FR3077462A1 - POWER SUPPLY APPARATUS FOR ROTARY ELECTRIC MACHINE AND METHOD OF MANUFACTURING THE SAME - Google Patents

Abstract

There is provided a rotary electric machine power supply apparatus capable of discharging a generated gas outside of a smoothing capacitor and capable of preventing water ingress into an inverter circuit and the smoothing capacitor. , and the method of manufacturing it. The rotary electric machine power supply apparatus (3) comprises a coating resin (27) which seals the inverter circuit in a container (55) and a housing space member (41) to form a an airtight housing space (40) which contains a smoothing capacitor (29); in the housing space forming member (41) a through-hole (32) is formed which places the housing space (40) in communication with the outside and a sealing member (43). for sealing the through hole (32) is mounted in the through hole (32). Figure for the abstract: Figure 1

Description

Description

Title of the invention: ELECTRICAL POWER SUPPLY APPARATUS FOR ROTARY ELECTRICAL MACHINE AND MANUFACTURING METHOD THEREOF [0001] Background [0002] The present disclosure relates to an electric power supply apparatus for a rotary electric machine and the manufacturing process for it. this one.

As a power supply apparatus for a rotary electric machine, a rotary electric machine apparatus is known, as disclosed in

WO 2014/188 803, which integrally comprises a rotary electric machine, a power supply apparatus, and a control apparatus. In the technology disclosed in WO 2014/188 803, the rotary electrical machine apparatus is provided with an electrical circuit for converting between DC electrical energy and AC electrical energy, a smoothing capacitor for absorbing a current of ripple caused during the operation of a switching device in the electric circuit, a magnetic field circuit for controlling a current to be supplied to the magnetic field winding of the rotary electric machine, and a control circuit for controlling the electric circuit and the magnetic field circuit. The electrical circuit, the smoothing capacitor, the magnetic field circuit and the control circuit are contained in a space consisting of a heat sink, a housing, and the like.

Summary [0005] Resistance to humidity and vibrations is necessary depending on the environment in which a power supply device is used. However, WO 2014/188 803 does not disclose detailed measures to combat humidity and vibration.

It is conceivable that, to increase resistance to humidity and vibration, the respective circuits of the power supply device are contained, in an airtight manner, in a container using a resin d 'coating. Although the smoothing capacitor is used, gas can be generated from the electrolytic material therein. Since, when the smoothing capacitor is directly covered with the coating resin in an airtight manner, the gas generated cannot be evacuated outside the smoothing capacitor, the internal pressure of the smoothing capacitor increases, which can cause the smoothing capacitor to break.

It is therefore desirable to provide an electrical power supply device for a rotary electrical machine capable of discharging a gas generated outside the smoothing capacitor and capable of preventing any penetration of water into an inverter circuit and into the smoothing capacitor, as well as the manufacturing process thereof.

A power supply device for a rotary electric machine according to the present disclosure is provided with:

An inverter circuit converting between DC electrical energy to be supplied to an energy source connection terminal and AC electrical energy to be supplied to a rotary electrical machine, a smoothing capacitor connected to a wire electric which connects the connection terminal of energy source to the inverter circuit, a container, [0012] a coating resin which seals the inverter circuit in the container, and [0013] a member for forming space housing to form an airtight housing space which contains the smoothing capacitor; in the housing space forming member, a through hole is formed putting the housing space in communication with the outside; a sealing member for sealing the through hole is mounted in the through hole.

In the electrical power supply apparatus of a rotary electrical machine, the inverter circuit is contained, in an airtight manner, in the container using coating resin, so that the resistance to humidity and vibration can be increased. Gas generated during the operation of the power supply unit of the rotary electric machine can be vented into the accommodation space. Since the housing space is sealed, the exhaust gas increases the internal pressure; however, since the volume of the accommodation space is greater than the interior volume of the smoothing capacitor, it is possible to prevent any increase in pressure. Therefore, the smoothing capacitor cannot be broken by the increase in pressure. In some cases, to facilitate curing of the coating resin and the like, heat is applied to the apparatus in a manufacturing process. When at this point the accommodation space is sealed, the heater increases the internal pressure in the accommodation space. It is possible that the increased internal pressure pushes the resin and the like which have not hardened towards the outside and a ventilation hole is then formed which puts the housing space in communication with the outside. The through hole is formed in the housing space forming member; thus, when heat is applied in the manufacturing step, the internal pressure of the housing space can be vented through the through hole, thereby preventing the formation of a ventilation hole in the resin and the uncured adhesive. At the end of heating, the through hole is sealed with the sealing member, which makes it possible to prevent any penetration of water into the housing space and into the smoothing capacitor through the through hole, during Γuse of the power supply unit.

In a process for manufacturing the power supply device for a rotary electric machine, it is implemented:

An organ preparation step during which it is prepared an inverter circuit carrying out a conversion between the DC electrical energy to be supplied to an energy source connection terminal and an AC electrical energy to supplying a rotary electric machine, a smoothing capacitor connected to an electric wire which connects the terminal for connecting the energy source to the inverter circuit, [0019] an uncured coating resin having a facilitating property of thermal hardening, a housing space-forming member which forms a housing space to contain the smoothing capacitor and in which a through hole is formed which places the housing space in communication with the outside, and A sealing member for sealing the through hole, a capacitor capacity step to which, after the organ preparation step, the conde smoothing nsateur is contained in the housing space formed by the housing space forming member in which the sealing member has not been mounted in the through hole, a filling step of resin in which, after the capacitor capacity stage, an uncured coating resin is filled in a container in which the inverter circuit has been arranged, a heating stage in which, after the filling stage resin, the coating resin is heated so as to be hardened, and a through hole sealing step in which, after the heating step, the sealing member is mounted in the through hole so as to seal the accommodation space.

In the manufacturing process of the electric power supply apparatus of a rotary electric machine, due to the heating step, the curing time of the coating resin is reduced, which makes it possible to carry out a rapid transition to the next step; hence an increase in productivity. In the heating stage, the sealing member is not mounted in the through hole. Thus, when heat is applied, the internal pressure of the housing space can be vented through the through hole, thereby preventing the formation of a ventilation hole in the resin and similar uncured elements. Due to the through hole sealing step, the through hole is sealed with the sealing member, which helps prevent water from entering the housing space and the smoothing capacitor. through the through hole, while using the power supply unit.

