is fixed.

[0033] The stator 21 configures a section of a magnetic path and also generates a rotating magnetic field by the flow of a current. The stator 21 is equipped with a stator core 21a and two sets of stator coils 21b and 21c.

[0034] The stator 22 configures part of the magnetic path and also forms a magnetic pole due to a flowing current. The stator 22 is equipped with a rotating shaft 22a, a rotor core 22b, and a rotor coil 22c.

[0035] The slip ring 23 and the brush 24 supply a direct current (DC) to the rotor coil 22c. The slip ring 23 is attached to an outer circumferential surface of the rotating shaft 22a via an insulating element 23a. The brush is held in a brush holder 24b and is pressed against one side of the rotating shaft 22a by a spring 24a, with one end surface of the brush being in close contact with an outer circumferential surface of the slip ring 23.

[0036] The magnet for sensing the angle of rotation 25 generates a magnetic field for detecting an angle of rotation of the rotor 22. The magnet for sensing the angle of rotation 25, which is held in a magnet holding device 25a, is attached to an end section of the rotating shaft 22a in the axial direction. (Control unit)

[0037] The control unit 3 controls the electrical power supplied to the rotating electric machine 2 from battery B to generate the driving force of the rotating electric machine 2. The control unit 2 also converts the electrical power generated by the rotating electric machine 2 and supplies the converted power to battery B. The control unit 3 is equivalent to a power converter.

[0038] As it is in Fig. 1 to Fig. 3 and Fig. As shown in Figure 17, the control unit 3 is provided with a wiring board 30, power supply wiring sections 31a, 31b, a stator wiring section 31c (fixed wiring section), a rotor wiring section 31d, a wiring section for external communication 31e, a rotary angle detection circuit IC32, power modules 33 (33A, 33B, 33C), a field system circuit IC34, a microcomputer 35, a container part 36a, mounting parts 36b and 36c, a cover part 36d, a heat sink 37 (37A, 37B, 387C) for the respective power modules 33 (33A, 33B, 33C), a heat sink for a field system circuit 37D, a heat sink for a microcomputer 37E and a filling element 38.

[0039] Fig. Figure 3 shows a top view of the container part 36a of the rotating electric machine with integrated control device 1 as viewed from side 2b of the rotating electric machine according to the preferred embodiment. Fig. Figure 17 shows the container part 36a with the wiring boards positioned on it, viewed from side 2b of the rotating electrical machine.

[0040] The wiring board 30 is an internal wiring section board for connecting the rotary angle sensing circuit IC32, the power modules 33A, 33B, and 33C, the field system circuit IC34, and the microcomputer 35. The wiring board 30 forms a wiring pattern on a surface and an inner layer thereof. The wiring board 30 is equivalent to a control board, and the power modules 33 (33A, 33B, 33C) are equivalent to a module.

[0041] The wiring board 30 is shaped to extend perpendicularly to a projecting direction of the rotating shaft 22a of the rotating electric machine 2, and partially forms an open circular shape. The so-called "open circle" refers to a portion of a circuit with an open section. More precisely, the open circular shape lacks a circumferential portion and forms, for example, a C-shape or a U-shape. Additionally, the circular shape lacking the circumferential portion of the open circular shape cannot achieve a center (reach a central point). That is, the open circle can be configured such that it has a missing portion extending from an outer circumferential end toward a central point.

[0042] Power supply wiring sections 31a and 31b are external wiring sections for connecting a power supply connector of the wiring board 30 and a power supply terminal of the power modules 33A, 33B and 33C to the battery B, which are located outside the container part 36a, as shown in Fig. 3 and Fig. Figure 4 shows the power supply wiring sections 31a and 31b, which are made of a conductive metal. For example, the power supply wiring sections 31a and 31b could be made of copper or steel sheets formed in a curved shape. A cross-sectional view across line IV-IV is shown in Figure 4. Fig. 3 is in Fig. 4 shown.

[0043] The power supply wiring sections 31a and 31b are inserted into the container part 36a, which exposes the connectors 31f and 31g of the wiring board 30 as well as the connectors 31h and 31i of the power modules 33A, 33B and 33C inside the container part 36a and also exposes the connectors 31j and 31k of the battery B outside the container part 36a.

[0044] The power supply wiring section 31b projects from the open section of the open circular shape of the wiring board 30, and a connection terminal (not shown) connecting an external battery B to an end section of the power supply wiring section 31b may also be provided at a front end thereof. The connection terminal is made of a conductive metal for connection to the battery B, for example, a copper sheet or a steel sheet in a curved shape. The connection terminal is preferably formed from a curved steel sheet. By providing the connection terminal formed from a steel sheet, the power supply wiring section 31b can still be rigidly attached to an external terminal to connect the external battery B, even if the power supply wiring section 31b is formed from a flexible metal such as copper.In this case, the connection port is preferably arranged with the power supply wiring part 31b, which is inserted inside the container part 36a.

[0045] The stator wiring section 31c is an external wiring section formed from a conductive metal to connect an output terminal of the power modules 33A, 33B to the stator coils 21b and 21c, which are located outside the housing part 36a. The stator wiring section 31c is, for example, a copper or steel sheet in a curved shape. Additionally, the stator wiring section 31c is inserted into the housing part 36a with a connector 31l of the power modules 33A, 33B, and 33C, which is exposed inside the housing part 36a, and a connector 31m of the stator coil 21b, which is exposed outside the housing part 36a. Fig. Figure 5 shows a top view of the container part 36a from one side in which the rotating electric machine is mounted.

