JP2016158500A - Control device built-in rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a control device built-in rotary electric machine of which electrical corrosion resistance is improved.SOLUTION: A control device built-in rotary electric machine comprises: an external power source; a power circuit part that is disposed between rotor windings of a rotary electric machine main body; a voltage input/output terminal bolt that is arranged to the power circuit part, and is electrically connected to the external power source; a plate pressed-in the voltage input/output terminal bolt; a voltage input/output conductor that is contacted with the plate; a bus bar that is connected to the voltage input/output conductor; a power module that is connected to the bus bar and the rotor winding; and a case communication part of the power circuit part that is fixed to a heat sink for cooling the power module. A head part of the voltage input/output terminal bolt is contacted with a bolt fixed member, and is penetrated to a penetration hole provided to the voltage input/output conductor. The voltage input/output terminal bolt is screwed with a nut, and is fixed to the voltage input/output conductor through a spacer, is pressed-in to the plate embedded in the base communication part, and a space of the voltage input/output terminal bolt and the bus bar is separated.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a controller-integrated rotating electrical machine in which a rotating electrical machine and a control device that controls the rotating electrical machine are integrally configured.

BACKGROUND ART A controller-integrated rotating electrical machine mounted on a vehicle such as an automobile includes a power conversion circuit that performs power conversion between an armature winding of the rotating electrical machine and a battery provided outside the rotating electrical machine. This power conversion circuit usually includes a plurality of power modules incorporating switching elements made of semiconductor, and operates as an inverter or a converter by controlling a gate signal applied to the gates of these switching elements.
When the rotating electrical machine is operated as an electric motor, the power conversion circuit is operated as an inverter, and the DC power of the battery is converted into AC power by the inverter and supplied to the armature winding of the rotating electrical machine. On the other hand, when the rotating electrical machine is operated as a generator, the power conversion circuit is operated as a converter, and AC power induced in the armature winding of the rotating electrical machine is converted into DC power by the converter and supplied to the battery.

  In the controller-integrated rotating electrical machine configured as described above, between the power input / output terminal of the armature winding of the rotating electrical machine and the power input / output terminal that is the AC side terminal of the power module constituting the power conversion circuit. In addition, in the power input / output terminal constituting the DC side terminal of the power module, the bus bar includes one electrical connection portion and at least one mechanical connection portion other than the electrical connection portion. There is one that is electrically connected to a terminal by an electrical connection portion at a location, and mechanically connected to a heat sink or bracket via an insulator by at least one mechanical connection portion (for example, Patent Documents) 1).

International Publication No. 2012-081068

However, in the conventional controller-integrated dynamoelectric machine as disclosed in Patent Document 1, since the power input / output terminal bolt is directly press-fitted into the bus bar, the power input / output terminal bolt head is externally provided. Due to the penetration of salt water, etc., the peripheral area of the bus bar press-fit deteriorates by electric corrosion, and finally the engine is vibrated, causing cracks in the peripheral area of the press-in of the bus bar. there were.
In addition, the bus bar needs to have a press-fit length as a mechanical joint surface, and in view of the above problems, it is necessary to unnecessarily increase the thickness of the bus bar regardless of electrical heat generation, resulting in an increase in size. There was a problem.

  The present invention has been made to solve the above-mentioned problems in conventional rotating electrical machines, and mainly improves the electrical corrosion resistance on the electrical connection surface between the power input / output terminal bolt and the bus bar, while It is an object of the present invention to provide a controller-integrated rotating electrical machine that reduces the size of output terminal bolts and bus bars.

  The controller-integrated rotating electrical machine according to the present invention includes a power circuit unit provided between an external power source and a stator winding of the rotating electrical machine body, and provided in the power circuit unit, electrically connected to the external power source. A power input / output terminal bolt to be connected; a plate press-fitted into the power input / output terminal bolt; a power input / output conductor in contact with the plate; a bus bar connected to the power input / output conductor; A power module connected to the bus bar and the stator winding; and a case connecting part of the power circuit part fixed to a heat sink for cooling the power module, the power input / output terminal bolt The head is in contact with a bolt fixing member and penetrates through a through hole provided in the power input / output conductor, and the power input / output terminal bolt is screwed with a nut, Is secured to the power input conductor through the support, it said being pressed into the plate which is embedded in the case connecting portion, the bus bar and the power output terminal bolt are those spaced.

  According to the controller-integrated rotating electrical machine of the present invention, it is possible to improve the electric corrosion resistance on the electrical connection surface between the power input / output terminal bolt and the bus bar and to reduce the size of the power input / output terminal bolt and the bus bar. it can.