Brief description of the drawings [fig-1] is a cross-sectional view of a rotary electric machine apparatus according to embodiment 1;

[Fig.2] is a circuit diagram of the rotary electric machine apparatus according to embodiment 1;

[Fig.3] is a view of an electrical power supply device excluding the coating resin and the control device, according to embodiment 1, seen from the opening side of it this ;

[Fig.4] is a view of the power supply unit covered, in an airtight manner, with the coating resin, according to embodiment 1, seen from the side of opening of it;

[Fig.5] is a cross-sectional view of a main part of the power supply apparatus according to embodiment 1;

[Fig.6] is a view of a heat sink according to embodiment 1 seen from the bottom side thereof;

[Fig.7] is an enlarged partial view of Figure 5;

[Fig.8] is a flow chart for explaining a method of manufacturing the power supply apparatus according to embodiment 1;

[Fig.9] is a cross-sectional view of a main part of an electrical supply device according to embodiment 2;

[Fig.10] is a cross-sectional view of a main part of an electrical power supply device according to embodiment 3;

[Fig.l 1] is a cross-sectional view of a main part of the power supply apparatus according to embodiment 3;

[Fig. 12] is a cross-sectional view of a main part of the power supply apparatus according to embodiment 3;

[Fig. 13] is a cross-sectional view of a main part of the power supply apparatus according to embodiment 4;

[Fig. 14] is a view of a heat sink according to embodiment 4, seen from the lower side thereof;

[Fig. 15] is a side view of a sealing member according to embodiment 4;

[Fig. 16] is a cross-sectional view of a main part of the power supply apparatus according to embodiment 4;

[Fig. 17] is a cross-sectional view of a main part of a power supply device according to embodiment 5; and [fig. 44 18] is a view of an insertion hole of a planar member according to embodiment 5, seen from the lower side thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS Embodiment 1 An electrical supply device 3 for a rotary electrical machine 1 (to which reference is simply made hereinafter as a supply device electrical 3) according to an embodiment 1 will be explained with reference to the accompanying drawings. In the present embodiment, a rotary electrical machine apparatus integrally comprises the rotary electrical machine 1, the power supply apparatus 3, and a control apparatus 20. Figure 1 is a cross-sectional view of the apparatus of rotary electric machine. Figure 2 is a circuit diagram of the rotary electrical machine apparatus.

Rotary electrical machine 1 In this embodiment, the rotary electrical machine apparatus is mounted in a vehicle and includes an electrical energy generator function of generating electrical energy by means of a driving force of an internal combustion engine and an engine function of assisting the driving force of the internal combustion engine. The rotary electric machine 1 is a synchronous rotary electric machine with field winding in which a three-phase winding 11 is provided on a stator 12 and a magnetic field winding 6 is provided on a rotor 5.

The rotary electric machine 1 is contained in a front cover 7 and a rear cover 8. An axis of rotation 4 of the rotor 5 is supported, so as to be able to pivot, by the front cover 7 via a front bearing 9 and it is also supported, so as to be able to pivot, by the rear cover 8, by means of a rear bearing 10. The stator 12 is fixed to the front cover 7 and to the rear cover 8.

The axis of rotation 4 of the rotary electric machine 1 projects from the front cover 7 to one side in the axial direction (which is referred to below as the front side); a pulley 13 is fixed to the front end portion at the front side of the axis of rotation 4. The pulley 13 is coupled to the crankshaft of the internal combustion engine by means of a belt. The axis of rotation 4 of the rotary electric machine 1 projects from the rear cover 8 to the other side (referred to below as the rear side) in the axial direction. A rotation position detection sensor 14 is provided on the rotation axis 4 at a more advanced position towards the rear side than towards the rear bearing 10. Slip rings 15 of positive pole and of negative pole connected to the winding magnetic field 6 are provided at the rear end portion of the rear side of the axis of rotation 4. Respective brushes 17 held by a brush holder 16 are in sliding contact with the slip rings 15. The apparatus power supply 3 supplies electrical energy to the magnetic field winding 6 via the contact surfaces between the slip rings 15 and the brushes 17.

Electrical supply device 3 The electrical supply device 3 and the control device 20 are arranged so as to be circumferentially separated from each other in a cylindrical tubular space which is at rear side in the axial direction of the rotary electric machine 1 (the rear cover 8) and on the outer side in the radial direction of the rear side projection of the rotation axis 4. The power supply unit 3 and l the control unit 20 are configured in full; the outer rear and radial sides of the power supply unit 3 and the control unit 20 are covered with a drive unit cover 28.

As illustrated in FIG. 2, the electrical supply device 3 is provided with an energy source connection terminal 56 to be connected to a DC energy source 50, inverter circuits 39, each of them carrying out a conversion between a DC electrical energy supplied to the power source connection terminal 56 and an AC electrical energy to be supplied to the three-phase winding 11 of the rotary electrical machine 1, and of a capacitor of smoothing 29 connected to an electric wire to connect the power source connection terminal 56 to the inverter circuits 39.

In this embodiment, two groups are provided each of the three-phase windings 11 and inverter circuits 39. In each of the two groups of inverter circuits 39, there are provided three sets of circuits in series corresponding to the respective windings of three phases. In each of the series circuits, a positive electrode side switching device 40a to be connected to the positive electrode terminal (the power source connection terminal 56) of the DC energy source 50 and a device negative electrode side switch 40b to be connected to the negative electrode terminal (ground, in this example) of the DC power source 50 are connected in series with each other. The connection point between the two switching devices 40a and 40b in each of the series circuits is connected to the winding 11 of the corresponding phase. As a switching device, a MOSFET (metal oxide semiconductor field effect transistor), an IGBT (bipolar insulated gate transistor) to which a diode is antiparallelically connected, or the like is used.

The gate terminal of each of the switching devices is connected to the control unit 20 (not shown). Thus, each of the switching devices is activated or deactivated by a control signal to be delivered from the control apparatus 20.

