JP2016007108A - Controller integrated rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve a cooling performance of a smoothing capacitor while attaining downsizing of a controller.SOLUTION: A substrate of a control module 25 is disposed oppositely to surfaces of a power module 21 and a field module 22 at a side opposite to a heat sink 23 for cooling. On the substrate of the control module 25, a plurality of snubber circuits 37 are provided for preventing surge from being generated when switching elements 32a and 32b are to be switched. The snubber circuits 37 are formed in portions opposite to the power modules 21 in the substrate of the control module 25. A controller 2 includes a smoothing capacitor for preventing a voltage of a DC power source from being varied by operating a rotary electric machine. The smoothing capacitor is brought into contact with the heat sink 23 for cooling.

Description

  The present invention relates to a control unit-integrated rotating electrical machine in which a control unit is mounted on a drive unit.

  In a conventional power conversion device, a snubber capacitor substrate that suppresses a surge of the switching element is attached to the upper surface of the module on which the switching element is mounted. The smoothing capacitor that suppresses fluctuations in the output voltage is fixed on the cooling member, and is connected to the module main body via a bus bar and a wiring board. A ceramic capacitor is used as the smoothing capacitor (see, for example, Patent Document 1).

JP 2000-333476 A

  In the conventional power converter as described above, since the control board and the snubber capacitor board are separately provided, the number of parts increases, the control unit becomes larger, and the manufacturing cost increases. Also, an example using a capacitor substrate dedicated to a smoothing capacitor is shown, but in this case also, the number of parts increases, the control unit becomes larger, and the manufacturing cost increases. Further, even when a ceramic capacitor having excellent temperature characteristics is used, cooling is necessary when a large voltage fluctuation is applied to the smoothing capacitor, and the control unit described in Patent Document 1 is integrated with a rotating electrical machine used at a high temperature. It is difficult to do.

  The present invention has been made to solve the above-described problems, and provides a control unit-integrated dynamoelectric machine capable of improving the cooling performance of a smoothing capacitor while reducing the size of the control unit. Objective.

  A control unit-integrated dynamoelectric machine according to the present invention includes a drive unit having a rotor, a stator including a multi-phase stator winding, and a switching element that controls a current flowing in the stator winding. Including a plurality of power modules, a cooling heat sink for cooling the power modules, and a control module for controlling the power modules, and including a control unit fixed to the drive unit. And a plurality of snubber circuits for suppressing switching surges of the switching elements, and a smoothing capacitor for suppressing voltage fluctuations of the DC power supply, the snubber circuit being a portion facing the power module of the substrate of the control module The smoothing capacitor is in contact with the cooling heat sink.

  In the controller-integrated rotating electrical machine according to the present invention, the snubber circuit is formed in a portion of the control module substrate facing the power module, and the smoothing capacitor is in contact with the cooling heat sink. As a result, the cooling performance of the smoothing capacitor can be improved.

1 is a cross-sectional view of a control unit-integrated dynamoelectric machine according to Embodiment 1 of the present invention. FIG. 2 is an electric circuit diagram of the controller-integrated dynamoelectric machine of FIG. 1. It is a rear view which shows the control part integrated rotary electric machine of the state which removed the control part protection cover and control module of FIG. It is a rear view which shows the control part integrated rotary electric machine by Embodiment 2 of this invention.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.
Embodiment 1 FIG.
FIG. 1 is a cross-sectional view of a controller-integrated rotating electrical machine according to Embodiment 1 of the present invention. In this example, a rotating electrical machine for a vehicle mounted on an automobile is shown. FIG. 2 is an electric circuit diagram of the control unit-integrated dynamoelectric machine of FIG. In the figure, the rotating electrical machine is roughly divided into a driving unit 1 as a rotating electrical machine body and a control unit 2 as a power converter (inverter assembly). The control unit 2 is fixed to the axial end of the drive unit 1.

