Rotating electric machine

Abstract

To provide a rotary electric machine that suppresses a refrigerant from leaking out without being made radially large in size.SOLUTION: A rotary electric machine comprises a motor part provided with a rotor, a stator and a bracket, and an inverter part provided with a power module, a field module and a cooler. The cooler comprises a heat transfer member which has the power module and the field module thermally connected to a face on the other side and also has a flow passage groove part, hollowed to the other side, formed on a face on one side, a lid member which closes an opening of the flow passage groove part, a seal material which is charged in a circumference of the flow passage groove part, and a refrigerant feed / discharge part which feeds and discharges a refrigerant to and from a flow passage, wherein the heat transfer member has a plurality of projection parts which project from an axially one-side face surrounding the flow passage groove part to an axially one side, and the lid member has a through hole that the projection parts penetrate, and is provided with a lid fixation part larger than the diameter of the through hole at the part of the projection parts projecting to the axially one side more than the lid member, which is fixed to the heat transfer member by the lid fixation part.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] This application relates to a rotating electrical machine.

Background Art

[0002] A control device integrated rotating electrical machine, which includes a motor unit that is a rotating electrical machine body having a rotor and a stator, and an inverter unit that includes a power conversion unit and controls the power supplied to the motor unit, is mounted on, for example, a vehicle such as an automobile. The control device integrated rotating electrical machine mounted on a vehicle is often installed and used in an engine room. Since there is a limit to the space where the rotating electrical machine can be installed in the engine room, downsizing of the radial dimension of the rotating electrical machine is required.

[0003] In order to effectively cool the power module, the field excitation module, etc. included in the power conversion unit, a cooler having a flow path through which a refrigerant flows is generally provided in the inverter unit. For the refrigerant, for example, water, a long-life coolant (LLC) is used. The configuration of a power conversion device provided with a cooler is disclosed (see, for example, Patent Document 1). The cooler is composed of a flow path groove portion that opens toward the outside of the case that houses the power conversion unit, and a lid member that closes the flow path groove portion. The lid member has a plurality of through holes. By inserting a bolt through the through hole and fastening the bolt to a screw hole portion provided in the case, the lid member is fixed to the case. The space between the flow path groove portion and the lid member becomes a flow path through which the refrigerant flows. Also, in order to ensure the sealing performance between the flow path groove portion and the lid member, a sealing material such as a liquid gasket is provided between the case and the lid member.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In power converter cases like the one shown in Patent Document 1 above, die-cast products are often used because they can be produced in large quantities and with high precision in a short time. However, there are multiple casting defects inside the casting. If one end of a casting defect is exposed on the surface of the flow channel groove and the other end is exposed on the outside surface, and the flow channel groove and the outside are connected via the casting defect, there is a problem that refrigerant will leak to the outside. Also, if the surface of the casting is processed by cutting or other methods, the possibility of casting defects being exposed on the surface increases. When tapping is performed on the outside of the case to form screw holes for fixing the lid member to the case, there is a problem that refrigerant will leak from the screw holes via the casting defects. Furthermore, by moving the position of the screw holes away from the flow channel groove, it is possible to suppress the connection between the flow channel groove and the screw holes via the casting defects. However, moving the position of the screw holes away from the flow channel groove presents the problem that the rotating electric machine will become larger in the radial direction.

[0006] Therefore, the present invention aims to provide a rotating electric machine that suppresses refrigerant leakage to the outside without increasing its size in the radial direction. [Means for solving the problem]

[0007] The rotating electric machine disclosed herein comprises a motor section having a rotating shaft, a rotor having a field core around which field windings are wound and rotating integrally with the rotating shaft, a stator having a stator core around which stator windings are wound, a bracket covering the outside of the field core and stator core and holding one end and the other end of the rotating shaft via bearings, a power module having a switching element for switching the supply current to the stator windings on and off, a field module having a switching element for switching the supply current to the field windings on and off, and a cooler for cooling the power module and the field module, and an inverter section having been disposed on the other axial side of the bracket and fixed to the bracket, wherein the cooler is The heat transfer member comprises a heat transfer member to which a power module and a field module are thermally connected on the other side in the axial direction, a flow channel groove formed on one side in the axial direction that is recessed on the other side in the axial direction, a cover member that closes the opening on one side in the axial direction of the flow channel groove, a sealing material provided along the periphery of the flow channel groove in the gap between the heat transfer member and the cover member, and a refrigerant supply and discharge section that supplies and discharges refrigerant into the flow channel surrounded by the flow channel groove and the cover member, wherein the heat transfer member has a plurality of protrusions projecting from one side in the axial direction that surrounds the flow channel groove, the cover member has through holes through which the protrusions pass, and a cover fixing portion larger than the diameter of the through hole is provided on the portion of the protrusion that projects axially further than the cover member, and the cover member is fixed to the heat transfer member by the cover fixing portion. The protrusion has a first protrusion that protrudes from one axial side surface of the heat transfer member to one axial side, and a second protrusion that protrudes from one axial end of the first protrusion to one axial side, wherein the radial size of the first protrusion is larger than the radial size of the second protrusion, the second protrusion passes through the through hole and the other axial side of the lid member abuts with one axial end of the first protrusion, a lid fixing portion is provided on the portion of the second protrusion that protrudes from the lid member to one axial side, a male thread is formed on the outer circumference of the portion of the second protrusion that protrudes from the lid member to one axial side, and the lid fixing portion is a nut fastened to the male thread. ru. [Effects of the Invention]

[0008] According to the rotating electric machine disclosed in this application, the heat transfer member has a plurality of protrusions that project from one axial side surface surrounding the flow channel groove to one axial side, the lid member has a through hole through which the protrusions pass, and a lid fixing portion larger than the diameter of the through hole is provided on the portion of the protrusion that projects from the lid member to one axial side, and the lid member is fixed to the heat transfer member by the lid fixing portion. As a result, the fixing point of the lid member can be moved axially away from the main body portion of the heat transfer member in which the flow channel groove is formed, and surface processing such as cutting to fix the lid member to the main body portion of the heat transfer member can be eliminated. Therefore, the connection between the flow channel groove and the outside via casting defects is suppressed, and a rotating electric machine can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine. [Brief explanation of the drawing]