The series circuit consisting of the positive electrode side switching device 40a and the negative electrode side switching device 40b consists of a modular energy module 23. Three parts each of the modules d energy 23 are provided in each group of inverter circuits 39, ie six energy modules 23 in total. As in the circuit arrangement illustrated in FIG. 3, the energy module 23 has the form of a rectangular flat plate chip which seals with resin the two switching devices 40a and 40b and wiring wires; connection terminals protrude from the side thereof. The energy module 23 is provided with a positive electrode side connection terminal 23a to be connected to a positive electrode side wiring wire 26a, with a control signal connection terminal 23b as the terminal grid of the switching device, a winding connection terminal 23c to be connected to the winding via a connection line 26b, and a ground connection terminal 23d to be connected to a wire negative electrode side wiring 26c. The positive electrode side wiring wire 26a is connected to the power source connection terminal 56, and the negative electrode side wiring wire 26c is connected to ground.

The power supply device 3 is provided with a magnetic field winding drive circuit 24 which controls the supply of electric power DC to the magnetic field winding 6. The circuit magnetic field winding attack 24 is provided with three switching devices 24e, 24f, and 24g connected in series between the positive electrode terminal (the power source connection terminal 56) of the DC power source 50 and the negative electrode terminals (ground) of the DC 50 energy source. The connection point between the two switching devices 24e and 24f at the positive electrode terminal side and the connection point between the two switching devices 24f and 24g at the negative electrode terminal side are connected to the two respective terminals of the magnetic field winding 6, by means of the corresponding brush 17 and the corresponding slip ring 15 .

The magnetic field winding drive circuit 24 consists of a modular magnetic field module 24. As illustrated in FIG. 3, the magnetic field module 24 has the form of a chip flat rectangular plate which seals the three switching devices 24e, 24f and 24g and the wiring wires with resin; connection terminals protrude from the side thereof. The magnetic field module 24 is provided with a positive electrode side connection terminal 24a to be connected to the positive electrode side wiring wire 26a, with a control signal connection terminal 24b as the terminal grid of the switching device, two terminals for connecting the magnetic field winding 24c 1 24c2 to be connected at the two respective ends of the magnetic field winding 6, and a ground connection terminal 24d for connecting to the wire negative electrode side wiring 26c.

The smoothing capacitor 29 absorbs a ripple current caused during the operation of the inverter circuit switching device 39. The smoothing capacitor 29 is connected between the positive electrode terminal (the source connection terminal of energy 56) of the DC energy source 50 and the negative electrode terminal (ground) of the DC energy source 50. In the present embodiment, four smoothing capacitors 29 are provided. the smoothing capacitor 29, an electrolytic capacitor, a conductive polymer capacitor, a hybrid aluminum electrolytic capacitor with a conductive polymer or the like is used.

Control device 20 The control device 20 controls the rotary electric machine 1 by activating / deactivating the switching devices in the inverter circuits 39 and the switching devices in the drive circuit d magnetic field winding 24. The control device 20 is provided with at least two processing circuits. For example, the control device 20 comprises, as processing circuits, a computer processing unit such as a CPU (central unit), a storage device which exchanges data with the computer processing unit, a circuit d input which inputs external signals into the computer processing unit, an output circuit which outputs signals from the computer processing unit to the outside, a switching circuit in which the computer processing unit performs communication data with external devices, and the like. The input circuit is provided with an analog-to-digital converter, which converts input output signals from various types of sensors, and the like. The output circuit is provided with a gate driver, which outputs a drive signal to the gate terminal of each of the switching devices, and the like.

Each of the processing circuits of the control device 20 is mounted on a control card 25. An external connection connector for connecting the communication circuit to the external devices is mounted on the control card 25. As the basic material of the control card 25, there is used a glass-epoxy resin having excellent electrical and mechanical characteristics.

Sealing resin for the electrical supply device 3 and the control device 20 As regards a rotary electrical machine device to be mounted in a vehicle, for example, in the engine compartment, resistance to humidity and vibration is required. The respective circuits, with the exception of the smoothing capacitor 29 of the electrical power supply apparatus 3, are contained, in a sealed manner, in a container 55 using a coating resin 27. In the present embodiment, the control device 20 is also contained, in a leaktight manner, in the same container 55 using the coating resin 27. Since it is prevented any penetration of water into the power supply device 3 and the device control 20, the reliability of the power supply apparatus 3 and the control apparatus 20 with respect to humidity is increased. In addition, since the respective circuit environments are fixed with resin, the service life of the vibration resistance is also increased. The coating resin 27 has a property of facilitating thermal curing. The coating resin 27 is, for example, an epoxy resin or the like. The curing of the coating resin 27 is facilitated by heating, although the curing can be carried out at normal temperature.

Figure 4 is a view of a single waterproof module in which the power supply device 3 and the control device 20 are contained, in a sealed manner, in the container 55 using a coating resin 27, seen from the opening of the container 55. FIG. 5 is a cross-sectional view of a main part of the sealed module taken at the cross-sectional position AA in each of FIGS. 3 and 4. FIG. 3 is a view of the waterproof module excluding the coating resin 27 and the control device 20, seen from the opening of the container 55, to explain the arrangement of the respective circuits of the power supply device 3 in the container 55. FIG. 6 is a view of a heat sink 21 near a housing space 40, seen from the bottom of the container 55. At the opening side of the respective circuits in the appliance power supply 3, the bus control unit 25 of the control unit 20 is provided (cf. Figure 5); the control card 25 is connected to the connection terminals, control systems for the electrical module 23 and the magnetic field module 24, which extend towards the opening side. The opening side of the container 55 coincides with the rear side in the axial direction.

The container 55 has the shape of a bottom tube. In the present embodiment, an opening for arranging the axis of rotation 4, the brush 17 and similar elements is provided in the center of the container 55. The container 55 has the shape of a double-bottomed tube having a side wall of outside diameter 51, a side wall of inside diameter 52, and a lower ring-shaped wall 53 to cover the space between the side wall of outside diameter 51 and the side wall of inside diameter 52. The side wall of diameter outside 51, the side wall of the inside diameter 52, and a part of the bottom wall 53 of the container 55 constitute a resin casing 30. A part of the side wall with an outside diameter 51 and a part of the side wall with an inside diameter 52 are connection terminals to be connected to the connection terminals of the electrical system for the electrical module 23 and the magnetic field module 24.

