Inverter device and inverter-integrated electric compressor provided with same

Abstract

Provided is an inverter device that makes it possible to visually confirm and inspect an electric component installed in an inverter case. An inverter device (7) is provided with: IGBTs (10) which control AC power supplied to an electric motor; and an inverter box (9) which house the IGBTs (10) and which is attached to a motor housing that houses the electric motor. The inverter box (9) is provided with a base plate (9c), the surface of which has the IGBTs (10) fixed thereto and the rear surface of which contacts and is fixed to the motor housing. A base plate opening (22) is formed in the base plate (9c) at a position at which the IGBTs (10) fixed to the surface of the base plate (9c) can be visually confirmed from the rear surface of the base plate (9c).

Description

Inverter device and inverter-integrated electric compressor equipped with the same

[0001] The present disclosure relates to an inverter device and an inverter-integrated electric compressor including the inverter device.

[0002] As disclosed in Patent Document 1, an inverter-integrated electric compressor incorporating an inverter device is known as a compressor for air conditioning systems mounted on hybrid vehicles, electric vehicles, etc. This inverter-integrated electric compressor is configured such that an inverter accommodating section (inverter box) is provided in a housing that incorporates an electric motor and a compression mechanism, and an inverter device is incorporated inside the inverter box to convert DC power supplied from a power source into AC power and apply the AC power to the electric motor.

[0003] The inverter device generally includes a plurality of electrical components such as IGBTs that convert DC power into AC power.

[0004] Patent No. 7306282

[0005] In Patent Document 1, although an opening is formed in the inverter case, a capacitor and a coil pass through this opening, making it impossible to visually check other electrical components installed in the inverter case. This makes it impossible to visually check the electrical components installed in the inverter case before assembling the inverter case to the compressor main body, making it impossible to perform a sufficient inspection.

[0006] The present disclosure has been made in consideration of the above circumstances, and aims to provide an inverter device that allows for visual inspection of electrical components installed in an inverter case, and an inverter-integrated electric compressor equipped with the same.

[0007] An inverter device according to one aspect of the present disclosure comprises electrical components that control the AC power supplied to an electric motor, and an inverter box that houses the electrical components and is attached to a housing that houses the electric motor, the inverter box comprising a base plate to which the electrical components are fixed on a surface and whose back surface is fixed in contact with the housing, and an opening is formed in the base plate at a position that allows the electrical components fixed on the surface of the base plate to be viewed from the back surface of the base plate.

[0008] An inverter-integrated electric compressor according to one aspect of the present disclosure includes an electric motor, a compression mechanism driven by the electric motor to compress a refrigerant, a housing that accommodates the electric motor and the compression mechanism, and the above-mentioned inverter device attached to an outer wall of the housing.

[0009] Electrical components installed inside the inverter case can be visually inspected.

[0010] Fig. 4 is a side view of an inverter-integrated electric compressor according to an embodiment of the present disclosure; Fig. 5 is a perspective view showing an IGBT; Fig. 6 is a side view showing the inverter-integrated electric compressor of Fig. 1 in a separated state; Fig. 7 is a front view showing the inside of an inverter box; Fig. 8 is a perspective view of the inverter box of Fig. 4 as seen from the back; Fig. 9 is a perspective view showing an enlarged lower part of the inverter box of Fig. 4; Fig. 10 is a rear view of the lower part of the inverter box of Fig. 4 as seen from the IGBT side, showing the board; Fig. 11 is a front view of the inside of an inverter box showing a modified example of the present disclosure.

[0011] Hereinafter, an embodiment according to the present disclosure will be described with reference to the drawings. FIG. 1 shows an inverter-integrated electric compressor 1 according to one embodiment of the present disclosure. The inverter-integrated electric compressor 1 includes a housing 2 that forms an outer shell. The housing 2 is configured by integrally fastening together a motor housing 3 that houses an electric motor (not shown) and a compressor housing 4 that houses a compression mechanism (not shown) with bolts or the like. The motor housing 3 and the compressor housing 4 are pressure-resistant containers made of aluminum die-cast.

[0012] An electric motor and a compression mechanism (not shown) housed inside the housing 2 are connected via a motor shaft, and the compression mechanism is driven by rotation of the electric motor. The compression mechanism may be, for example, a scroll compression mechanism.