[0009] [Figure 1] This is a cross-sectional view showing a schematic of the rotating electric machine according to Embodiment 1. [Figure 2] This is a plan view showing the side of the inverter section of the rotating electric machine according to Embodiment 1. [Figure 3] This is a cross-sectional view illustrating the connection between the stator and the inverter section of a rotating electric machine according to Embodiment 1. [Figure 4] This is a plan view of the cover member of the rotating electric machine according to Embodiment 1. [Figure 5] This is a cross-sectional view of the main part of the inverter section of the rotating electric machine according to Embodiment 1. [Figure 6] This is a cross-sectional view of another main part of the inverter section of the rotating electric machine according to Embodiment 1. [Figure 7] This is a cross-sectional view illustrating the manufacturing process of the main part of the inverter section of a rotating electric machine according to Embodiment 2. [Figure 8] This is a cross-sectional view of the main part of the inverter section of a rotating electric machine according to Embodiment 2. [Figure 9] This is a cross-sectional view of the main part of the inverter section of a rotating electric machine according to Embodiment 3. [Figure 10] This is a cross-sectional view of another inverter section of the rotating electric machine according to Embodiment 3. [Figure 11]This is a cross-sectional view of another inverter section of the rotating electric machine according to Embodiment 3. [Figure 12] This is a cross-sectional view of the main part of the inverter section of a rotating electric machine according to Embodiment 4. [Figure 13] This is a cross-sectional view of another inverter section of the rotating electric machine according to Embodiment 4. [Modes for carrying out the invention]

[0010] The rotating electric machine according to the embodiment of the present application will be described below with reference to the drawings. In each drawing, the same or equivalent members and parts will be denoted by the same reference numerals. The present application is not limited to the following description and may be modified as appropriate without departing from the gist of the present application. In the drawings shown below, the scale of each member may differ from the actual scale for ease of understanding, and the illustration of components not related to the features of the present application will be omitted.

[0011] Embodiment 1. Figure 1 is a schematic cross-sectional view of the rotating electric machine 1 according to Embodiment 1, Figure 2 is a plan view showing the inverter section 40 of the rotating electric machine 1 with the rear cover 15 removed, with the internal components of the inverter section 40 shown by dashed lines, Figure 3 is a cross-sectional view illustrating the connection between the stator 3 and the inverter section 40 of the rotating electric machine 1, Figure 4 is a plan view of the cover member 32 of the rotating electric machine 1, Figure 5 is a cross-sectional view of the main part of the inverter section 40 of the rotating electric machine 1, showing the section where the cover member 32 is fixed to the heat transfer member 31, and Figure 6 is a cross-sectional view of another main part of the inverter section 40 of the rotating electric machine 1, showing the section where the cover member 32 is fixed to the heat transfer member 31. As shown in Figure 1, the rotating electric machine 1 is a control device integrated rotating electric machine 1 equipped with a motor section 30 and an inverter section 40. In this embodiment, an example is shown in which the control device integrated rotating electric machine 1 is mounted on a vehicle and applied to an AC generator motor that uses the rotating electric machine 1 for driving assistance and power generation.

[0012] The motor unit 30 has a rotor 2 and a stator 3, and operates as an electric motor that drives an internal combustion engine (not shown). Alternatively, the motor unit 30 functions as a generator that is driven by the internal combustion engine to generate electricity. The inverter unit 40 is arranged side by side with the motor unit 30 on the other axial side of the motor unit 30, and controls the power supplied to the motor unit 30. The inverter unit 40 is fixed to the motor unit 30, and the motor unit 30 and the inverter unit 40 are integrated.

[0013] <Motor unit 30> First, the motor unit 30 will be described. The motor unit 30 includes a rotary shaft 11, a rotor 2 that rotates integrally with the rotary shaft 11, a stator 3 disposed outside the rotor 2, and a bracket that houses these and holds the rotary shaft 11 rotatably.

[0014] The rotor 2 has a field winding 2a and a field core 2b around which the field winding 2a is wound. The stator 3 disposed on the radially outer side of the field core 2b has a plurality of phases of stator windings 3a and a stator core 3b around which the stator windings 3a are wound. The plurality of phases of stator windings 3a are, for example, one set of three-phase windings or two sets of three-phase windings, but are not limited thereto, and are set according to the type of rotating electrical machine. The bracket covers the outside of the field core 2b and the stator core 3b. The bracket includes a front bracket 4 and a rear bracket 5. The front bracket 4 holds one end side of the rotary shaft 11 via a bearing 7 and covers the front side, which is one side of the rotor 2 and the stator 3. The rear bracket 5 holds the other end side of the rotary shaft 11 via a bearing 8 and covers the rear side, which is the other side of the rotor 2 and the stator 3. The front bracket 4 and the rear bracket 5 are arranged at an axial interval and are connected by bolts 5a.

[0015] The rotating shaft 11 is equipped with a pulley 12 at one end of the rotating shaft 11 that protrudes from a through hole in the front bracket 4. The pulley 12 transmits torque in both directions between the rotor 2 and an external internal combustion engine (not shown). The pulley 12 and the internal combustion engine are connected via a belt (not shown). The rotating shaft 11 is equipped with a slip ring 13 at the other end of the rotating shaft 11 that protrudes from a through hole in the rear bracket 5. The slip ring 13 and the field winding 2a are electrically connected, and field current is supplied from the slip ring 13 to the field winding 2a. The brush 16 that slides against the slip ring 13 and supplies current to the field winding 2a is held in a brush holder 16a. The brush holder 16a is positioned in the space through which the rotating shaft 11 passes, located in the center of the inverter unit 40, after the inverter unit 40 is mounted on the motor unit 30 before the rear cover 15 is attached. The brush holder 16a is fixed to the inverter unit 40.