The bottom wall 53 of the container 55 consists of the casing 30, the heat sink 21 and a smoothing capacitor card 44, as will be described below. Specifically, at least two openings for bringing the electrical module 23 and the magnetic field module 24 to abut on the heat sink 21 and for placing the smoothing capacitor card 44 are formed in the bottom wall of the casing 30. Aux portions of openings, the bottom wall 53 of the container 55 consists of the heat sink 21 or the smoothing capacitor card 44.

The surface of the heat sink 21 at the opening side of the container 55 has the shape of a plane and constitutes the bottom surface of the container 55. The heat sink 21 has the shape of a ring in accordance with the shape of the bottom wall 53 of the container 55. As is partially illustrated in FIG. 5, the casing 30 is linked to the surface at the opening side of the container 55 of the heat sink 21 by the use of an adhesive 46 having a thermal curing facilitation property. The heat sink 21 is made of a metal, such as an aluminum alloy, with high thermal conductivity. At least two flat-plate-shaped heat radiating fins 22 and at least two support posts 79 are provided on the lower side which is the side opposite the opening side of the container 55 of the heat sink 21.

As described above, part of the bottom wall 53 of the container 55 consists of the smoothing capacitor card 44. In the present embodiment, a recess portion which is recessed towards the the bottom side of the container 55 is formed in the surface at the opening side of the container 55 of the heat sink 21; the opening of the recess portion is covered by the smoothing capacitor card 44. The opening side of the recess portion coincides with the opening side of the container 55; the bottom side of the recess portion coincides with the bottom side of the container 55.

The casing 30 is fixed to the heat sink 21 and the smoothing capacitor card 44 is mounted on the recess portion of the heat sink 21, so as to form the container 55. After the arrangement of the power supply unit 3 and the control unit 20 in the container 55, the coating resin 27, which is not hardened, is filled in the container 55.

Housing space for smoothing capacitor

During its use, the smoothing capacitor 29 can generate a gas (for example hydrogen gas) from the electrolytic material inside it. If, unlike the present embodiment, the environment of the smoothing capacitor 29 is directly covered by the coating resin 27 in a sealed manner, the gas generated cannot be evacuated outside the smoothing capacitor 29; therefore, the internal pressure of the smoothing capacitor 29 increases and the smoothing capacitor 29 can therefore break. It is therefore desirable that the power supply device 3 has a structure by which the generated gas can be evacuated outside the smoothing capacitor 29, while preventing any penetration of water into the smoothing capacitor 29.

Therefore, in this embodiment, as illustrated in the cross-sectional view of Figure 5, the power supply apparatus 3 is provided with a housing space forming member 41 to form the sealed housing space 40 which contains the smoothing capacitor 29. In the housing space forming member 41, a through hole 32 is formed which places the housing space 40 in communication with the outside. A sealing member 43 for sealing the through hole 32 is mounted in the through hole 32. A space is provided between the smoothing capacitor 29 and the housing space-forming member 41.

This configuration allows to evacuate the gas generated in the smoothing capacitor 29 in use, from inside the smoothing capacitor 29 in the housing space 40. Since the housing space 40 is sealed , the exhaust gas increases the internal pressure; however, since the volume of the housing space 40 is greater than the interior volume of the smoothing capacitor 29, this can prevent the pressure from increasing. Therefore, suppressing the increase in pressure can prevent the smoothing capacitor 29 from breaking. In addition, since the housing space 40 is sealed, this can prevent any penetration of water into the housing space 40 and the smoothing capacitor 29.

In some cases, to facilitate the curing of the coating resin 27, adhesives 31 and 46, and the like, heat is applied to the device at a manufacturing step. When, at this point, the housing space 40 is sealed, the heat increases the internal pressure in the housing space 40. It may happen that the increased internal pressure pushes the uncured resin and adhesive outward. , so much so that a ventilation hole is formed which places the housing space 40 in communication with the outside. In the previous configuration, the through hole 32 is formed in the housing space-forming member 41; thus, when heat is applied in the manufacturing step, the internal pressure of the housing space 40 can be vented through the through hole 32, which prevents the formation of a ventilation hole in the resin and uncured adhesive. At the end of heating, the through hole 32 is sealed with the sealing member 43, so as to prevent any penetration of water into the housing space 40 and into the smoothing capacitor 29 through the through hole 32 , while the power supply unit 3 is in use.

In this embodiment, the housing space forming member 41 comprises a recess portion forming member 45, inside which there is formed a recess portion in which the capacitors smoothing 29 are arranged, and the smoothing capacitor card 44 which covers the opening of the recess portion and to which the smoothing capacitors 29 arranged at the recess side are connected. The through hole 32 is formed in the recess portion forming member 45. The recess portion whose opening is covered becomes the housing space 40.

This configuration allows that, when the smoothing capacitor card 44 is simply arranged so that its side on which the smoothing capacitors 29 are arranged is arranged so as to face the side of the recess portion and for cover the opening of the recess portion, the housing space 40 can be quickly formed, and the smoothing capacitors 29 can be quickly arranged in the housing space 40.

The recess portion forming member 45 and the smoothing capacitor card 44 are linked to each other by the use of the adhesive 31 having a property of thermal curing facilitation. Each of the adhesives 31 is 46, for example, an epoxy resin or a silicone rubber. The curing of the adhesives 46 and 31 is facilitated by heating, although curing at normal temperature is possible. The area of the smoothing capacitor card 44 is greater than the area of opening of the recess portion; the ring-shaped end face at the opening side of the recess portion forming member 45 and the surface at the bottom side of the smoothing capacitor card 44 are face to face; the adhesive 31 is provided over the entire front portion.

This configuration allows the spacing between the recess portion forming member 45 and the smoothing capacitor card 44 to be covered by the adhesive 31 so as to increase the tightness of the housing space 40. In addition, when, in the manufacturing step, the adhesive 31 having a thermal curing facilitation property is heated, the curing time is reduced and a rapid passage to the next step can therefore be carried out, this which increases productivity. When the heating is carried out, the internal pressure of the housing space 40 can be discharged through the through hole 32; it is therefore possible to prevent the formation of a ventilation hole in the uncured adhesive 31. Then, at the end of the heating, the through hole 32 is sealed with the sealing member 43, which ensures the water tightness property.