[0013] A refrigerant suction port (not shown) is provided at one end (e.g., the left side in FIG. 1) of the motor housing 3. Low-temperature, low-pressure refrigerant gas is drawn into the motor housing 3 from this refrigerant suction port, circulates around the electric motor along the motor axis (left-right direction in FIG. 1), and is then drawn into the compression mechanism where it is compressed. The high-temperature, high-pressure refrigerant gas compressed by the compression mechanism is discharged into the compressor housing 4 and then sent to the outside from a discharge port (not shown) provided at one end (e.g., the right side in FIG. 1) of the compressor housing 4.

[0014] The housing 2 is provided with a plurality of mounting legs (not shown) so that the inverter-integrated electric compressor 1 is fixedly installed in a motor room (or engine room) of a vehicle.

[0015] An inverter device 7 including an inverter box 9 is fixed to the rear end surface 3a (left end surface in FIG. 1 ) of the motor housing 3. The inverter box 9 can be opened and closed using a lid 9a, and is box-shaped with a peripheral wall 9b of a predetermined height and a base plate 9c. The inverter box 9 is sealed by fixing the lid 9a to the peripheral wall 9b with screws or the like.

[0016] The inverter box 9 accommodates and installs electrical components that convert DC power supplied via a power cable from a power supply unit or battery (not shown) mounted on the vehicle into three-phase AC power and apply the AC power to the electric motor accommodated inside the motor housing 3. Figure 1 shows a plurality of IGBTs (electrical components) 10, which are semiconductor switching elements.

[0017] The IGBT 10 comprises an IGBT body 10a and terminals 10b provided on the IGBT body 10a. As shown in Fig. 2, each IGBT body 10a has three terminals 10b: an emitter, a collector, and a gate. The terminals 10b extend parallel to one another. The distance between the terminals 10b is the insulation distance.

[0018] 1, the IGBT body 10a is fixed to the surface of the base plate 9c. The IGBT body 10a is cooled by the low-pressure refrigerant circulating within the motor housing 3 via the base plate 9c and the rear end surface 3a of the motor housing 3.

[0019] The tip of the terminal 10b of the IGBT 10 is electrically connected to the substrate 12 by solder or the like. The substrate 12 is fixed to the inverter box 9 in a state parallel to the surface of the base plate 9c at a predetermined distance. A switching circuit connected to the IGBT 10 is mounted on the substrate 12.

[0020] In addition to the circuit board 12, the inverter box 9 is provided with a PN terminal to which a high-voltage power supply line is connected, a UVW terminal for supplying three-phase AC power to the electric motor, an earth terminal, and the like.

[0021] 3 shows a separated state of the inverter-integrated electric compressor 1. As shown in the figure, the motor housing 3 and the inverter box 9 are separable. By assembling the inverter box 9 with the base plate 9c of the inverter box 9 in contact with the rear end surface 3a of the motor housing 3, the inverter-integrated electric compressor 1 shown in FIG. 1 is obtained.

[0022] 4 shows the inside of the inverter device 7 with the cover 9a (see FIG. 1) of the inverter box 9 removed. In this figure, the circuit board 12 (see FIG. 1) has been removed.

[0023] 4, the lower part of the inverter box 9 is a cylindrical portion 9d that is cylindrical in shape to match the outer shape of the motor housing 3. A rectangular portion 9e is connected to the upper part of the cylindrical portion 9d.

[0024] A P-N connector 14, to which DC power is supplied, is provided at an upper corner of the rectangular portion 9e. The P-N connector 14 is attached to the base plate 9c of the inverter box 9. Two wires 15 extend separately from the P-N connector 14, with, for example, the P wire 15a extending downward and the N wire 15b extending to the side (right).

[0025] An inductor coil 16 and a smoothing capacitor 17 are provided below the P-N connector 14. As shown in Figure 5, the inductor coil 16 and the smoothing capacitor 17 are housed in a recess 19 formed in the base plate 9c. The recess 19 is assembled so that its bottom 19a contacts the rear end surface 3a (see Figure 3) of the motor housing 3. This allows the inductor coil 16 and the smoothing capacitor 17 to be cooled.

[0026] 4, a UVW busbar assembly 18 is provided below the inductor coil 16 and the smoothing capacitor 17. The UVW busbar assembly 18 is provided between the rectangular portion 9e and the cylindrical portion 9d.

[0027] Six IGBTs 10 are mounted on the cylindrical portion 9d of the inverter box 9. Each IGBT body 10a is fixed to a surface 9c1(F) of an IGBT fixing plate (electrical component fixing portion) 9c1 of the base plate 9c with a fixing screw 20. The IGBT fixing plate 9c1 has a generally rectangular shape extending upward from the lower end of the peripheral wall 9b of the inverter box 9. Three IGBTs 10 are arranged on each side of the rectangular IGBT fixing plate 9c1. The IGBTs 10 are arranged so that the terminals 10b of the IGBTs 10 facing each other on the left and right sides face each other. As shown in FIG. 5, the back surface 9c1(R) of the IGBT fixing plate 9c1, which is the surface on which the IGBTs 10 are not fixed, is assembled so that its entire surface contacts the rear end surface 3a of the motor housing 3 (see FIG. 3).