[0016] An air-cooling fan 20 is fixed to the front end face of the field core 2b of the rotor 2. An air-cooling fan 21 is fixed to the rear end face of the field core 2b of the rotor 2. The air-cooling fans 20 and 21 rotate together with the rotor 2. Cooling air is generated as the air-cooling fans 20 and 21 rotate, cooling the inside of the bracket. In addition, a gap is provided between the cooler 37 of the inverter unit 40 and the rear bracket 5, which serves as a cooling gas passage, and the cooling air passes through the cooling gas passage to cool the cooler 37.

[0017] The magnetic pole position detection sensor 6 consists of a sensor stator 6a and a sensor rotor 6b. The sensor rotor 6b is installed between the slip ring 13 and the bearing 8 on the other end of the rotating shaft 11 that protrudes from the rear bracket 5. The sensor rotor 6b is made of an iron core and rotates integrally with the rotating shaft 11. The sensor stator 6a is arranged coaxially with the sensor rotor 6b and is provided on the heat transfer member 31 of the inverter section 40. The magnetic pole position detection sensor 6 detects the magnetic pole position of the rotating shaft 11, i.e., the rotor 2, from the position of the sensor rotor 6b.

[0018] <Inverter section 40> The inverter unit 40 comprises a power module 9 and a field module 10 that supply power to the motor unit 30, a control module 17 that controls the power module 9 and the field module 10, a cooler 37 that cools the power module 9 and the field module 10, a case 14 equipped with terminals 14a that electrically connect the power module 9 and the motor unit 30, and a rear cover 15 that covers these components from the rear and radially outward. The inverter unit 40 is located on the other axial side of the rear bracket 5 and is fixed to the rear bracket 5. In this embodiment, as shown in Figure 2, the inverter unit 40 has six power modules 9, but the number of power modules 9 is not limited to this.

[0019] The power module 9 comprises a switching element and peripheral circuitry. The switching element is, for example, a MOSFET (Metal Oxide Semiconductor Field Effect Transistor). As shown in Figure 3, the power module 9 is connected to the stator lead wires 3c via terminals 14a and 19. The switching element is arranged on a lead frame that forms the electrical wiring and is sealed with resin material together with the peripheral circuitry. The AC terminal 9a, ground terminal 9b, input terminal 9c, and control terminal 9d of the power module 9 are exposed from the resin material. When driven, the switching element switches the supply current from the DC power supply to the stator winding 3a on and off, supplying stator current to the stator winding 3a. The switching element rectifies the stator current when power is generated.

[0020] The field module 10 comprises a switching element and peripheral circuitry. The field module 10 is connected to the field winding 2a via terminals 14b, brushes 16, and slip rings 13. The switching element is arranged on a lead frame forming the electrical wiring and is sealed with a resin material together with the peripheral circuitry. The switching element controls the field current by switching the supply current to the field winding 2a on and off.

[0021] The control module 17 includes a control circuit for controlling the power module 9 and the field module 10. The control module 17 is, for example, mounted on a substrate made of glass epoxy resin, which has excellent electrical and mechanical properties, with multiple electronic components (not shown) and external connection connectors (not shown) for transmitting and receiving signals between the control module 17 and external devices. The control module 17 is positioned on the other axial side of the power module 9 and the field module 10, and is spaced apart from the power module 9 and the field module 10. The control terminal 9d of the power module 9 is connected to the control module 17. The signal wiring of the magnetic pole position detection sensor 6 is connected to the control module 17.

[0022] The case 14 surrounds the power module 9, field module 10, and control module 17 from the radially outer side, with openings on one side and a portion of the other side in the axial direction. The case 14 is made of an insulating resin material. The resin material is a thermoplastic resin such as PPS (Poly Phenylene Sulfide) or PBT (Poly Butylene Terephthalate). As shown in Figure 2, the case 14 is equipped with a terminal 14a that is electrically connected to the power module 9 at one end and protrudes from the case 14 at one end. The terminal 14a is a terminal for connecting the power module 9 and the motor section 30. The terminal 14a is integrally insert-molded into the case 14.

[0023] <Connection configuration between stator 3 and inverter unit 40> The configuration of the electrical connection between the stator 3 and the inverter unit 40 will now be described. The rotating electric machine 1 includes a connecting board 18, as shown in Figure 3. The connecting board 18 is a board with insert-molded terminals 19 that electrically connect the stator 3 and the inverter unit 40. The connecting board 18 is provided between the inverter unit 40 and the rear bracket 5 and is fixed to the rear bracket 5 with screws (not shown).

[0024] The stator lead wire 3c is the end of the stator winding 3a. The stator lead wire 3c passes through the rear bracket 5 and is welded to the terminal 19 at the connection point 19a on one end of the terminal 19 provided on the connecting board 18. After this connection, the inverter unit 40, before the rear cover 15 is attached, is mounted on the axial rear side of the rear bracket 5. One end of the terminal 14a provided on the case 14 is connected to the terminal 19 by a screw 19c at the connection point 19b on the other end of the terminal 19. The AC terminal 9a of the power module 9 and the other end of the terminal 14a are joined by welding or the like. The ground terminal 9b of the power module 9, which is not shown in Figure 3, is fixed to the heat transfer member 31 with a screw (not shown). The ground terminal 9b and the heat transfer member 31 are electrically connected, and the heat transfer member 31 becomes the ground.