[0046] The rotor wiring section 31d is an external wiring section formed from a conductive metal to connect a rotor coil connector of the wiring board 30 to the rotor coil 22c, which is located outside the housing part 36a, via the brush 24 and the slip ring 23. The rotor wiring section 31d can, for example, be formed from a copper sheet or a steel sheet with a curved shape. The rotor wiring section 31d is inserted into the housing part 36a with a connector 31n connected to the wiring board 30, which is exposed inside the housing part 36a, and a connector 31o connected to the brush 24, which is exposed outside the housing part 36a.

[0047] The external communication wiring section 31e is an external wiring section made of a conductive metal for connecting the external communication section of the wiring board 30 to an external device located outside the container part 36a. The external communication wiring section is, for example, a copper plate or a steel plate in a curved shape. Additionally, the external communication wiring section 31e is inserted into the container part 36a by means of a connector 31p connected to the wiring board 30, which is exposed inside the container part 36a, and a connector 31q connected to the external device, which is exposed outside the container part 36a.

[0048] The rotation angle detection circuit IC32 is an electronic component that detects the rotation angle of the rotor 22 based on the magnetic field generated by the magnet for rotation angle detection 25. The rotation angle detection circuit IC32 is provided on the wiring board 30.

[0049] The power module 33 is an electronic component that configures an inverter circuit. The power module 33 is equipped with four switching elements (MOSFETs 33a to 33d), a diode 33e, and a temperature sensing element 33f. The power module 33 is controlled by a microcomputer 35, which converts a direct current (DC) supplied from battery B into a three-phase alternating current and also supplies the three-phase alternating current to the stator coils 21b and 21c by switching the switching elements (MOSFETs 33a to 33d) according to a predefined timing schedule. Furthermore, the three-phase alternating current supplied from the stator coils 21b and 21c is converted into a direct current (DC) by the diode 33e and supplied to the battery B by terminating the switching of the switching element (MOSFETS 33a to 33d).

[0050] According to the preferred embodiment, the three power modules 33A, 33B and 33C are provided as the power module 33. Fig. Figure 22 shows a circuit diagram of the rotating electric machine with integrated control device 1 according to the preferred embodiment.

[0051] The power module 33A has four switching elements (MOSFETs 33Aa to 33Ad). MOSFETs 33Aa and 33Ab are connected in series, as are MOSFETs 33Ac and 33Ad. The sources of MOSFETs 33Aa and 33Ac are each connected to a drain of MOSFET 33Aba and 33Ad, respectively. Of the two series-connected MOSFETs 33Aa and 33Ab, MOSFET 33Aa is a switching element on the high-voltage side, and MOSFET 33Ab is a switching element on the low-voltage side. The power module 33A is equivalent to at least one module or a first module.

[0052] The power module 33B has four switching elements (MOSFETs 33Ba to 33Bd). MOSFETs 33Ba and 33Bb are connected in series, as are MOSFETs 33Bc and 33Bd. The sources of MOSFETs 33Ba and 33Bc are each connected to a drain of MOSFET 33Bb and 33Bd, respectively. Of the two series-connected MOSFETs 33Ba and 33Bb, MOSFET 33Ba, which is connected to a positive terminal of battery B, is a switching element for the high-voltage side, and MOSFET 33Bb is a switching element for the low-voltage side. The power module 33B is equivalent to a second module.

[0053] The power module 33C has four switching elements (MOSFETs 33Ca to 33Cd). MOSFETs 33Ca and 33Cb are connected in series, as are MOSFETs 33Cc and 33Cd. The sources of MOSFETs 33Ca and 33Cc are each connected to a drain of MOSFET 33Cb and 33Cd, respectively. Of the two MOSFETs 33Ca and 33Cb connected in series, MOSFET 33Ca, which is connected to a positive electrode of battery B, is the high-voltage switching element, and MOSFET 33Cb is the low-voltage switching element. The power module 33C is equivalent to the second module.

[0054] As it is in Fig. As shown in Figure 22, the power module 33A connects each of the respective MOSFETs 33Aa and 33Ab to one set of three-phase stator coils 21b and the respective MOSFETs 33Ac and 33Ad to another set of three-phase stator coils 21c. In particular, the power module 33A controls two sets of three-phase stator coils 21b and 21c.

[0055] Power module 33B connects MOSFETs 33Ba to 33Bd to one set of three-phase stator coils 21b. Power module 33C connects MOSFETs 33Ca to 33Cd to the other set of stator coils 21c. In particular, each of the power modules 33B and 33C controls a different set of three-phase stator coils 21b and 21c, respectively.

[0056] Temperature sensing elements 33Af, 33Bf, and 33Cf, mounted in the respective power modules 33A, 33B, and 33C, detect the temperature of the module in which the temperature sensing element is located. According to the present embodiment, a diode is used for the temperature sensing elements 33Af, 33Bf, and 33Cf; however, a conventional design can also be used. The temperature sensing elements 33Af, 33Bf, and 33Cf are equivalent to sensing elements. There is no limit to the mounting position of the temperature sensing elements 33Af, 33Bf, and 33Cf in the respective power modules 33A, 33B, and 33C. This means that the temperature sensing elements 33Af, 33Bf and 33Cf are preferably mounted in a center (where the distance to the switching elements is the same) of the 4 switching elements (MOSFETs 33a to 33d).

[0057] The mounting method for the temperature sensing elements 33Af, 33Bf, and 33Cf in the power modules 33A, 33B, and 33C is not limited to the method described. For example, if the power modules 33A, 33B, and 33C are encapsulated in resin along with other electronic components such as the switching elements (MOSFETs 33a to 33d), the temperature sensing elements can be arranged in close contact with the resin (the components adhered to the resin), even if the temperature sensing elements 33Af, 33BF, and 33Cf are encapsulated together.