  The drive unit 1 mainly includes a rotor 3, a stator 4, a front housing 5, a rear housing 6, a first bearing (front bearing) 7, a second bearing (rear bearing) 8, and a pulley 9. Yes. The rotor 3 and the stator 4 are accommodated inside the front housing 5 and the rear housing 6. The first bearing 7 is held by the front housing 5. The second bearing 8 is held by the rear housing 6. The size of the second bearing 8 is smaller than the size of the first bearing 7.

  The rotor 3 includes a rotary shaft 10 rotatably supported by first and second bearings 7 and 8, a field core 11 fixed to the rotary shaft 10, and a field winding wound around the field core 11. It has a line 12. A first axial end portion (right end portion in FIG. 1) of the rotating shaft 10 protrudes outside the front housing 5.

  The pulley 9 is fixed to the first axial end of the rotating shaft 10 (hereinafter, the pulley 9 side is referred to as a front side, and the opposite side to the pulley 9 is referred to as a rear side). The pulley 9 is connected to an internal combustion engine (not shown) via a belt (not shown), and transmits and receives torque to and from the internal combustion engine.

  A second axial end portion (left end portion in FIG. 1) of the rotor 3 protrudes rearward from the rear housing 6. A slip ring 13 for supplying a field current to the field winding 12 is provided at the second axial end of the rotor 3.

  A brush holder 14 is disposed on the opposite side of the rear housing 6 from the field core 11. The brush holder 14 holds a plurality of brushes 15. The tip of the brush 15 is in contact with the outer peripheral surface of the slip ring 13.

  A first centrifugal fan 16 is fixed to the front end face of the field iron core 11. A second centrifugal fan 17 is fixed to the rear end face of the field core 11. The first and second centrifugal fans 16 and 17 generate cooling air by the rotation of the rotor 3.

  The stator 4 has a stator core 18 and a plurality of phases of stator windings (armature windings) 19 wound around the stator core 18. The stator core 18 is disposed so as to surround the rotor 3. The stator winding 19 is held in a plurality of slots provided on the inner peripheral side of the stator core 18.

  The control unit 2 is disposed on the rear side of the rear housing 6 and is fixed to the rear housing 6. In addition, a connection end portion drawn from each stator winding 19 is connected to the control unit 2. Furthermore, the control unit 2 mainly includes a plurality of (here, six) power modules 21, a field module 22, a cooling heat sink 23, a case 24, and a control module 25.

  Each power module 21 is connected in series between a positive electrode and a negative electrode of a DC power source (battery) 31, and controls first and second switching elements 32 a and 32 b that control current flowing in the stator winding 19, and DC The first DC terminal 33a connected to the positive electrode of the power supply 31; the second DC terminal 33b connected to the negative electrode of the DC power supply 31; and the connection line of the first and second switching elements 32a and 32b. The AC terminal 34 connected to the corresponding one phase of the stator winding 19 and the first and second control terminals 35a and 35b for controlling the switching elements 32a and 32b.

  That is, the power module 21 is a combination of switching elements 32a and 32b together with peripheral circuits for supplying armature current during driving and rectifying armature current during power generation. The field module 22 is a combination of switching elements 36 for controlling the field current together with peripheral circuits.

  The power module 21 and the field module 22 have a structure in which a switching element or the like is mounted on a lead frame for wiring and the whole is resin-molded. The power module 21 and the field module 22 are mounted on a cooling heat sink 23 for cooling them. The cooling heat sink 23 is disposed so as to surround the slip ring 13 and the brush holder 14.

  A rotation sensor (magnetic pole position detection sensor) 26 for detecting the rotation phase of the rotor 3 is provided between the slip ring 13 and the second bearing 8 outside the rear housing 6. The rotation sensor 26 includes a sensor stator 26 a fixed to the rear housing 6 and a sensor rotor 26 b fixed to the rotation shaft 10.

  The signal wiring from the sensor stator 26 a is connected to the control module 25. A rotation sensor protective cover 27 that covers the rotation sensor 26 is attached to the rear housing 6.