[0025] <Cooler 37> The cooler 37, which includes the essential parts of the present invention, will now be described. As shown in Figure 1, the cooler 37 comprises a heat transfer member 31, a cover member 32, a sealing material 35, and a refrigerant input / output pipe 33 which is a refrigerant supply and discharge section. The power module 9 and the field module 10 are thermally connected to the other axial side of the heat transfer member 31, and a flow channel groove 31a is formed on one axial side, recessed toward the other axial side. The cover member 32 is provided to close the opening on one axial side of the flow channel groove 31a. As shown in Figure 4, the cover member 32 is formed in the shape of a plate. The heat transfer member 31 is manufactured by casting using an inexpensive and lightweight aluminum alloy such as ADC12, but is not limited to this, and may be manufactured from other metal materials. The cover member 32 is manufactured from a metal material such as carbon steel or aluminum. As shown in Figure 1, the sealing material 35 is provided along the periphery of the flow channel groove 31a in the gap between the heat transfer member 31 and the cover member 32. The material of the sealing material 35 is, for example, silicone resin, but is not limited to this; it may also be fluorine-based silicone resin, epoxy resin, other resins such as acrylic, or rubber. By providing the sealing material 35, airtightness of the flow path 36 can be achieved. The refrigerant input / output pipe 33 is provided on the side surface of the heat transfer member 31 and supplies and discharges refrigerant to the flow path 36 surrounded by the flow path groove 31a and the cover member 32. For example, water, antifreeze, or ethylene glycol liquid can be used as the refrigerant. The heat transfer member 31 is cooled by the refrigerant in addition to the cooling air described above.

[0026] The structure of the part of the present invention where the lid member 32 is fixed to the heat transfer member 31 will be explained with reference to Figure 5. The heat transfer member 31 has a plurality of protrusions 31b that project outwards from one axial side surface surrounding the flow channel groove 31a. The lid member 32 has through holes 32a through which the protrusions 31b pass. The through holes 32a are provided along the outer circumference of the lid member 32, as shown in Figure 4. The dashed line shown in Figure 4 indicates the position of the rotation axis 11 when the lid member 32 is placed on the heat transfer member 31. The shape of the lid member 32 and the arrangement of the lid member 32 with respect to the heat transfer member 31 are not limited to this and may be changed according to the shape or arrangement of the flow channel groove 31a, etc. The arrangement and number of through holes 32a are also not limited to the configuration shown in Figure 4. As shown in Figure 5, a lid fixing part 34 larger than the diameter of the through hole 32a is provided on the portion of the protrusion 31b that projects outwards from the lid member 32 on one axial side. The lid member 32 is fixed to the heat transfer member 31 by the lid fixing part 34.

[0027] The structure of the portion where the lid member 32 is fixed to the heat transfer member 31 in this embodiment will now be described in detail. The protrusion 31b has a first protrusion 31c that protrudes from one axial side surface of the heat transfer member 31 to one axial side, and a second protrusion 31d that protrudes from one axial end portion of the first protrusion 31c to one axial side. The radial size of the first protrusion 31c is larger than the radial size of the second protrusion 31d, and the second protrusion 31d penetrates the through hole 32a. The other axial side portion of the lid member 32 and the axial end portion of the first protrusion 31c are in contact. A lid fixing portion 34 is provided on the portion of the second protrusion 31d that protrudes to one axial side from the lid member 32. A male threaded portion 31d1 is formed on the outer circumference of the second protruding portion 31d which protrudes to one side in the axial direction from the lid member 32, and the lid fixing portion 34 is a nut fastened to the male threaded portion 31d1.

[0028] The sealing material 35 is positioned in the gap between the portion of the heat transfer member 31 on the side of the flow channel groove 31a of the first protrusion 31c and the cover member 32, and is sandwiched and pressed between the heat transfer member 31 and the cover member 32. The gap between the heat transfer member 31 and the cover member 32 is formed by the portion of the first protrusion 31c that protrudes from the heat transfer member 31. The arrangement of the sealing material 35 is not limited to this, but by configuring it in this way, the sealing material 35 can be reliably provided in a position adjacent to the flow channel groove 31a, thereby improving the sealing performance of the flow channel 36 by the sealing material 35.

[0029] By using the multiple protrusions 31b extending from the heat transfer member 31 to fix the lid member 32 to the heat transfer member 31 with the lid fixing part 34, the fixing point of the lid member 32 can be moved axially away from the main body portion of the heat transfer member 31 in which the flow channel groove portion 31a is formed. This suppresses the connection between the flow channel groove portion 31a and the outside via casting defects, so that a rotating electric machine 1 can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine 1.

[0030] In this embodiment, the protrusion 31b is shown to have a first protrusion 31c and a second protrusion 31d, but it is not limited to this configuration, and the protrusion 31b may not have a first protrusion 31c and a second protrusion 31d, but may be formed by a single protrusion. When the protrusion 31b has a first protrusion 31c and a second protrusion 31d, and the other axial side of the lid member 32 is brought into contact with one axial end of the first protrusion 31c, the sealing material 35 can be reliably positioned in the gap between the heat transfer member 31 and the lid member 32, thereby ensuring that the flow path 36 is sealed by the sealing material 35.

[0031] In this embodiment, the lid fixing portion 34 is configured with a nut fastened to the male threaded portion 31d1, but the configuration of the lid fixing portion 34 is not limited to a nut, and other configurations such as those described in other embodiments later may be used. When the lid fixing portion 34 is configured with a nut, the lid member 32 can be securely fixed to the heat transfer member 31 by fastening the nut to the male threaded portion 31d1. Since the lid member 32 is securely fixed to the heat transfer member 31, the airtightness of the flow path 36 by the sealing material 35 can be reliably obtained.

[0032] Using Figure 6, the configuration of another inverter section 40 of the rotating electric machine 1 will be explained. A recess 31e is provided on the side of the first protrusion 31c between the first protrusion 31c and the flow channel groove 31a, on one axial side of the heat transfer member 31. By providing the recess 31e, the gap between the heat transfer member 31 and the cover member 32 is partially widened, making it difficult for the sealing material 35 to reach the male threaded portion 31d1 when fixing the cover member 32 to the heat transfer member 31. If the sealing material 35 adheres to the male threaded portion 31d1 when tightening the nut, the tightening torque of the nut changes, making it impossible to control the process by tightening torque, and thus it becomes impossible to reliably fix the cover member 32 to the heat transfer member 31. When the recess 31e is provided, adhesion of the sealing material 35 to the male threaded portion 31d1 is reliably suppressed, so the cover member 32 can be reliably fixed to the heat transfer member 31.