In the case where the adhesive 31 for bonding the recess portion forming member 45 (the heat sink 21) to the smoothing capacitor card 44 is an adhesive identical to the adhesive 46 for bond the casing 30 to the heat sink 21, it is possible to coat the surface of the heat sink 21 with the two adhesives 31 and 46 in a single step, to heat the two adhesives 31 and 46 during in a single step, then harden the two adhesives 31 and 46.

The surface on the housing space side 40 (the lower side) of the smoothing capacitor card 44 forms a wall face of the housing space 40, in which the wall face covers the opening of the recess portion; the smoothing capacitors 29 are arranged on the housing space side 40 of the smoothing capacitor card 44. The surface on the side opposite to the housing space side 40 (on the opening side) of the capacitor card smoothing 44 is covered with the coating resin 27.

This configuration allows the coating resin 27 to further increase the airtightness of the connection portion between the recess portion forming member 45 and the smoothing capacitor card 44. When the coating resin 27 having a thermal curing facilitation property is heated, the internal pressure of the housing space 40 can be vented through the through hole 32; therefore, the formation of a ventilation hole can be prevented.

As described above, the container 55 contains, in an airtight manner, the inverter circuit 39 (in this example, the magnetic field winding drive circuit 24 and the apparatus 20 are also included) using coating resin 27; the smoothing capacitor card 44 is part of the container 55. This configuration makes it possible to efficiently use the coating resin 27 to contain, in an airtight manner, the respective circuits so as to increase the airtightness air in the accommodation space 40.

As described above, the recess portion forming member 45 and the heat sink 21 are integrally formed from one another. In this configuration, it is not necessary to provide a member dedicated to the formation of the recess portion and it suffices to provide a recess portion in the heat sink 21, which makes it possible to prevent any increase in cost. The heat generated by the smoothing capacitor 29 can be radiated by being transferred to the heat sink 21 via the smoothing capacitor card 44; the heat sink 21 surrounding the smoothing capacitor 29 allows efficient radiation of heat.

The smoothing capacitor card 44 includes an electric wire of positive electrode 47 for connecting the positive electrode side terminal of the smoothing capacitor 29 to the positive electrode terminal, an electric wire of negative electrode 48 to connect the negative electrode side terminal of the smoothing capacitor 29 to the negative electrode terminal, and a card member 49 to support the positive electrode electric wire 47 and the negative electrode electric wire 48. Each electric wires from positive electrode 47 and electric wire from negative electrode 48 is a flat copper member. The card member 49 is made of resin and covers, in an airtight manner, the electric wire of positive electrode 47 and the electric wire of negative electrode 48. The electric wire of negative electrode 48 is connected to the heat sink 21 to be grounded using a screw 81. The positive electrode electrical wire 47 is connected to the positive electrode side wiring wire 26a (not shown). The portion of the heat sink 21, to which the screw 81 is screwed, is an upright of columnar cylindrical support 79 whose force is increased.

The smoothing capacitor 29 is a capacitor of the insert mounting type which comprises two conducting wires 29a and 29b. The smoothing capacitor 29 is connected to the smoothing capacitor board 44 so as to be arranged at the housing space side 40 of the smoothing capacitor board 44 and in such a way that the two conducting wires 29a and 29b are inserted respectively in two insertion holes 91 and 92 which penetrate the smoothing capacitor board 44. The two insertion holes 91 and 92 are sealed by welding 33 so that the two conducting wires 29a and 29b are respectively inserted in them. The two insertion holes 91 and 92 are formed respectively in the positive electrode electrical wire 47 and in the negative electrode electrical wire 48. In the present embodiment, four smoothing capacitors 29 are provided; thus, a total of four groups of conductive wires 29a and 29b and four groups of insertion holes 91 and 92 are provided.

In this configuration, even when the insertion-mount type capacitor is used, the two insertion holes 91 and 92, in which the two conducting wires 29a and 29b are respectively inserted, are sealed by the solder 33, which increases the airtightness of the housing space 40. In the case where an insert mount type capacitor is used, the mounting area on the card can be reduced compared to the case where a surface mount type capacitor having a base larger than the outside diameter of the actual capacitor is used; therefore, at least two smoothing capacitors 29 can be arranged more densely, which makes it possible to reduce the size of the apparatus. Since the two insertion holes 91 and 92 sealed by the weld 33 are covered by the coating resin 27, the airtightness can be ensured more effectively.

In this embodiment, the sealing member 43 is made of an elastic material such as rubber. In this configuration, the sealing member 43 is formed to adhere to the through hole 32, so as to increase the airtightness.

In an enlarged partial view of Figure 5 illustrated in Figure 7, the through hole 32 has the shape of a staggered cylindrical column whose radius changes every two steps. The outer rung is a portion of large radius hole 32a; the rung on the side of the housing space 40 is a portion of hole of small radius 32b whose radius is less than that of the portion of hole of large radius 32a.

The sealing member 43 has the form of a staggered cylindrical column whose radius changes every three steps as a function of the shape of the through hole 32. The sealing member 43 comprises a column portion of large radius 43a corresponding to the large radius hole portion 32a of the through hole 32, a small radius column portion 43b corresponding to the small radius hole portion 32b of the through hole 32 and whose radius is less than that of the column portion with a large radius 43a, and a column section with a large front end radius 43c which is disposed on the housing space side 40 of the column portion with small radius 43b and whose radius is greater than that of the portion of small radius column 43b. The large radius column portion 43a and the front end large radius column portion 43c pinch the small radius column portion 32b on both sides thereof, so that the sealing member 43 can be more effectively attached to the through hole 32. The radius of the front end to the housing space side 40 of the column portion of the large front end radius 43c gradually decreases; thus, the sealing member 43 is quickly inserted into the through hole 32 from outside the housing space 40.

Method for manufacturing an electrical power supply device [0091] The method for manufacturing the electrical power supply device 3 will be explained below with reference to FIG. 8.