[0058] The power modules 33A, 33B, and 33C are arranged along the circumferential direction (CIRC) of the open circuit of the wiring board 30. The power modules are arranged in the respective sequence 33B, 33A, 33C from one end of the circumferential direction (CIRC) of the open circuit of the wiring board to the other end thereof (as shown in Fig. 15 is shown, clockwise).

[0059] This means that power module 33A is arranged diametrically opposite to the open section of the open circuit of the wiring board 30. Power modules 33B and 33C are arranged on either side of power module 33A in a circular direction (CIRC) of it. The switching elements (MOSFETs 33Aa to 33Ab and 33Ba to 33Bd) that control the three-phase stator coils 21b are located on one side of line IV-IV of Fig. 3. The switching elements (MOSFET 33Ac to 33Ad and 33Ca to 33Cd) that control the set of three-phase stator coil 21c are arranged on a lower side, which is below line IV-IV of Fig. 3 is taken.

[0060] The field system circuit IC34 is an electronic component that is a circuit for supplying a direct current to the rotor coil 22C, which is controlled by the microcomputer 35.

[0061] The microcomputer 35 is an electronic component that controls the power modules 33A, 33B, and 33C, as well as the field system circuit IC34, based on an externally supplied command and a detected result from the rotary angle detection circuit IC32. The microcomputer 35 operates according to a pre-recorded program and controls the power modules 33A, 33B, and 33C and the field system circuit IC34.

[0062] A detected signal is supplied from the temperature sensing elements 33Af, 33Bf and 33C arranged in the power modules 33A, 33B and 33C, and the microcomputer 35 detects a state of the power modules 33A, 33B and 33C.

[0063] More precisely, if the temperature sensing element 33Af (located in power module 33A) detects an abnormal temperature in power module 33A, at least one of the two sets of stator coils is determined to be abnormal. Additionally, if the temperature sensing elements 33Bf and 33Cf, located in the respective power modules 33B and 33C, also detect an abnormal temperature in one of the power modules 33B and 33C, the corresponding sets of stator coils are determined to be abnormal, in addition to the results detected by power module 33A.

[0064] It should be noted that the power modules 33A, 33B, and 33C, the field system circuit IC34, and the microcomputer 35 generate heat during operation. Incidentally, the field system circuit IC34 and the microcomputer 35 are electronic components that generate little heat; that is, the amount of heat they produce is low. In contrast, the power modules 33A, 33B, and 33C are electronic components that generate a significant amount of heat, producing a greater quantity than the field system circuit IC34 and the microcomputer 35. The heat-generating components described above are equipped with heat sinks 37A to 37E, the specifications of which are described later.

[0065] Container part 36a is molded from resin and houses the rotary angle detection circuit IC32, the power modules 33A, 33B and 33C, field system circuit IC34 and the microcomputer 35, as shown in Fig. 2 to Fig. 5 and Fig. 15 to Fig. Figure 21 shows that the container element 36a is provided with a lower part 36e, a circumferential wall section 36f, an opening section 36g, and an engagement section 36h. The lower part 36e is a plate-shaped section. The circumferential wall section 36f is a cylindrical section formed on one surface side of the lower part 36e. The engagement section 36h is an arc-shaped section formed on a second surface side of the lower part, which engages with the engagement section 20a of the housing 39 when the rotating electric machine 2 is installed.

[0066] Fig. Figure 15 shows a top view of the container part 36a with the power modules 33A, 33B and 33C arranged in the container part 36a from side 2b, which is the side opposite side 2a, viewed from the rotating electrical machine. Fig. Figure 16 shows a cross-sectional view taken along line XVI-XVI.

[0067] Fastening parts 36b and 36c are metal components that attach the container part 36a to the housing 20. Additionally, fastening parts 36b and 36c also dissipate heat generated by the rotating electric machine. Parts 36b and 36c are made of aluminum, for example.

[0068] As it is in Fig. 6 to Fig. As shown in Figure 8, the fastening part 36b is provided with a main body section 36i, a rib section 36j and a hole section 36k. Additionally, as shown in Fig. 9 to Fig. As shown in Figure 11, the fastening part 36c is provided with a main body section 36l, a rib section 36m, and a hole section 36n. The main body sections 36i and 36l are plate-shaped sections. The rib sections 36j and 36m are thin plate sections formed in multiples positioned at fixed intervals on a surface side of the main body sections 36i and 36l. The hole sections 36k and 36n formed on the main body sections 36i and 36l are openings through which a bolt, which fastens the container part 36a to the housing 20, is inserted. As shown in Fig. As shown in Figure 5, the fastening parts 36b and 36c are inserted into the container part 36a, with the rib parts 36j and 36m and the hole sections 36k and 36n being exposed outside the container part 36a on side 2a, on which the rotating electrical machine is mounted.

[0069] Fig. Figure 6 shows a top view of the fastening part 36b, viewed from side 2b of the rotating electrical machine. Fig. Figure 7 shows a side view of the fastening part 36b. Fig. Figure 8 shows a top view of the mounting part 36b, viewed from the side in which the rotating electric machine is mounted. Additionally, it shows Fig. 9 a top view of the fastening part 36c, viewed from side 2b, which is opposite side 2a on which the rotating electrical machine is mounted. Fig. Figure 10 shows a side view of the fastening part 36c, and Fig. Figure 11 shows a top view of the mounting part 36c, viewed from the side on which the rotating electric machine is mounted. The cover part 36d is a plate design made of resin that covers the opening part 36g.