[0033] As described above, in the rotating electric machine 1 according to Embodiment 1, the heat transfer member 31 has a plurality of protrusions 31b that project outwards from one axial side surface surrounding the flow channel groove 31a, the lid member 32 has a through hole 32a through which the protrusions 31b pass, and a lid fixing portion 34 larger than the diameter of the through hole 32a is provided on the portion of the protrusion 31b that projects outwards from the lid member 32 in one axial direction, and the lid member 32 is fixed to the heat transfer member 31 by the lid fixing portion 34. As a result, the fixing location of the lid member 32 can be moved axially away from the main body portion of the heat transfer member 31 in which the flow channel groove 31a is formed, and the connection between the flow channel groove 31a and the outside via casting defects is suppressed. Therefore, a rotating electric machine 1 can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine 1.

[0034] If the protrusion 31b has a first protrusion 31c that protrudes from one axial side surface of the heat transfer member 31 to one axial side, and a second protrusion 31d that protrudes from one axial end of the first protrusion 31c to one axial side, and the radial size of the first protrusion 31c is larger than the radial size of the second protrusion 31d, and the second protrusion 31d penetrates the through hole 32a, and the other axial side of the lid member 32 comes into contact with one axial end of the first protrusion 31c, and a lid fixing portion 34 is provided on the portion of the second protrusion that protrudes to one axial side beyond the lid member 32, then the sealing material 35 can be reliably positioned in the gap between the heat transfer member 31 and the lid member 32, so that the sealing of the flow path 36 by the sealing material 35 can be reliably obtained.

[0035] If the sealing material 35 is positioned in the gap between the portion of the heat transfer member 31 on the side of the flow channel groove 31a of the first protrusion 31c and the lid member 32, and is sandwiched and pressed between the heat transfer member 31 and the lid member 32, then the sealing material 35 can be reliably provided at a position adjacent to the flow channel groove 31a, thereby improving the airtightness of the flow channel 36 by the sealing material 35. Furthermore, if a male threaded portion 31d1 is formed on the outer circumference of the portion of the second protrusion 31d that protrudes to one side in the axial direction from the lid member 32, and the lid fixing portion 34 is a nut fastened to the male threaded portion 31d1, then the lid member 32 can be reliably fixed to the heat transfer member 31 by fastening the nut to the male threaded portion 31d1. Since the lid member 32 is reliably fixed to the heat transfer member 31, the airtightness of the flow channel 36 by the sealing material 35 can be reliably obtained.

[0036] If a recess 31e is provided on the side of the first protrusion 31c between the first protrusion 31c and the flow channel groove 31a, and on one axial side of the heat transfer member 31, the sealing material 35 will have difficulty reaching the male thread portion 31d1 when fixing the lid member 32 to the heat transfer member 31. As a result, adhesion of the sealing material 35 to the male thread portion 31d1 is reliably suppressed, and the lid member 32 can be reliably fixed to the heat transfer member 31.

[0037] Embodiment 2. A rotating electric machine 1 according to Embodiment 2 will now be described. Figure 7 is a cross-sectional view illustrating the manufacturing process of the part of the inverter section 40 of the rotating electric machine 1 according to Embodiment 2 where the lid member 32 is fixed to the heat transfer member 31, and Figure 8 is a cross-sectional view of the main part of the inverter section 40 of the rotating electric machine 1, showing the part where the lid member 32 is fixed to the heat transfer member 31. The rotating electric machine 1 according to Embodiment 2 has a different configuration for the lid fixing part 34 than Embodiment 1.

[0038] As shown in Figure 8, the lid fixing portion 34 of Embodiment 2 is a second protruding portion 31d that protrudes from the lid member 32 on one side in the axial direction and has a diameter larger than the diameter of the through hole 32a. The lid fixing portion 34 is a deformed portion 31f obtained by deforming the second protruding portion 31d.

[0039] The manufacturing process for the deformed portion 31f will now be described. As shown in Figure 7, first, the second protrusion 31d is inserted through the through hole 32a provided in the lid member 32, and the lid member 32 is installed on the heat transfer member 31. Next, the portion of the second protrusion 31d that protrudes from the lid member 32 on one side in the axial direction is processed. Through processing, the deformed portion 31f is formed as the portion of the second protrusion 31d having a diameter larger than the diameter of the through hole 32a. The formation of the deformed portion 31f fixes the lid member 32 to the heat transfer member 31. Specifically, the deformed portion 31f can be formed by melting and solidifying the portion of the second protrusion 31d that protrudes on one side in the axial direction using a heat source such as an arc or laser. The heat transfer member 31 and the lid member 32 may also be welded when forming the deformed portion 31f. Alternatively, the deformed portion 31f can also be formed by applying a large amount of pressure from one side in the axial direction to the portion of the second protrusion 31d that protrudes on one side in the axial direction, thereby causing plastic deformation of the second protrusion 31d.

[0040] In this fixing structure of the lid member 32 with the deformed portion 31f to the heat transfer member 31, similar to Embodiment 1, the fixing location of the lid member 32 can be moved axially away from the main body portion of the heat transfer member 31 in which the flow channel groove portion 31a is formed. Furthermore, since no surface processing such as cutting is performed on the main body portion of the heat transfer member 31 for fixing the lid member 32, the connection between the flow channel groove portion 31a and the outside via casting defects is suppressed. As a result, a rotating electric machine 1 can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine 1.