[0028] As shown in Fig. 4, connecting portions 9c2 extending diagonally upward and to the sides are provided on both sides of the upper portion of the IGBT fixing plate 9c1. The upper portion of the IGBT fixing plate 9c1 is supported by each connecting portion 9c2. The other end of each connecting portion 9c2 is connected to the peripheral wall 9b. As shown in Fig. 5, the rear surface 9c2(R) of each connecting portion 9c2 is assembled so that its entirety contacts the rear end surface 3a of the motor housing 3 (see Fig. 3).

[0029] 6, base plate openings (openings) 22 are formed on the left and right sides and on the top of the IGBT fixing plate 9c1. The base plate 9c is not present at the position of each base plate opening 22 and has been removed. Each base plate opening 22 allows the interior of the inverter box 9 to be viewed from the back side of the base plate 9c, allowing the IGBT 10 (particularly the terminals 10b) to be inspected.

[0030] The openings 22 include side openings 22a on both sides of the IGBT fixing plate 9c1 and an upper opening 22b above the IGBT fixing plate 9c1. The side openings 22a and the upper opening 22b are separated by a connecting portion 9c2. Note that the connecting portion 9c2 may be removed to form a single opening 22 that is continuously formed from both sides to the top of the IGBT fixing plate 9c1.

[0031] As shown in Figure 5, a seal portion 9c3 is provided around the cylindrical portion 9d so as to partially protrude from the back surface of the base plate 9c. The seal portion 9c3 is provided in a generally annular shape so as to surround and cover each base plate opening 22. When the inverter box 9 is attached to the rear end surface 3a of the motor housing 3 (see Figure 3), the seal portion 9c3 prevents moisture and the like from entering the inverter box 9 from the outside through the base plate opening 22.

[0032] 7 shows the substrate 12 viewed from the IGBT 10 side with the IGBT fixing plate 9c1 removed. The substrate 12 is fixed to the inverter box 9 using the fixing holes 12a. Three substrate fixing screws 24 for fixing the substrate 12 using the fixing holes 12a are shown in FIG.

[0033] The effects of the present embodiment described above are as follows. The back surface of the base plate 9c of the inverter box 9 is fixed in contact with the motor housing 3, which accommodates the electric motor. As a result, heat generated by the IGBTs 10 fixed to the surface of the base plate 9c is transferred to the motor housing 3, thereby cooling the IGBTs 10. The base plate 9c has a base plate opening 22 formed in a position that allows the IGBTs 10 to be viewed from the back surface of the base plate 9c. This allows the IGBTs 10 (particularly the terminals 10b) to be visually inspected before attaching the inverter box 9 to the motor housing 3. Furthermore, the formation of the base plate opening 22 allows the weight of the base plate 9c to be reduced.

[0034] A seal portion 9c3 is provided on the back surface of the base plate 9c, surrounding the base plate opening 22 on the inside, and the seal portion 9c3 seals between the base plate 9c and the motor housing 3. This makes it possible to prevent moisture and the like from entering the IGBT 10 side from the outside through the base plate opening 22 when the inverter box 9 is assembled to the motor housing 3.

[0035] As shown in FIG. 8 , an opening 26 may be formed in the IGBT fixing plate 9c1. The opening 26 is formed in a position that can be seen from the back surface of the IGBT fixing plate 9c1. Specifically, the opening 26 is formed in a vertically elongated rectangular shape extending in the vertical direction, in the center between two rows of IGBTs 10 aligned vertically on the left and right in FIG. 8 . The number of openings 26 is not limited to one, and multiple openings 26 may be formed as long as each terminal 10b can be seen from the back surface of the IGBT fixing plate 9c1. The shape of the opening 26 is also not limited to a rectangle, and may be an oval, ellipse, or the like.

[0036] Since the openings 26 are formed at positions where each terminal 10b of the IGBT 10 fixed to the surface of the IGBT fixing plate 9c1 can be seen from the back surface, the terminals 10b of the IGBT 10 can be seen and inspected through the openings 26.

[0037] The inverter device and the inverter-integrated electric compressor including the inverter device according to the above-described embodiments can be understood, for example, as follows.