[0070] The heat sink 37A for the power module dissipates heat generated by the power module 33A to the outside of the housing section 36a. Specifically, the heat sink 37A is made of a metal to dissipate a large amount of heat generated by components that produce high temperatures. For example, the heat sink 37A is made of aluminum. The heat sinks 37B and 37C are mounted on the respective power modules 33B and 33C.

[0071] As it is in Fig. 12 to Fig. As shown in Figure 14, the heat sink 37A for the power module is provided with a main body 37Aa and a finned section 37Ab. The main body 37Aa is a plate-shaped section. The finned section 37Ab is a thin plate section formed in plurality, positioned at fixed intervals on one surface side of the main body sections 36i and 36l. The heat sink 37A for the power module is electrically insulated and inserted into the lower part 36e, with a second surface of the main body section 37Aa exposed within the container part 36a and the finned section 37Ab also exposed outside the container part 36a on the side (2a) of the rotating electric machine 2. The heat sinks 37B and 37C for the respective power modules 33B and 33C have the same configuration as the heat sink 37A for the power module 33A.This means that the heat sink 37B for the power module 33B is provided with a main body section 37Ba and a fin section 37Bb. The heat sink 37C for the power module 33C is provided with a main body section 37Ca and a fin section 37Cb.

[0072] Fig. Figure 12 shows a top view of the heat sink 37A for the power module 33A as seen from side 2b of the rotating electric machine. Fig. Figure 13 shows a side view of the heat sink 37A for the power module 33A, and Fig. Figure 14 shows a top view of the heat sink 37A for the power module 33A from the side on which the rotating electric machine is mounted.

[0073] The heat sink 37D for the field system circuit IC dissipates heat generated by the field system circuit IC34 to the outside of the housing section 36a. This means that the heat sink 37D is made of metal and dissipates the generated heat. The heat sink is made of aluminum, for example. Additionally, the heat sink 37D for the field system circuit IC can be configured (shaped) in the same way as the heat sink 37A for the power module 33A. More precisely, the heat sink 37D is provided with a main body section 37Da and a finned section 37Db.

[0074] The heat sink 37E of the microcomputer 35 dissipates heat generated by the microcomputer 35 to the outside of the housing part 36. The heat sink 37E is made of metal and dissipates the generated heat. The heat sink 37E is made of aluminum, for example. The heat sink 37E for the microcomputer 35 can be configured (shaped) in the same way as the heat sink 37D for the field system circuit IC and the heat sink 37A for the power module. That is, the heat sink 37E is provided with a main body section 37Ee and a finned section 37Eb.

[0075] The mounting parts 36b and 36c, the heat sinks 37A, 37B and 37C for the respective power modules 33A, 33B and 33C, the heat sink 37D for the field system circuit IC and the heat sink 37E for the microcomputer 35 are inserted into the container part 36a, between the resin that forms the container element 36a, with an interval that separates each component from the others (i.e. in a thermally insulated state). More precisely, the heat transfer is regulated by each heat sink.

[0076] The heat sinks 37A, 37B, and 37C for the power modules, the heat sink 37D for the field system circuit IC, and the heat sink 37E for the microcomputer 35 are arranged in the container part 36a such that the total area of ​​the container part 36a is smaller than the area enclosed by the outline of the container part 36a when viewed from side 2a, on which the rotating electric machine is mounted. Additionally, the mounting parts 36b and 36c are arranged in the container part 36a such that the total area of ​​the container part 36a is smaller than the total area of ​​the heat sinks 37A, 37B, and 37C for the modules, the heat sink 37D for the field system circuit IC, and the heat sink 37E for the microcomputer 35 when viewed from side 2a, on which the rotating electric machine is mounted.

[0077] The power module 33A is arranged such that it is in contact with the second side of the main body section 37Aa of the heat sink 37A for the power module via a thermally conductive element 39 of the thin-plate design with electrically insulating properties. The power source terminal of the power module 33A is connected to each of the connectors 31h and 31i of the power source wiring sections 31a and 31b and to the connector 31l of the stator wiring section 31c. The power modules 33B and 33C are also connected to each of the respective heat sinks 37B and 37C via an external terminal, in addition to the power module 33A.

[0078] The rotary angle detection circuit IC32 is mounted on a rear surface of the wiring board 30. The field system circuit IC34 and the microcomputer 35 are mounted on a surface of the wiring board 30. The wiring board 30 is secured inside the container part 36a and connected to a signal terminal of the power modules 33A, 33B, and 33C, as shown in Fig. 18 is shown. Furthermore, it shows Fig. 18 a cross-sectional view over a line XVIII-XVIII according to Fig. 17.

[0079] The rotary angle detection circuit IC32 is positioned opposite the rotary angle detection magnet 25 and in the axial direction. As shown in Fig. As shown in Figure 19, the field system circuit IC34 is arranged to be in contact with a second surface of the main body section 37Da of the heat sink 37D for the field system circuit IC34 via the wiring board 30. As shown in Fig. As shown in Figure 20, the microcomputer 35 is arranged such that it is in contact with the second surface of the main body section 37Da of the heat sink 37E.

[0080] Fig. Figure 19 shows a cross-sectional view illustrating the field system circuit IC34 and the heat sink 37D for the field system circuit IC. Additionally, it shows Fig. 20 a cross-sectional view illustrating the microcomputer 35 mounted on the wiring board 30 and the heat sink 37E for the microcomputer.

[0081] The filling material 38 is a filling material or casting resin that has electrical insulating properties, which is filled inside the container part 36a, thus providing water resistance for the rotary angle circuit IC32, the power modules 33A, 33B and 33C and the field system circuit, for example, which are housed inside the container part 36A, as shown in Fig. 21 is shown. Fig. Figure 21 shows a cross-sectional view illustrating the filling material part 38 inside the container part 36a.