[0041] Since the lid fixing portion 34 is the second protruding portion 31d that protrudes to one side in the axial direction from the lid member 32 and has a diameter larger than the diameter of the through hole 32a, the part forming the lid fixing portion 34 is not a separate part, and the number of parts constituting the rotating electric machine 1 is reduced, thereby improving the productivity of the rotating electric machine 1 and reducing the cost of the rotating electric machine 1. In addition, in the process of machining and deforming the second protruding portion 31d, casting defects can be crushed and sealed, further enhancing the effect of suppressing refrigerant leakage to the outside.

[0042] Embodiment 3. A rotating electric machine 1 according to Embodiment 3 will now be described. Figure 9 is a cross-sectional view of the main part of the inverter section 40 of the rotating electric machine 1 according to Embodiment 3, showing the section where the cover member 32 is fixed to the heat transfer member 31. Figure 10 is a cross-sectional view of the main part of another inverter section 40 of the rotating electric machine 1, showing the section where the cover member 32 is fixed to the heat transfer member 31. Figure 11 is a cross-sectional view of the main part of another inverter section 40 of the rotating electric machine 1, showing the section where the cover member 32 is fixed to the heat transfer member 31. The rotating electric machine 1 according to Embodiment 3 has a configuration in which an intermediate member 38 is added to the cooler 37.

[0043] An intermediate member 38 is provided between the lid fixing portion 34 and the lid member 32, through which a second projection 31d passes. The lid fixing portion 34 shown in Figure 9 is a nut. In the configuration shown in Figure 9, the intermediate member 38 is provided between the nut and the lid member 32, and the intermediate member 38 is fixed to the heat transfer member 31 together with the lid member 32 by the nut. The intermediate member 38 has a through hole 38a, and the second projection 31d passes through the through hole 38a. The intermediate member 38 is made of a metal material with excellent thermal conductivity, such as aluminum. The shape of the intermediate member 38 when viewed in the axial direction is, for example, circular, but the shape of the intermediate member 38 when viewed in the axial direction is not limited to circular.

[0044] By providing the intermediate member 38 in this manner, the intermediate member 38 can assist in the heat dissipation of the cooler 37, thereby improving the cooling performance of the cooler 37. For example, if an intermediate member is provided in the configuration shown in Patent Document 1, the intermediate member will be provided between the screw head of the bolt and the cover member. In that case, heat from the power module and field module is conducted to the heat transfer member, and then the heat is conducted to the bolt via the contact surface between the heat transfer member and the bolt of the cover member. Furthermore, the heat is conducted to the intermediate member via the other end surface of the screw head. In contrast, in the structure shown in this embodiment, heat is conducted from the heat transfer member 31 to the nut via the contact surface between the second protrusion 31d and the nut which is the cover fixing part 34. Next, it is transmitted to the intermediate member 38 via the other end surface of the nut, so the heat transfer path is shortened, and the cooling performance of the cooler 37 can be improved.

[0045] In the configuration shown in Figure 10, multiple heat dissipation fins 38b are formed on the intermediate member 38. The lid fixing part 34 is a nut, as in Figure 9. By forming heat dissipation fins 38b on the intermediate member 38, the cooling performance of the cooler 37 can be further improved.

[0046] Figure 11 shows a configuration in which an intermediate member 38 is added to the fixing structure of the lid member 32, which has a deformable portion 31f, to the heat transfer member 31. Multiple heat dissipation fins 38b are formed on the intermediate member 38. Similar to the configuration shown in Figure 9 or Figure 10, the intermediate member 38 can assist in heat dissipation from the cooler 37, thereby improving the cooling performance of the cooler 37. In Figure 10, the heat dissipation fins 38b of the intermediate member 38 are arranged in the axial direction, while in Figure 11, the heat dissipation fins 38b of the intermediate member 38 are arranged in the radial direction. The heat dissipation fins 38b may be arranged in either direction, and the shape of the heat dissipation fins 38b is not limited to these shapes.

[0047] Embodiment 4. A rotating electric machine 1 according to Embodiment 4 will now be described. Figure 12 is a cross-sectional view of the main part of the inverter section 40 of the rotating electric machine 1 according to Embodiment 4, showing the section where the cover member 32 is fixed to the heat transfer member 31. Figure 13 is a cross-sectional view of the main part of another inverter section 40 of the rotating electric machine 1, showing the section where the cover member 32 is fixed to the heat transfer member 31. The rotating electric machine 1 according to Embodiment 4 has a configuration in which the cover member 32 has a cover member projection 32b.

[0048] The lid member 32 has a lid member projection 32b that protrudes to one side in the axial direction around the through hole 32a on one side in the axial direction, and the lid member projection 32b and the lid fixing part 34 are in contact. The lid member projection 32b shown in Figure 12 is formed, for example, by burring. The lid fixing part 34 shown in Figure 12 is a nut. With this configuration, the fixing point of the lid member 32 can be moved further in the axial direction away from the main body portion of the heat transfer member 31 in which the flow channel groove 31a is formed, and the connection between the flow channel groove 31a and the outside via casting defects is further suppressed, so that a rotating electric machine 1 can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine 1. In addition, since the surface area of ​​the lid member 32 is increased by providing the lid member projection 32b, the cooling performance of the cooler 37 can be further improved.

[0049] Figure 13 shows a configuration in which a lid member projection 32b is provided for fixing the lid member 32, which has a deformable portion 31f, to the heat transfer member 31. The lid member projection 32b shown in Figure 13 is formed, for example, by extrusion. Similar to the configuration shown in Figure 12, the fixing point of the lid member 32 can be moved further axially away from the main body portion of the heat transfer member 31 in which the flow channel groove portion 31a is formed. Furthermore, since no surface processing such as cutting is performed on the main body portion of the heat transfer member 31 for fixing the lid member 32, the connection between the flow channel groove portion 31a and the outside via casting defects is further suppressed. As a result, a rotating electric machine 1 can be obtained in which leakage of refrigerant to the outside is suppressed without increasing the radial size of the rotating electric machine 1. In addition, since the surface area of ​​the lid member 32 is increased by providing the lid member projection 32b, the cooling performance of the cooler 37 can be further improved.