First, a step of preparing SOI organs to prepare respective organs of the power supply device 3 is implemented. Specifically, the inverter circuit 39, the smoothing capacitor 29, the uncured coating resin 27 having a thermal curing facilitation property, the housing space-forming member 41, and the sealing member 43 are prepared. In addition, the smoothing capacitor board 44, on which are mounted the uncured adhesives 31 46 having a thermal curing facilitation property, the heat sink 21, the housing 30, the controller 20, and the capacitor smoothing 29, and the like are prepared.

After the step of preparing SOI organs, a capacitor capacity step S02 is used in which the smoothing capacitor 29 is contained in the housing space 40 formed by the forming member d housing space 41 in which the sealing member 43 has not been mounted in the through hole 32. In the present embodiment, at the capacitor capacity step S02, the spacings other than the through hole 32 of the housing space former 41 are sealed with the uncured adhesive 31, and the adhesive 31 is heated to be cured. The housing space forming member 41 includes the recess portion forming member 45 and the smoothing capacitor board 44; the spacing between the recess portion forming member 45 and the smoothing capacitor board 44 is coated with the uncured adhesive 31. When the heating is carried out, the housing space forming member 41 is also heated, which causes the gas to expand in the housing space 40. However, the expanded gas can be discharged to the outside the housing space 40 through the through hole 32, which prevents the formation of a ventilation hole in the uncured adhesive 31. In the capacitor capacity step S02, the heat sink 21, the casing 30 and the smoothing capacitor card 44 are linked to each other so as to assemble the container 55.

After the capacitor capacity step S02, a step of filling the resin S03 is implemented, in which the uncured coating resin 27 is filled in the container 55 in which the inverter circuit 39 has been arranged. . In the present embodiment, the control device 20 is also placed in the container 55, then the uncured coating resin 27 is filled in the container 55. Thanks to the resin filling step S03, the surface on the side opposite the housing space side 40 of the smoothing capacitor board 44 is covered with the uncured coating resin 27.

After the resin filling step S03, a heating step S04 to heat and harden the coating resin 27 is implemented. Thanks to the heating step S04, the hardening time of the coating resin 27 is reduced, which makes it possible to quickly go to the next step and thus to increase the productivity. When the heating is carried out, the housing space forming member 41 is also heated, which causes the gas to expand in the housing space 40. However, the expanded gas can be discharged to the outside the housing space 40 through the through hole 32, which prevents the formation of ventilation holes in the uncured resin and adhesive.

After the heating step S04, a step of sealing the through hole S05 is implemented, in which the sealing member 43 is mounted in the through hole 32, then the housing space 40 is sealed. During the use of the power supply apparatus 3, it is possible to prevent any penetration of water into the housing space 40 and the smoothing capacitor 29 through the through hole 32. [0097] Mode of embodiment 2 The power supply device 3 according to embodiment 2 will be explained below. The constituent parts identical to that of embodiment 1, described above, are not described again. Figure 9 is a cross-sectional view of a main part of the power supply apparatus 3 according to the present embodiment, taken at the cross-sectional position AA, in each of Figures 3 and 4, as in the case of figure 5.

In the present embodiment, the sealing member 43 consists of an adhesive 43. In the present embodiment, the adhesive 43 is coated so as to cover the external opening of the through hole 32 In this configuration, it is not necessary to prepare a dedicated molded component. The through hole 32 can be sealed by simply coating the through hole with adhesive 32 and curing the adhesive 43.

Embodiment 3 [0101] The power supply apparatus 3 according to an embodiment 3 will be explained below. The constituent parts identical to those of embodiment 1 described above are not described again. Each of Figures 10, 11 and 12 is a cross-sectional view of a main part of the power supply apparatus 3 according to the present embodiment, taken at the cross-sectional position AA in each of Figures 3 and 4 , as in the case of figure 5.

In the present embodiment, an interior space 95 which communicates with the housing space 40 is formed in the sealing member 43; the interior space 95 undergoes an expansion or a contraction as a function of a change in the pressure in the housing space 40. In the present embodiment, the sealing member 43 is provided with a tubular main body cylindrical 97 to be fitted into the inner circumferential surface of the through hole 32 and of a bag-shaped portion 98 which extends from the main body 97 outwards and forms the interior space 95. A ventilation hole is provided in the center of the main body 97; the outside of the ventilation hole communicates with the opening of the bag-shaped portion 98 and is covered by the bag-shaped portion 98. The bag-shaped portion 98 is provided outside the space of housing 40. The sealing member 43 is made of a material such as rubber.

In this configuration, an expansion or contraction of the interior space 95 can prevent any change in the pressure in the housing space 40. For example, in the case in which, when its temperature is high, the power supply device 3 is sprayed with cold water and, consequently, the pressure in the housing space 40 decreases, the bag-shaped portion 98 contracts and is deformed, as illustrated in FIG. 11, which prevents any reduction in the pressure in the housing space 40. It is thus possible to prevent any aspiration of water, due to the negative pressure, through the adjustment portion between the sealing member 43 and the through hole 32, and any penetration of water into the housing space 40. In contrast, in the case where the pressure in the housing space 40 increases due to the gas generated by the smoothing capacitor 29 , the door Bag-shaped ion 98 expands and is deformed, as illustrated in Figure 12, which prevents any increase in pressure in the housing space 40. It is therefore possible to prevent that, due to the increase in pressure in the housing space 40, the sealing member 43 is not blown and does not fall out of the through hole 32.

Embodiment 4 [0105] The power supply device 3 according to Embodiment 4 will be explained below. The constituent parts identical to those of embodiment 1, described above, are not explained again. Figure 13 is a cross-sectional view of a main part of the power supply apparatus 3 according to the present embodiment, taken at the cross-sectional position AA in each of Figures 3 and 4, as in the case of Figure 5. Figure 14 is a view of the heat sink 21 near the housing space 40, seen from the bottom of the container 55. Figure 15 is a side view of a screw as the 'sealing member 43 according to the present embodiment.

In this embodiment, a screw thread is formed in the through hole 32, and the sealing member 43 is a screw screwed onto the screw thread. This configuration allows the sealing member 43 to be securely mounted in the through hole 32 and to prevent the sealing member 43 from falling out of the through hole 32 due to a change in pressure in the housing space 40. The screw comprises a screw portion and a head portion, as illustrated for example in FIG. 15. The screw is screwed into the through hole 32 from the outside of the housing space 40.