[0082] The filler material section 38 is located within the container section 36a. The filler material section 38 also houses the rotary angle sensing circuit IC32, the power modules 33A, 33B and 33C, the field system circuit IC34 and the microcomputer 35 within the container section 36a, which are connected by the wiring board 30, the power source wiring sections 31a and 31b, the stator wiring section 31c, the rotor wiring section 31d and the external communication wiring section 31e. An opening 36g of the container section 36a is covered by the lid section 36d.

[0083] The control device 3 secures the housing 20 by engaging the engagement part 36h of the container part 36a with an engagement part 20a of the rotating electric machine, and by securing the bolt 36o, which is inserted through the hole section 36c. A connection part 31t, intended for connecting the positive terminal of battery B, is connected to the power source wiring part 31a. The connector 31k of the power source wiring part 31a is connected to a negative terminal of battery B through a vehicle body. The connector 31m of the stator wiring section 31c is connected to the stator coils 21b and 21c through the wiring part 31r. The connector 31o of the rotor wiring part 31d is connected to the brush 24 through the wiring part 31s. (Operation of the rotating electric machine)

[0084] The operation of the rotating electric machine with integrated control device is described below. (Heat dissipation)

[0085] The operation described here occurs when a motive force is generated to propel the vehicle. The negative terminal of battery B is connected to the vehicle and to connector 31k of the power source wiring section 31b through the housing 20. The positive terminal of battery B is connected to connector 31j of the power source wiring section 31a via connector 31t when the vehicle's ignition switch (not shown) is turned on. As a result, a DC current is supplied to the power supply terminal of the power modules 33A to 33C through connectors 31h and 31i of the power source sections 31a and 31b.Direct current is supplied to the wiring board 30 through the connectors 31f and 31g of the respective power source wiring parts 31a and 31b, and direct current is also supplied to the rotary angle detection circuit IC32, the field system circuit IC34 and the microcomputer 35 via the wiring pattern of the wiring board 30.

[0086] The operation of the rotation angle detection circuit IC32, the field system circuit IC34, and the microcomputer 35 is initiated by the supply of direct current. The rotation angle detection circuit IC32 detects the rotation angle of the rotor 22 based on the magnetic field generated by the magnet for rotation angle detection 25a.

[0087] The microcomputer 35 controls the power modules 33A, 33B and 33C as well as the field system circuit IC34 on the basis of a command supplied from outside through the wiring element for external communication 31e and the wiring pattern of the wiring board 33, in addition to a detected result of the rotary angle detection circuit IC32.

[0088] The wiring board 30 is connected to connector 31n of the rotor wiring section 31d. Connector 31o of the wiring section 31d is connected to the brush section 24 via the wiring section 31s. The field system circuit IC34 is controlled by the microcomputer 35 and supplies a DC current to the stator coil 22c through the wiring pattern of the wiring board 30, the rotor wiring section 31d, the wiring section 31s, the brush 24, and the slip ring 23.

[0089] Wiring board 30 is connected to a signal terminal of power modules 33A, 33B, and 33C. Output terminals of the respective power modules 33A, 33B, and 33C are connected to connector 31l of stator wiring section 31c. Connector 31m of stator wiring section 31c is connected to stator coils 21b and 21c via terminal 31t. Power modules 33A, 33B, and 33C, controlled by microcomputer 35, convert the direct current supplied to the power source terminal into three-phase alternating current (AC) and supply this three-phase AC to stator coil 21b via stator wiring section 31c and connector 31r. As a result, the rotating electric machine 2 generates the driving force to propel the vehicle. (Load)

[0090] The operation is described below when electrical power is generated to charge battery B.

[0091] By supplying the driving force from the power machine, the stator coils 21b and 21c generate a three-phase alternating current. The microcomputer 35 terminates the switching of the switching elements of the respective power modules 33A, 33B, and 33C. The diodes of the respective power modules 33A, 33B, and 33C convert the three-phase alternating current supplied from the stator coils 21b and 21c through the wiring section 31r and the stator wiring section 31c into direct current and supply the direct current to battery B through the power source wiring sections 31a and 21b and the terminal section 31t. As a result, battery B is charged by the power source generated by the rotating electric machine 2.Furthermore, the microcomputer 35 can switch the switching elements of the respective power modules 33A, 33B and 33C on the basis of the rotation angle detected by the rotary angle detection circuit IC32 and can convert the alternating current generated by the stator coils of a 21b and 21c into direct current. (Determination of the state)

[0092] The rotating electric machine with integrated control device 1 according to the preferred embodiment can determine a state of the power modules on the basis of a detected signal from the temperature sensing elements 33Af, 33Bf and 33Cf, which are arranged in the respective power modules 33A, 33B and 33C.

[0093] In particular, electricity flows to the two sets of stator coils 21b and 21c during recharging. When the rotating electric machine 1 operates normally, the temperature of each of the power modules 33A, 33B, and 33C will not exceed a predetermined temperature. If an anomaly occurs in the rotating electric machine 1, the temperature of at least one of the power modules 33A, 33B, and 33C will rise and exceed a predetermined temperature. In a case where the temperature exceeds the predetermined temperature and continues to rise, or in a case where the temperature continues to exceed the predetermined temperature for a long period of time, the electrical insulating capacity of the stator coils 21b and 21c decreases, which in turn leads to a reduction in the electrical power generated that charges the battery.

[0094] Additionally, if an anomaly occurs in one of the two sets of stator coils 201b and 21c, abnormal heat generation occurs in a communication path of the stator coil where the anomaly occurred. For example, if the anomaly occurs in stator coil 21b, the temperature of the power modules 33A and 33B, which control stator coil 21b, rises and exceeds the predetermined temperature.