  A space through which the second axial end of the rotating shaft 10 passes is provided at the center of the control unit 2. The brush holder 14 is disposed in the central space of the control unit 2 and is fixed to the control unit 2.

  The control unit 2 is covered with a control unit protective cover 28 for protecting and electrically insulating the control unit 2, the brush 15, and the like. The control unit protective cover 28 is provided with a plurality of suction ports 28a for sucking cooling air.

  The control module 25 has an annular (or C-shaped) substrate on which a control circuit for controlling the power module 21 and the field module 22 is provided. The substrate of the control module 25 is arranged to face the surface (upper surface) opposite to the cooling heat sink 23 of the power module 21 and the field module 22.

  The substrate of the control module 25 is provided with a plurality of snubber circuits 37 (collectively shown in FIG. 2) for suppressing surges generated when the switching elements 32a and 32b are switched. Each snubber circuit 37 is configured in a portion of the substrate of the control module 25 that faces the power module 21. Further, the control unit 2 is provided with a smoothing capacitor 38 for suppressing voltage fluctuations of the DC power source generated by the operation of the rotating electrical machine.

  Each power module 21 is provided with four snubber circuit connection terminals 39a, 39b, 39c, and 39d (not shown in FIG. 2) branched from the DC terminals and AC terminals of the switching elements 32a and 32b, respectively. Yes. These snubber circuit connection terminals 39 a to 39 d are connected to the substrate of the control module 25 in the immediate vicinity of the snubber circuit 37. Further, the snubber circuit connection terminals 39 a to 39 d are arranged in parallel to each other and at right angles to the substrate of the control module 25.

  The case 24 is disposed on the power module 21 side of the cooling heat sink 23 so as to surround the power module 21, the field module 22, and the control module 25.

  FIG. 3 is a rear view (a view of the case 24 seen from the left side of FIG. 1) showing the control unit-integrated rotating electrical machine with the control unit protective cover 28 and the control module 25 of FIG. 1 removed. The planar shape of each power module 21 is a rectangle. The power modules 21 are arranged in three locations in groups of two. In each set, the power modules 21 adjacent to each other are configured symmetrically.

  In each set, the snubber circuit connection terminals 39 a to 39 d are arranged at adjacent ends of the power module 21. The power module 21 is provided with third to fifth control terminals 35c, 35d, and 35e connected to the control module 25 in addition to the first and second control terminals 35a and 35b. These control terminals 35a to 35e are arranged at the end portions of the power modules 21 opposite to the snubber circuit connection terminals 39a to 39d.

  In each power module 21, the first DC terminal 33 a is disposed at the end (the end on the center side of the case 24) that faces the slip ring 13. Further, in each power module 21, the second DC terminal 33b and the AC terminal 34 are disposed at the end opposite to the first DC terminal 33a.

  A rectangular opening is provided in the center of the case 24. Further, a bus bar 40 connected to the positive electrode of the DC power supply 31 is insert-molded in the case 24. Although partially shown in FIG. 3, the bus bar 40 is arranged in a U shape along three sides of the opening of the case 24 (left side, right side, and lower side in FIG. 3).

  The smoothing capacitor 38 is accommodated in a hole provided in the cooling heat sink 23 and is in contact with the cooling heat sink 23. The smoothing capacitor 38 is connected to a bus bar 40 inserted in the case 24. The case 24 is provided with a plurality of terminals connected to the power system terminals of the power module 21 and the field module 22, and a plurality of GND terminals.

  In such a controller-integrated rotating electrical machine, the snubber circuit 37 is provided in a portion of the substrate of the control module 25 facing the upper surface of the power module 21, so that the switching surge of the power module 21 is effectively suppressed. Can do.

  Moreover, since the snubber circuit 37 is comprised corresponding to each power module 21, the capacitor | condenser of each snubber circuit 37 can be reduced in capacity. Thereby, size reduction of the control part 2 can be achieved.