[0038] The inverter device according to the first aspect of the present disclosure comprises an electrical component (10) that controls AC power supplied to an electric motor, and an inverter box (9) that houses the electrical component and is attached to a housing (3) that houses the electric motor, the inverter box comprising a base plate (9c) to which the electrical component is fixed on its front surface and whose back surface is fixed in contact with the housing, the base plate having an opening (22) formed in a position that allows the electrical component fixed on the front surface of the base plate to be viewed from the back surface of the base plate.

[0039] The back surface of the base plate of the inverter box is fixed in contact with the housing that accommodates the electric motor. This allows heat generated by electrical components fixed to the surface of the base plate to be transferred to the housing, thereby cooling the electrical components. The base plate has openings formed at positions that allow the electrical components to be viewed from the back surface of the base plate. This allows the electrical components to be visually inspected before the inverter box is attached to the housing. Furthermore, the formation of the openings allows the weight of the base plate to be reduced. Examples of electrical components include semiconductor switching elements such as IGBTs.

[0040] In the inverter device according to the second aspect of the present disclosure, in the first aspect, the base plate is provided with an electrical component fixing portion (9c1) for fixing the electrical component, and one or more of the openings (22a, 22b) are formed around the electrical component fixing portion.

[0041] One or more openings are formed around the electrical component fixing portion that fixes the electrical component, thereby enabling the electrical component to be visually inspected from the periphery thereof.

[0042] In the inverter device according to the third aspect of the present disclosure, in the first or second aspect, a terminal (10b) provided on one of the electrical components and a terminal provided on the other of the electrical components are arranged opposite each other, and the opening (26) is formed between the terminals arranged opposite each other.

[0043] Since an opening is formed between the opposing terminals, both of the opposing terminals can be seen from the rear surface of the base plate through the same opening.

[0044] The inverter device according to the fourth aspect of the present disclosure is, in any of the first to third aspects, provided on the back surface of the base plate with a sealing portion (9c3) that surrounds the opening on the inside and seals between the base plate and the housing.

[0045] A seal is provided on the back surface of the base plate, surrounding the opening on the inside, to seal between the base plate and the housing. This prevents moisture and other foreign matter from entering the electrical components from the outside through the opening when the inverter box is attached to the housing.

[0046] An inverter-integrated electric compressor according to a first aspect of the present disclosure includes an electric motor, a compression mechanism driven by the electric motor to compress a refrigerant, a housing that accommodates the electric motor and the compression mechanism, and an inverter device described above that is attached to an outer wall of the housing.

[0047] REFERENCE SIGNS LIST 1 inverter-integrated electric compressor 2 housing 3 motor housing 3a rear end surface 4 compressor housing 7 inverter device 9 inverter box 9a lid portion 9b surrounding wall 9c base plate 9c1 IGBT fixing plate (electrical component fixing portion) 9c1 (F) front surface 9c1 (R) rear surface 9c2 connection portion 9c2 (R) rear surface 9c3 seal portion 9d cylindrical portion 9e rectangular portion 10 IGBT (electrical component) 10a IGBT body 10b terminal 12 substrate 12a fixing hole 14 P-N connector 15 wiring 15a P wiring 15b N wiring 16 inductor coil 17 smoothing capacitor 18 UVW busbar assembly 19 recess 19a bottom portion 20 fixing screw 22 Base plate opening (opening) 22a Side opening 22b Top opening 24 Board fixing screw

Claims

1. An inverter device comprising: electrical components that control AC power supplied to an electric motor; and an inverter box that houses the electrical components and is attached to a housing that houses the electric motor, wherein the inverter box has a base plate to which the electrical components are fixed on a surface and whose back surface is fixed in contact with the housing, and wherein openings are formed in the base plate at positions that allow the electrical components fixed on the surface of the base plate to be viewed from the back surface of the base plate.

2. The inverter device according to claim 1, wherein the base plate has an electrical component fixing portion for fixing the electrical component, and one or more of the openings are formed around the electrical component fixing portion.

3. An inverter device as described in claim 1, wherein a terminal provided on one of the electrical components and a terminal provided on another of the electrical components are arranged opposite each other, and the opening is formed between the terminals arranged opposite each other.

4. The inverter device according to claim 1, wherein a seal portion is provided on the rear surface of the base plate, the seal portion being formed to surround the opening on the inside and providing a seal between the base plate and the housing.

5. An inverter-integrated electric compressor comprising: an electric motor; a compression mechanism driven by the electric motor to compress a refrigerant; a housing accommodating the electric motor and the compression mechanism; and an inverter device according to any one of claims 1 to 4 attached to an outer wall of the housing.

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