The portion between the screw as the sealing member 43 and the screw thread of the through hole 32 is coated with a sealing resin 100. For example, as illustrated in FIG. 15, after the screw portion is coated with the uncured sealing resin 100, the screw is screwed into the through hole 32. Alternatively, after the screw thread of the through hole 32 is coated with the sealing resin 100 not hardened, the screw is screwed into the through hole 32. In this configuration, the sealing resin 100 can increase the airtightness.

As illustrated in FIG. 16, the opening at the side of the housing space 40 of the through hole can be covered with a sheet member 99. This configuration allows the sheet member 99 to block the chips produced when the screw is screwed into the through hole 32 and to prevent their penetration into the housing space 40. This makes it possible to prevent chips of an aluminum alloy having a conductivity or the like from running -circuit the connection of the smoothing capacitor 29.

Before the opening of the recess portion forming member 45 (the heat sink 21) is covered by the smoothing capacitor card 44, the sheet member 99 is caused to adhere to opening the side of the housing space 40 of the through hole Γ using a sticky adhesive. The sheet member 99 has a tiny gap and therefore is not airtight, allowing gas which has expanded or contracted during a heating step to pass through the gap .

Embodiment 5 [0111] The power supply apparatus 3 according to Embodiment 5 will be explained below. The constituent parts identical to those of embodiment 1, described above, are not explained again. Figure 17 is a cross-sectional view of a main part of the power supply apparatus 3 according to the present embodiment, taken at the cross-sectional position AA in each of Figures 3 and 4, as in the case of Figure 5. Figure 18 is an enlarged view of the main parts of an insertion hole 75a of a planar member 75, seen from the bottom side.

As in embodiment 4, a screw thread is formed in the through hole 32, and the sealing member 43 is a screw screwed onto the screw thread. In the present embodiment, the screw, as the sealing member 43, passes through the insertion hole 75a provided in the planar member 75, then is screwed onto the screw thread. This configuration allows the fixing of the planar member 75 and the sealing of the through hole 32 to be carried out simultaneously, thereby reducing the number of components. The planar organ 75 is a planar organ made of a metal. The planar member 75 has the shape of a ring conforming to the shape of the heat sink 21. The planar member 75 abuts against the heat radiation fins 22 of the heat sink 21, the support upright 79, and the surface on the lower side of the recess portion forming member 45. The planar member 75 makes it possible to increase the area of radiation, which makes it possible to increase the performance of heat radiation of the heat sink 21 .

As illustrated in FIG. 18, the insertion hole 75a of the planar member 75 comprises a notched portion 75b having an increased diameter, at a single position in the circumferential direction or at each of a plurality of positions in the circumferential direction (in this example, four positions). In Figure 18, the screw, as the seal 43, is indicated by a dotted line. In the case in which the portion between the screw, as the sealing member 43, and the through hole 32 is coated with the sealing resin 100 and the screw coated with the sealing resin 100 is screwed onto the screw thread of the through hole 32 from the bottom side, an excess of sealing resin 100 comes out of the through hole 32 towards the bottom side. The excess sealing resin 100 is accumulated in the notched portion 75b of the insertion hole 75a and the head portion of the screw covers the underside of the insertion hole 75a, so that the excess resin d the seal 100 is maintained in the insertion hole 75a thereby preventing its dispersion outside.

[0114] Other Embodiments [0115] Other embodiments of the present invention will be explained below. Each of the configurations of the embodiments which will be explained below is not limited to a separate use, but it can be used in combination with the configurations of other embodiments provided that it does not generate incongruity.

(1) In each of the previous embodiments, it has been explained, as an example, a case in which the rotary electric machine 1, the electric power supply device 3 and the control device 20 are fully configured. However, embodiments of the present disclosure are not limited to the preceding case. In other words, the rotary electric machine 1, the electric power supply unit 3 and the control unit 20 can be arbitrarily combined so as to constitute distinct configurations. For example, it is possible that the power supply unit 3 and the control unit 20 are configured entirely and that the rotary electrical machine 1 is configured separately. It is also possible that each of the rotary electric machine 1, the power supply unit 3 and the control unit 20 is configured separately.

(2) In each of the previous embodiments, it has been explained, as an example, a case in which the control device 20 and the respective circuits except for the smoothing capacitor 29 of the power supply device 3 is contained, in an airtight manner, in a container 55 by the use of a coating resin 27. However, embodiments of the present disclosure are not limited in the previous case. Indeed, it is possible that the control device 20 is not contained in a sealed manner in the container 55 by using coating resin 27. It is possible that the control device 20 is separated from the device power supply 3.

(3) In each of the previous embodiments, it has been explained, as an example, a case in which the housing space forming member 41 comprises the portion forming member d recess 45 and the smoothing capacitor card 44, and the through hole 32 is formed in the recess portion forming member 45. However, it is possible that the housing space forming member 41 is a member having an arbitrary shape and being made of an arbitrary material, provided that the housing space-forming member 41 is a member forming the airtight housing space 40 to contain the smoothing capacitor 29. For example, it is possible that the recess portion forming member 45 is a tube casing member with a bottom made of resin or it is possible that the smoothing capacitor card 44 is replaced by a planar member consisting of r sine.

(4) In each of the preceding embodiments, it has been explained, as an example, a case in which the electric rotary machine 1 is a synchronous rotary electric machine with field winding and the apparatus d power supply 3 is provided with the magnetic field winding drive circuit 24. Nevertheless, it is possible that the rotary electric machine 1 is a synchronous rotary electric machine with permanent magnet in which a permanent magnet is provided in the rotor and that the power supply device 3 is not provided with the magnetic field winding drive circuit 24.

(5) In each of the previous embodiments, it has been explained, as an example, a case in which part of the housing space-forming member 41 is covered with the resin d coating 27. However, it is possible that the housing space-forming member 41 is not covered with the coating resin 27.

(6) In each of the previous embodiments, it has been explained, as an example, a case in which at least two sealing members 43 are provided. However, it is possible that the sealing member 43 is a member having an arbitrary shape and is made of an arbitrary material, provided that the sealing member 43 is a member mounted in the through hole 32 and seals the through hole 32.