  Furthermore, since the smoothing capacitor 38 is in contact with the cooling heat sink 23, the cooling performance can be improved and the life of the smoothing capacitor 38 can be extended.

  Furthermore, since the power module 21 is provided with the snubber circuit connection terminals 39a to 39d, the connection path can be shortened, and the switching surge can be more effectively suppressed.

  Further, since the snubber circuit connection terminals 39a and 39b are arranged in parallel to each other, noise generated in the connection path can be reduced.

  Furthermore, since the bus bar 40 insert-molded in the case 24 is connected to the power module 21 and also connected to the smoothing capacitor 38, the connection between the smoothing capacitor 38 and the power module 21 is performed at one place. It is possible to improve the workability.

Embodiment 2. FIG.
Next, FIG. 4 is a rear view showing a control unit-integrated dynamoelectric machine according to Embodiment 2 of the present invention, and shows a state in which the control unit protective cover 28 and the control module 25 are removed as in FIG. In the second embodiment, each set of power modules 21 is connected to a corresponding snubber circuit 37 via common snubber circuit connection terminals 39a and 39b.

  The snubber circuit connection terminals 39a and 39b are arranged between the power modules 21 adjacent to each other. Further, the snubber circuit connection terminal 39 a is formed to branch from the bus bar 40 in the vicinity of the power module 21. Furthermore, the snubber circuit connection terminal 39b is formed in the vicinity of the power module 21 and branched from the ground line to which the second DC terminal 33b of the power module 21 is connected.

  Each power module 21 is connected to a corresponding snubber circuit 37 via a bus bar 40 and a snubber circuit connection terminal 39a, and a ground line and a snubber circuit connection terminal 39b. Further, the snubber circuit connecting terminals 39a and 39b are partially insert-molded in the case 24 and provided on the case 24 side. Other configurations are the same as those in the first embodiment.

  According to such a configuration, it is possible to improve the accuracy of the relative positions of the snubber circuit connection terminals 39a and 39b with respect to the substrate of the control module 25 and to improve the attachment property of the substrate.

  DESCRIPTION OF SYMBOLS 1 Drive part, 2 Control part, 3 Rotor, 4 Stator, 19 Stator winding, 21 Power module, 23 Cooling heat sink, 24 Case, 25 Control module, 31 DC power supply, 32a, 32b Switching element, 37 Snubber Circuit, 38 smoothing capacitor, 39a, 39b, 39c, 39d Snubber circuit connection terminal, 40 bus bar.

Claims (6)

A drive unit having a rotor and a stator including a stator winding of a plurality of phases; a plurality of power modules including a switching element for controlling a current flowing in the stator winding; and the power module. A cooling heat sink for cooling and a control module for controlling the power module, and a control unit fixed to the drive unit,
The control unit further includes a plurality of snubber circuits that suppress switching surges of the switching element, and a smoothing capacitor for suppressing voltage fluctuations of the DC power supply,
The snubber circuit is configured in a portion of the control module substrate facing the power module,
The smoothing capacitor is a controller-integrated rotating electrical machine in contact with the cooling heat sink. The control unit further includes a case disposed on the power module side of the cooling heat sink so as to surround the power module,
The control unit-integrated dynamoelectric machine according to claim 1, wherein a bus bar connected to the power module is insert-molded in the case.   The control unit-integrated dynamoelectric machine according to claim 2, wherein the smoothing capacitor is connected to the bus bar.   The control unit-integrated dynamoelectric machine according to any one of claims 1 to 3, wherein the power module is provided with a plurality of snubber circuit connection terminals connected to a substrate of the control module. .   The control unit-integrated dynamoelectric machine according to claim 4, wherein the snubber circuit connection terminals are arranged in parallel to each other. The power module is connected to the snubber circuit via a plurality of snubber circuit connection terminals,
4. The controller-integrated rotation according to claim 2, wherein the snubber circuit connection terminal is formed by branching a ground wire provided in the case and the bus bar in the vicinity of the power module. 5. Electric.

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