[0095] At this point, the temperature sensing element 33Af mounted in the power module 33A detects an abnormal temperature. The microcomputer 25 determines that an anomaly occurs in at least one of the two sets of stator coils 21b and 21c, based on the detection of the abnormal temperature by the temperature sensing element 33Af mounted in the power module 33A.

[0096] The temperature sensing element 33Bf, mounted in the power module 33B, detects an abnormal temperature of the power module 33B. The microcomputer 35 determines an anomaly occurring in the corresponding stator coil set (stator coil 21b) by means of detection results of the abnormal temperature of the power module 33B, together with detection results of the power module 33A. [Effects of the preferred embodiment]

[0097] The effects of the rotating electric machine with integrated control device 1 according to the preferred embodiment are described below. (Effect 1)

[0098] The rotating electric machine with integrated control device 1 according to the preferred embodiment comprises the rotating electric machine 2, which is provided with the stator 21, which has two sets of three-phase stator coils 21b and 21c, and the rotor 22, the power converter 3 (control device 3), which configures the control circuit of the rotating electric machine 2, the control board (wiring board 30), which is equipped with the electronic components, and the plurality of modules (power modules 33A, 33B and 33C), which have the plurality of switching elements that are controlled by the control circuit.The rotating electric machine with integrated control device 1 is configured with at least one of the modules (power module 33A) which is equipped with the switching elements (MOSFETs 33Aa to 33Ad) which control the two different sets of stator coils, and the sensing element (temperature sensing element 33Af) which detects the state of the module (power module 33A).

[0099] In the rotating electric machine with integrated control device 1 according to the preferred embodiment, at least one of the modules 33A controls two different sets of stator coils 21b and 21c. Additionally, the state of at least one of the modules 33A is detected by the temperature sensing element. In this example, by detecting the state of at least one module 33A with a single temperature sensing element, the state of two sets of stator coils can be detected (whether or not there is an abnormal temperature).

[0100] This demonstrates that an anomaly in the entire rotating electric machine with integrated control device 1 can be detected using a single detection element. In a conventional rotating electric machine, one module controls a set of stator coils; therefore, two detection elements are necessary to detect an anomaly in the entire machine. According to the rotating electric machine with integrated control device 1 of the preferred embodiment, the number of detection elements can be reduced. Furthermore, it is also shown that the number of communication ports of the microcomputer 35 and the number of connectors of the microcomputer 35 to which the detection elements are connected and to which the detected results are sent can also be reduced.This in turn reduces the bulkiness of the microcomputer 35 and the main body structure of the control board (wiring board 30) on which the microcomputer 35 is mounted. Since only a single detection element is still required, the processing time needed to handle the detected anomaly can be reduced. (Effect 2)

[0101] The rotating electric machine with integrated control device 1 according to the preferred embodiment comprises the power converter (control device 3) which includes the first module (power module 33A) that controls the two different sets of stator coils, and the second modules (power modules 33B and 33C) that control the same set of stator coils.

[0102] According to the rotating electric machine with integrated control device 1 as per the preferred embodiment, if an anomaly occurs in one of the two sets of stator coils, the stator coil in which the anomaly occurred can be determined based on the detection results for each of the first module (power module 33A) and the second modules (power modules 33B and 33C). In particular, in addition to detecting an anomaly in the two sets of stator coils as per the present embodiment, the location where the anomaly occurs can also be detected. (Effect 3)

[0103] The rotating electric machine with integrated control device 1 according to the preferred embodiment has the first module (power module 33A) which is provided with the temperature sensing element (33Af) as a sensing element that detects the temperature of it.

[0104] According to the preferred embodiment, the state of the first power module (power module 33A) is determined by measuring its temperature. This means that any anomaly can be easily detected. (Effect 4)

[0105] The rotating electric machine with integrated control device 1 according to the preferred embodiment has the second modules (power modules 33B and 33C) which are equipped with the respective temperature sensing elements (33Bf and 33Cf) as sensing elements that detect the temperatures of the second modules (33B and 33C).

[0106] Additionally, according to the preferred embodiment, the state of the second power modules (power modules 33B and 33C) can be determined by the temperature measured in each of the second power modules (33B and 33C). This means that any anomaly can be easily detected. In particular, by combining the third action with the fourth action, the location where an anomaly occurs can be easily determined. (Effect 5)

[0107] According to the preferred embodiment, each of the modules (power modules 33A, 33B and 33C) is provided with the respective heat sinks (heat sinks for power modules 37A, 37B and 37C) and is arranged in a thermally isolated state from a different module.

[0108] As a result, heat transfer from an adjacent module via the heat sinks (37A, 37B and 37C) to each of the modules (power modules 33A, 33B and 33C) is suppressed according to the described preferred embodiment. Consequently, a reduction in the accuracy of the measured results of the transferred heat is also suppressed. (Effect 6)

[0109] According to the preferred embodiment, the control board (wiring board 30) has an open circular shape, and each of the modules (power modules 33A, 33B, and 33C) is arranged in the direction of rotation (CIRC) of this shape. At least one of the modules (power module 33A) is positioned diametrically opposite to the open section of the circle.

[0110] The rotating electric machine with integrated control device 1 according to the preferred embodiment has at least one of the modules (power module 33A) arranged in a position that is not relatively close to the open section of the circular shape. In this case, even if heat dissipation occurs at the open section of the circular shape, heat dissipation from the at least one of the modules (power module 33A) away from the open section of the circular shape is suppressed. As a result, the reduction in the detection accuracy of the detection element is suppressed.