[0050] Furthermore, although this application describes various exemplary embodiments and examples, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but can be applied individually or in various combinations to the embodiments. Accordingly, countless variations not illustrated are conceivable within the scope of the technology disclosed herein. These include, for example, modifications, additions, or omissions of at least one component, as well as the extraction of at least one component and its combination with components of other embodiments.

[0051] The various aspects of this disclosure are summarized below as an appendix. (Note 1) A motor unit comprising: a rotating shaft; a rotor having a field core around which field windings are wound and which rotates integrally with the rotating shaft; a stator having a stator core arranged radially outside the field core and around which stator windings are wound; and a bracket covering the outside of the field core and the stator core and holding one end and the other end of the rotating shaft via bearings; The system includes a power module having a switching element for switching the supply current to the stator winding on and off, a field module having a switching element for switching the supply current to the field winding on and off, and a cooler for cooling the power module and the field module, and an inverter unit located on the other axial side of the bracket and fixed to the bracket, The cooler comprises a heat transfer member to which the power module and the field module are thermally connected on the other side in the axial direction, and a flow channel groove formed on one side in the axial direction that is recessed on the other side in the axial direction; a cover member that closes the opening on one side in the axial direction of the flow channel groove; a sealing material provided along the periphery of the flow channel groove in the gap between the heat transfer member and the cover member; and a refrigerant supply and discharge section that supplies and discharges refrigerant into the flow channel surrounded by the flow channel groove and the cover member. The heat transfer member has a plurality of protrusions that project from one axial side surface surrounding the flow channel groove to one axial side, The lid member has a through hole through which the protruding portion passes, A lid fixing portion, larger than the diameter of the through hole, is provided on the portion of the protruding part that protrudes to one side in the axial direction from the lid member. The lid member is fixed to the heat transfer member by the lid fixing portion of the rotating electric machine. (Note 2) The protrusion has a first protrusion that protrudes from one axial side surface of the heat transfer member to one axial side, and a second protrusion that protrudes from one axial end portion of the first protrusion to one axial side. The radial size of the first protrusion is greater than the radial size of the second protrusion. The aforementioned second projection penetrates the through hole, The other axial portion of the lid member and the axial end of the first protrusion come into contact with each other. The rotating electric machine according to Appendix 1, wherein the lid fixing portion is provided on the portion of the second protrusion that protrudes to one side in the axial direction from the lid member. (Note 3) The sealing material is placed in the gap between the portion of the heat transfer member on the flow channel groove side of the first protrusion and the cover member, and is sandwiched and pressed between the heat transfer member and the cover member in the rotating electric machine as described in Appendix 2. (Note 4) A male threaded portion is formed on the outer circumference of the second protruding portion which protrudes to one side in the axial direction from the cover member. The lid fixing portion is a nut fastened to the male thread portion, as described in Appendix 2 or 3 of the rotating electric machine. (Note 5) The rotating electric machine according to Appendix 2 or 3, wherein the lid fixing portion is the portion of the second protrusion that protrudes to one side in the axial direction from the lid member and has a diameter larger than the diameter of the through hole. (Note 6) The rotating electric machine according to any one of the appendices 2 to 5, wherein an intermediate member through which the second projection passes is provided between the lid fixing portion and the lid member. (Note 7) The lid member has a lid member projection that protrudes to one side in the axial direction around the through hole on one side in the axial direction. A rotating electric machine according to any one of the appendices 2 to 5, wherein the lid member protrusion and the lid fixing portion are in contact. (Note 8) The rotating electric machine according to Appendix 6, wherein a plurality of heat dissipation fins are formed on the intermediate member. (Note 9) The rotating electric machine according to any one of the appendices 2 to 5, wherein a recess is provided on the side of the first protrusion between the first protrusion and the flow channel groove, on one axial side of the heat transfer member. [Explanation of Symbols]

[0052] 1 Rotating electric machine, 2 Rotor, 2a Field winding, 2b Field core, 3 Stator, 3a Stator winding, 3b Stator core, 3c Stator lead wire, 4 Front bracket, 5 Rear bracket, 5a Bolt, 6 Magnetic pole position detection sensor, 6a Sensor stator, 6b Sensor rotor, 7 Bearing, 8 Bearing, 9 Power module, 9a AC terminal, 9b Ground terminal, 9c Input terminal, 9d Control terminal, 10 Field module, 11 Rotating shaft, 12 Pulley, 13 Slip ring, 14 Case, 14a Terminal, 14b Terminal, 15 Rear cover, 16 Brush, 16a Brush holder, 17 Control module, 18 Connecting board, 19 Terminal, 19a Connection point, 19b Connection point, 19c Screw, 20 Cooling fan, 21 Cooling fan, 30 Motor section, 31 Heat transfer member, 31a Flow channel groove, 31b Protrusion, 31c First protrusion, 31d Second protrusion, 31d1 Male screw section, 31e Recess, 31f Deformed section, 32 Cover member, 32a Through hole, 32b Cover member protrusion, 33 Refrigerant input / output pipe, 34 Cover fixing section, 35 Sealing material, 36 Flow channel, 37 Cooler, 38 Intermediate member, 38a Through hole, 38b Heat dissipation fin, 40 Inverter section