(7) In each of the previous embodiments, it has been explained, as an example, a case in which four smoothing capacitors 29 are provided. However, it is possible that an arbitrary number of smoothing capacitors 29 is provided.

Within the scope of this disclosure, the embodiments thereof may be freely combined with each other and may be modified or omitted as appropriate.

Claims (1)

[Claim 1] [Claim 2] [Claim 3] [Claim 4] claims Rotary electric machine power supply apparatus (3) comprising: an inverter circuit (39) converting between DC electrical energy to be supplied to an energy source connection terminal (56) and AC electrical energy to be supplied to a rotary electrical machine (1); a smoothing capacitor (29) connected to an electric wire which connects the power source connection terminal (56) to the inverter circuit (39); a container (55); a coating resin (27) which seals the inverter circuit (39) in the container (55); and a housing space forming member (41) for forming an airtight housing space (40) which contains the smoothing capacitor (29), wherein, in the space forming member housing (41), there is formed a through hole (32) putting the housing space (40) in communication with the outside, and in which a sealing member (43) for sealing the through hole (32) is mounted in the through hole (32). A rotary electric machine power supply apparatus (3) according to claim 1, wherein the housing space-forming member (41) comprises a recess portion forming member (45) therein from which a recess portion is formed in which the smoothing capacitor (29) is disposed, and a card (44) which covers the opening of the recess portion and to which the smoothing capacitor (29) is connected disposed at the recess portion side thereof, and wherein the through hole (32) is formed in the recess portion forming member (45). A rotary electric machine power supply apparatus (3) according to claim 2, wherein the recess portion forming member (45) and the board (44) are connected to each other by the use of an adhesive (31) having a property of facilitating thermal hardening. Rotary electrical machine power supply apparatus (3) [Claim 5] [Claim 6] [Claim 7] [Claim 8] [Claim 9] [Claim 10] according to any of claims 2 and 3, wherein a surface at the side of the housing space (40) of the card (44) forms a wall face of the housing space (40), in which the wall face covers the opening of the recess portion; the smoothing capacitor (29) is arranged on the side of the housing space (40) of the card (44), and in which a surface on the side opposite to the side of the housing space (40) of the card ( 44) is covered with a coating resin (27). A rotary electrical machine power supply apparatus (3) according to claim 4, wherein the card (44) is part of the container (55). A rotary electric machine power supply apparatus (3) according to any of claims 2 to 5, further comprising a heat sink, wherein the recess portion forming member (45) and the heat sink heat are formed integrally with each other. A power supply apparatus for a rotary electric machine (3) according to any one of claims 2 to 6, wherein the smoothing capacitor (29) is an insertion-mount type capacitor having two conductive wires; the smoothing capacitor (29) is connected to the card (44) so as to be arranged at the side of the housing space (40) of the card (44) and so that the two conductive wires are inserted in two holes respective insertion holes entering the card (44), and wherein the two respective insertion holes are sealed by soldering so that the two conductive wires are inserted therein. A power supply apparatus for a rotary electric machine (3) according to any of claims 1 to 7, wherein the coating resin (27) has a thermal curing facilitating property. Rotary electric machine power supply apparatus (3) according to any one of claims 1 to 8, wherein the sealing member (43) is an elastic member. A rotary electrical machine power supply apparatus (3) according to claim 9, wherein an interior space which communicates with the housing space (40) is formed in the sealing member (43); the interior space expands or contracts according to a change in pressure in the space of [Claim 11] [Claim 12] [Claim 13] [Claim 14] [Claim 15] [Claim 16] [Claim 17] housing (40). A rotary electrical machine power supply apparatus (3) according to claim 1, wherein the sealing member (43) is an adhesive. Rotary electric machine power supply apparatus (3) according to claim 1, wherein a screw thread is formed in the through hole (32), and the sealing member (43) is a screw screwed on the thread quote. A rotary electrical machine power supply apparatus (3) according to claim 12, wherein the portion between the screw and the screw thread is coated with a sealing resin. Rotary electrical machine power supply apparatus (3) according to any one of claims 12 and 13, wherein the screw passes through an insertion hole provided in a planar member and is then screwed onto the screw thread. Rotary electric machine power supply apparatus (3) according to claim 14, wherein the insertion hole provided in the planar member has a notched portion having an increased diameter, at a single position in the circumferential direction or at each of a plurality of positions in the circumferential direction. Rotary electric machine power supply apparatus (3) according to any one of claims 12 to 15, wherein the opening at the side of the housing space (40) of the through hole (32) is covered with a leaf organ. Method of manufacturing the power supply apparatus for a rotary electric machine (3), comprising: an organ preparation step during which an inverter circuit (39) is prepared carrying out a conversion between the DC electrical energy to be supplied to an energy source connection terminal (56) and an AC electrical energy to supplying a rotary electric machine (1), a smoothing capacitor (29) connected to an electric wire which connects the power source connection terminal (56) to the inverter circuit (39), a coating resin (27 ) uncured having a thermal curing facilitation property, a housing space forming member (41) forming a housing space (40) to contain the smoothing capacitor (29) and in [Claim 18] which is formed a through hole (32) which places the housing space (40) in communication with the outside, and a sealing member (43) for sealing the through hole (32); a capacitor capacity step in which, after the organ preparation step, the smoothing capacitor (29) is contained in the accommodation space (40) formed by the accommodation space forming member ( 41) in which the sealing member (43) has not been mounted in the through hole (32); a resin filling step in which, after the capacitor capacity step, an uncured coating resin (27) is filled in a container (55) in which the inverter circuit (39) has been arranged; a heating step in which, after the resin filling step, the coating resin (27) is heated so as to be cured; and a through hole sealing step in which, after the heating step, the sealing member (43) is mounted in the through hole (32) so as to seal the housing space (40). The manufacturing method for the power supply apparatus of a rotary electric machine (3) according to claim 17, wherein, in the organ preparation step, an uncured adhesive having a thermal curing facilitation property is in further prepared, and wherein, in the capacitor capacity step, gaps other than the through hole (32) of the housing space former (41) are sealed with the uncured adhesive, and the adhesive is heated so as to be cured.