[0111] In addition, modules other than power module 33A (power modules 33B and 33C) are arranged between the open section of the circular shape. In this case, heat from the modules other than power module 33A, that is, heat from power modules 33B and 33C, can be dissipated through the open section of the circular shape. As a result, the effect of heat from the module adjacent to power module 33A is suppressed. (Effect 7)

[0112] In the rotating electric machine with integrated control device 1 according to the preferred embodiment, the control board (wiring board 30) is circular in shape, and each module (the power modules 33A, 33B and 33C) is arranged along the open circular shape. The first module (power module 33A) is arranged symmetrically to the open section of the circular shape.

[0113] According to the preferred embodiment, since the first module (power module 33A) is arranged in the diametrically opposite position to the open section of the circular shape in a circular direction (CIRC) of the control board (wiring board 30), heat dissipation from the first module (power module 33A) from the open section can be reduced.

[0114] Specifically, this means that the distance between the first module (power module 33A), which detects the state (anomaly) of the stator coils 21b and 21c, and the open section of the circular shape becomes considerable, and that heat transfer to the open section of the circular shape becomes difficult. As a result, heat transfer to the open section also becomes difficult, even if the first module (power module 33A) generates heat. The distance for heat transfer between the first module (power module 33A) and the open section here refers to the distance between them across the control board.

[0115] Furthermore, the second modules (power modules 33B and 33C) are positioned between the first module (power module 33A) and the open section of the circular shape in the direction of rotation. As a result, positioning the second module (power modules 33B and 33C) in between prevents heat transfer, even if the first module (power module 33A) generates heat, or if heat transfer occurs in the direction of rotation to the open section of the circular shape. (Effect 8)

[0116] According to the preferred embodiment, the control board (wiring board 30) has a circular shape, and the connection sections (power source wiring sections 31a and 31b) connect the switching elements (MOSFETs 33a to 33d) that control the stator coils 21b and 21c to external connection sections provided on the open section thereof.

[0117] According to the preferred embodiment, the connection sections (power source wiring sections 31a and 31b) are also used for heat dissipation at the open section of the circular shape. The connection sections (power source wiring sections 31a and 31b) have good heat dissipation capacity; therefore, when the modules (power modules 33A, 33B, and 33C) generate heat, heat transfer occurs through the connection sections (power source wiring sections 31a and 31b) of the modules. This means that the amount of heat dissipated from the open section of the circular shape can be increased. As a result, the effect of heat transfer from another module adjacent to the normally functioning module is suppressed, and consequently, a reduction in the detection accuracy of the detection element is also suppressed. (Effects 9)

[0118] The rotating electric machine with integrated control device 1 according to the preferred embodiment comprises the power converter (control unit 3) which is integrated with the connection sections (power source wiring sections 31a and 31b) that connect the outer connection section and the heat sinks (for the power modules 33A, 33B and 33C) in the resin container part 36a, as well as casting resin (filler part 38) for encapsulating the control board (the wiring board 30) and the modules (power modules 33A, 33B and 33C).

[0119] According to the preferred embodiment, filling the resin reservoir 36 with the filler material (casting resin) reduces the effect of an ambient temperature on the temperature sensing elements 33Af, 33Bf, and 33Cf of the respective modules (power modules 33A, 33B, and 33C). Furthermore, if a foreign object is present inside the electrical power converter (control unit 3), the filler material 38 prevents contact or collision of the foreign object with other components within it. As a result, a reduction in the sensing accuracy of the sensing element is prevented. (Modified Form 1)

[0120] According to the preferred embodiment, each of the modules (power modules 33A, 33B and 33C) is provided with four switching elements. However, this is not limited to the structure described above. Fig. Figure 23 shows a circuit diagram of the rotating electric machine with integrated control device 1 according to the modified form 1. As it is in a modified control device according to Fig. As shown in 23, each of the modules can, for example, be equipped with two switching elements.

[0121] In modified form 1, the module is configured according to power module 33A (or the first module) to control the two different sets of stator coils. The modules corresponding to the other modules 33B and 33C (the second modules) can be configured to have stator coils with either a different phase or the same phase.

[0122] Furthermore, in the modified form 1, each of the power modules (power modules 33A, 33B, and 33C) is shown with two switching elements; however, the number of switching elements for each power module can be changed. For example, a power module equipped with four switching elements and a power module equipped with two switching elements can be used in the same configuration. Moreover, the rotating electric machine with integrated control device 1 according to the modified form 1 has the same configuration and exhibits the same effect as the rotating electric machine with integrated control device 1 according to the preferred embodiment. (Modified Form 2)

[0123] According to the preferred embodiment, the control unit 3 of the wiring board 30 is mounted such that the heat sinks 37A, 37B, and 37C for the power modules, which dissipate heat generated by each of the respective power modules 33A, 33B, and 33C, project in one direction toward the rotating electric machine 2. However, the heat sinks are not limited to the mounting positions described. For example, as shown in Fig. As shown in Figure 24, the heat sinks are mounted with the wiring board 30 in the reversed position. Furthermore, Figure 24 shows that the heat sinks are mounted with the wiring board 30 in the reversed position. Fig. 24 a cross-sectional view of the rotating electrical machine with integrated control device 1, which is provided with the wiring board 30 in an inverted position. Fig. Figure 24 shows the same cross-sectional view of the rotating electric machine with integrated control device 1, which is shown in Fig.Figure 2 shows the modified embodiment 2. According to the modified embodiment 2, the rotating electric machine with integrated control device 1 is provided with the same configuration as described in the preferred embodiment and also exhibits the same effect. Additionally, the heat sink 37 projects forward in one direction toward the container body 36a, and a ventilation channel can be provided to allow cooling air to pass through. As a result, the cooling effect of the heat sink 37 is improved. (Modified Form 3)