Claims

1. A motor unit comprising: a rotating shaft; a rotor having a field core around which field windings are wound and which rotates integrally with the rotating shaft; a stator having a stator core arranged radially outside the field core and around which stator windings are wound; and a bracket covering the outside of the field core and the stator core and holding one end and the other end of the rotating shaft via bearings; The system includes a power module having a switching element for switching the supply current to the stator winding on and off, a field module having a switching element for switching the supply current to the field winding on and off, and a cooler for cooling the power module and the field module, and an inverter unit located on the other axial side of the bracket and fixed to the bracket, The cooler comprises a heat transfer member to which the power module and the field module are thermally connected on the other side in the axial direction, and a flow channel groove formed on one side in the axial direction that is recessed on the other side in the axial direction; a cover member that closes the opening on one side in the axial direction of the flow channel groove; a sealing material provided along the periphery of the flow channel groove in the gap between the heat transfer member and the cover member; and a refrigerant supply and discharge section that supplies and discharges refrigerant into the flow channel surrounded by the flow channel groove and the cover member. The heat transfer member has a plurality of protrusions that project from one axial side surface surrounding the flow channel groove to one axial side, The lid member has a through hole through which the protruding portion passes, A lid fixing portion, larger than the diameter of the through hole, is provided on the portion of the protruding part that protrudes to one side in the axial direction from the lid member. The lid member is fixed to the heat transfer member by the lid fixing portion. The protrusion has a first protrusion that protrudes from one axial side surface of the heat transfer member to one axial side, and a second protrusion that protrudes from the axial end portion of the first protrusion to one axial side. The radial size of the first protrusion is greater than the radial size of the second protrusion. The aforementioned second projection penetrates the through hole, The other axial portion of the lid member and the axial end of the first protrusion come into contact with each other. The lid fixing portion is provided on the portion of the second protrusion that protrudes to one side in the axial direction from the lid member. A male threaded portion is formed on the outer circumference of the second protruding portion which protrudes to one side in the axial direction from the cover member. The lid fixing part is a nut fastened to the male screw part of the rotating electric machine.

2. The rotating electric machine according to claim 1, wherein the sealing material is placed in the gap between the portion of the heat transfer member on the flow channel groove side of the first protrusion and the cover member, and is sandwiched and pressed between the heat transfer member and the cover member.

3. The rotating electric machine according to claim 1, wherein an intermediate member through which the second protrusion passes is provided between the lid fixing portion and the lid member.

4. The lid member has a lid member projection that protrudes to one side in the axial direction around the through hole on one side in the axial direction. The rotating electric machine according to claim 1, wherein the lid member protrusion and the lid fixing portion are in contact.

5. A motor unit comprising: a rotating shaft; a rotor having a field core around which field windings are wound and which rotates integrally with the rotating shaft; a stator having a stator core arranged radially outside the field core and around which stator windings are wound; and a bracket covering the outside of the field core and the stator core and holding one end and the other end of the rotating shaft via bearings, The system includes a power module having a switching element for switching the supply current to the stator winding on and off, a field module having a switching element for switching the supply current to the field winding on and off, and a cooler for cooling the power module and the field module, and an inverter unit located on the other axial side of the bracket and fixed to the bracket, The cooler comprises a heat transfer member to which the power module and the field module are thermally connected on the other side in the axial direction, and a flow channel groove formed on one side in the axial direction that is recessed on the other side in the axial direction; a cover member that closes the opening on one side in the axial direction of the flow channel groove; a sealing material provided along the periphery of the flow channel groove in the gap between the heat transfer member and the cover member; and a refrigerant supply and discharge section that supplies and discharges refrigerant into the flow channel surrounded by the flow channel groove and the cover member. The heat transfer member has a plurality of protrusions that project from one axial side surface surrounding the flow channel groove to one axial side, The lid member has a through hole through which the protruding portion passes, A lid fixing portion, larger than the diameter of the through hole, is provided on the portion of the protruding part that protrudes to one side in the axial direction from the lid member. The lid member is fixed to the heat transfer member by the lid fixing portion. The protrusion has a first protrusion that protrudes from one axial side surface of the heat transfer member to one axial side, and a second protrusion that protrudes from the axial end portion of the first protrusion to one axial side. The radial size of the first protrusion is greater than the radial size of the second protrusion. The aforementioned second projection penetrates the through hole, The other axial portion of the lid member and the axial end of the first protrusion come into contact with each other. The lid fixing portion is provided on the portion of the second protrusion that protrudes to one side in the axial direction from the lid member. An intermediate member through which the second protrusion passes is provided between the lid fixing portion and the lid member. A rotating electric machine having multiple heat dissipation fins formed on the intermediate member.

6. A motor unit comprising: a rotating shaft; a rotor having a field core around which field windings are wound and which rotates integrally with the rotating shaft; a stator having a stator core arranged radially outside the field core and around which stator windings are wound; and a bracket covering the outside of the field core and the stator core and holding one end and the other end of the rotating shaft via bearings, The system includes a power module having a switching element for switching the supply current to the stator winding on and off, a field module having a switching element for switching the supply current to the field winding on and off, and a cooler for cooling the power module and the field module, and an inverter unit located on the other axial side of the bracket and fixed to the bracket, The cooler comprises a heat transfer member to which the power module and the field module are thermally connected on the other side in the axial direction, and a flow channel groove formed on one side in the axial direction that is recessed on the other side in the axial direction; a cover member that closes the opening on one side in the axial direction of the flow channel groove; a sealing material provided along the periphery of the flow channel groove in the gap between the heat transfer member and the cover member; and a refrigerant supply and discharge section that supplies and discharges refrigerant into the flow channel surrounded by the flow channel groove and the cover member. The heat transfer member has a plurality of protrusions that project from one axial side surface surrounding the flow channel groove to one axial side, The lid member has a through hole through which the protruding portion passes, A lid fixing portion, larger than the diameter of the through hole, is provided on the portion of the protruding part that protrudes to one side in the axial direction from the lid member. The lid member is fixed to the heat transfer member by the lid fixing portion. The protrusion has a first protrusion that protrudes from one axial side surface of the heat transfer member to one axial side, and a second protrusion that protrudes from the axial end portion of the first protrusion to one axial side. The radial size of the first protrusion is greater than the radial size of the second protrusion. The aforementioned second projection penetrates the through hole, The other axial portion of the lid member and the axial end of the first protrusion come into contact with each other. The lid fixing portion is provided on the portion of the second protrusion that protrudes to one side in the axial direction from the lid member. A rotating electric machine having a recess provided on the side of the first protrusion between the first protrusion and the flow channel groove, on one axial side of the heat transfer member.

Images