[0124] According to the preferred embodiment, the temperature sensing element is used as the sensing element for detecting the state of the module (power modules 33A, 33B, and 33C). However, the determination of the state of the power modules is not limited to that described. That is, for example, a sensing element that detects a current flow or a voltage can be incorporated. The rotating electric machine with integrated control device 1 according to modified form 3 is provided with the same configuration and exhibits the same effects as described in the preferred embodiment. (Modified Form 4)

[0125] According to the preferred embodiment, the design described includes an anodized layer for each heat sink; however, the heat sink is not limited to the described configuration. Each heat sink can be made of aluminum with an anodized layer on at least one surface that is in contact with the power modules 33A, 33B, and 33C. Additionally, a layer other than the anodized layer, for example, a resin layer with electrical insulating properties, can also be used.

[0126] The heat sinks can be made of a metal other than aluminum that has good thermal conductivity. For example, copper can also be used. The rotating electric machine with integrated control device 1 according to the modified design 4 has the same configuration and exhibits the same effects as described according to the preferred embodiment. (Modified Form 5)

[0127] According to the preferred embodiment, the rotor 22 of the rotating electric machine 2 is equipped with the rotor coil 22c, which forms the magnetic pole due to the current flow. However, the rotor 22 is not limited to the configuration described. That is, a magnet can be provided as an alternative to the rotor coil 22. In this case, the slip ring 23 and the brush 24 are no longer required, which also eliminates the need for the field system circuit IC34 of the control device 3. The rotating electric machine with integrated control device 1 according to the modified form 5 has the same configuration and exhibits the same effects as described in the preferred embodiment.

[0128] As described above, a rotating electric machine with an integrated control device comprises a rotating electric machine (2) having a stator with three-phase stator windings (21b and 21c) and a rotor (22), a power converter (3) that configures the control circuit of the rotating electric machine (2), a control board (30) equipped with electronic components, and a plurality of modules provided with a plurality of switching elements (33Aa to 33Ad, 33Ba to 33Bd, and 33Ca to 33Cd) controlled by the control circuit. At least one of the modules (33A) is provided with the switching elements (33A to 33Ad) that control the two different sets of stator windings (21b and 21c) and a sensing element (30Af) that detects a state of the module (33A). (Reference symbol list)

[0129] 1 Rotating electric machine with integrated control device, 2 Rotating electric machine, 3 Control device, 31 Wiring board, 33A, 33B and 33C Power module, 33Af, 33Bf and 33Cf Temperature sensing element, 35 Microcomputer, 38 Filler material part.

Claims

[1] Rotating electric machine with integrated control device (1) with a rotating electric machine (2) which is equipped with a stator (21) and a rotor (22), and a power converter (3) which is equipped with a control board (30) and a plurality of power modules (33A to 33C), wherein the stator (21) has two sets of three-phase stator coils (21b, 21c), the control board (30) is equipped with electronic components that configure a control circuit for the rotating electric machine (2), the large number of power modules (33A to 33C) are equipped with a large number of switching elements (33Aa to 33Ad, 33Ba to 33Bd, 33Ca to 33Cd), and at least one of the power modules (33A) is provided with switching elements (33Aa to 33Ad) that control two different sets of the stator coils, and with a sensing element (33Af) that detects a state of the power module, wherein: the power converter (3) is equipped with the power modules (33A, 33B, 33C) which are subdivided into a first power module (33A) and second power modules (33B, 33C), The first power module (33A) controls two different sets of stator coils (21b, 21c), and the second power modules (33B, 33C) control the same set of stator coils (21b, 21c). [2] Rotating electric machine with integrated control device (1) according to claim 1, wherein the first power module (33A) is provided with a temperature sensing element (33Af) as the sensing element which detects a temperature of the first power module (33A). [3] Rotating electric machine with integrated control device (1) according to claim 2, wherein the second power modules (33B, 33C) are provided with temperature sensing elements (33Bf, 33Cf) as sensing elements which detect a temperature of the second power modules (33B, 33C). [4] Rotating electric machine with integrated control device (1) according to one of claims 1 to 3, wherein each of the power modules (33A to 33C) is provided with a heat sink (37A to 37C) and is thermally isolated from other power modules below the power modules (33A to 33C). [5] Rotating electric machine with integrated control device (1) according to one of claims 1 to 4, wherein the control board (30) has an open circle which is provided with two open ends, wherein each of the power modules (33A to 33C) is arranged around a direction of rotation of the open circle, and at least one of the power modules is arranged diametrically opposite to a section which is an open section of the circle between the two ends. [6] Rotating electric machine with integrated control device (1) according to claim 5, wherein the control board (30) is provided with the open circle, wherein each of the power modules (33A to 33C) is arranged around a circumferential direction of the open circular shape, and the first power module (33A) is arranged diametrically opposite to the open section of the circular shape. [7] Rotating electric machine with integrated control device (1) according to claim 5 or 6, wherein the open section of the open circuit is provided with connectors (31a, 31b) which connect the switching elements (33Aa to 33Ad, 33Ba to 33Bd, 33Ca to 33Cd) to an external connection section. [8] Rotating electric machine with integrated control device (1) according to claim 7, wherein the power converter (3) which is integrated with the connector which connects the external section and the heat sinks (37A to 37C) for the power modules (33A, 33B and 33C) in the resin container part (36a) is provided with casting resin for encapsulating the control board (30) and the power modules (33A, 33B and 33C).

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