It is a longitudinal cross-sectional view of the control apparatus integrated generator by Embodiment 1 of this invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a rear side partially broken side view showing a configuration of a power circuit portion of a control device-integrated generator according to Embodiment 1 of the present invention; 1 is a circuit diagram of a controller-integrated dynamoelectric machine according to Embodiment 1 of the present invention. FIG. It is a longitudinal cross-sectional view which shows the principal part of the power circuit part of the control apparatus integrated rotary electric machine by Embodiment 1 of this invention.

Embodiment 1 FIG.
1 is a longitudinal sectional view of a control apparatus-integrated dynamoelectric machine according to Embodiment 1 of the present invention.
In FIG. 1, a controller-integrated rotating electrical machine 100 for a vehicle includes a stator core 3 supported by a front bracket 1 and a rear bracket 2, and a rotor core 4 inserted into an inner space of the stator core 3. It has. The rotor core 4 includes a plurality of rotor magnetic poles that are opposed to the inner peripheral surface of the stator core 3 via a gap.
A stator winding 300 as an armature winding in which a coil piece is inserted into a slot of the stator core 3 is fixed to the stator core 3. In the first embodiment, the stator winding 300 is connected in six phases. A rotor winding 7 as a field winding is fixed to the rotor core 4. The stator core 3 and the stator winding 300 constitute the stator 5 of the rotating electrical machine main body 102, and the rotor core 4 and the rotor winding 7 constitute the rotor 13 of the rotating electrical machine main body 102.

Further, the front bracket 1 and the rear bracket 2 are fastened in a direction approaching each other by a plurality of bolts 101, and firmly hold the stator core 3.
The rotor shaft 6 penetrating through the center of the rotor core 4 is rotatably supported by a front side bearing 61 supported by the front bracket 1 and a rear side bearing 62 supported by the rear bracket 2. . The front-side cooling fan 51 and the rear-side cooling fan 52 fixed to the front-side end surface and the rear-side end surface of the rotor core 4 rotate together with the rotor core 4 so as to move from the outside to the inside of the front bracket 1 and the rear bracket 2. Air is introduced to cool the inside of the rotating electrical machine main body 102.
A pulley 12 is fixed to the front side end of the rotor shaft 6. The pulley 12 is wound around a transmission belt (not shown) that interlocks with the rotation shaft of the engine. The pair of slip rings 8 fixed to the peripheral surface of the rotor shaft 6 is in sliding contact with the pair of brushes 9 supported by the brush holder 90.

A magnetic pole position detection sensor 10 constituted by a sync resolver includes a sensor rotor 111 fixed to the rear side end of the rotor shaft 6 and a sensor fixed to the rear side bracket 2 so as to face the sensor rotor 111. A stator 112 and a sensor winding 113 fixed to the sensor stator 112 are provided.
A control circuit board 40 provided with a control circuit is housed in a resin board housing case 41. The control circuit provided on the control circuit board 40 controls the switching operation of the power module 21 described later. The substrate storage case 41 is fixed to the outer surface portion of the heat sink 23.
The power circuit unit 20 is fixed to the outside of the rear bracket 2 and includes a power conversion circuit that performs power conversion between a stator winding 300 that is an armature winding and a battery (not shown). . This power conversion circuit is composed of six power modules 21 described later, and operates as a six-phase inverter or a six-phase converter.

FIG. 3 is a circuit diagram of the controller-integrated dynamoelectric machine according to Embodiment 1 of the present invention.
As shown in FIG. 3, in the first embodiment, each power module 21 includes two semiconductor switching elements connected in series and two diodes connected in reverse parallel to the respective semiconductor switching elements. The package is configured as one package. The two semiconductor switching elements sealed in one power module 21 are connected in series as described above, and one semiconductor switching element and a diode connected in reverse parallel to this are included in the six-phase bridge circuit. A positive-phase arm for one phase is configured, and the other semiconductor switching element and a diode connected in reverse parallel thereto constitute the negative-phase arm for the one phase. The series connection point of the two semiconductor switching elements is connected to the one-phase stator winding 300 of the six-phase stator windings.
Accordingly, the six power modules 21 configured as described above are connected to the terminals 22a connected to the B terminal 24 described later.

FIG. 2 is a partially broken side view on the rear side showing the configuration of the power circuit portion of the controller-integrated generator according to Embodiment 1 of the present invention.
In FIG. 2, the power circuit unit 20 includes six power modules 21 that configure a six-phase power conversion circuit and control energization of the stator winding 300, and these power modules 21 include an insulating layer (not shown). The power input / output terminal bolt 11 electrically connected to the positive electrode side of the battery, and the B terminal 24 and B electrically connected to the power input / output terminal bolt 11. A bus bar 30 and a power circuit case 25 are provided.

As shown in FIG. 1, the heat sink 23 is formed of a metal material such as aluminum die cast, and includes a through hole 231 at the center. A large number of cooling fins 23 a extending in the axial direction are integrally formed on the front surface of the heat sink 23 on the stator side of the rotating electrical machine main body 102. The through hole 231 of the heat sink 23 is penetrated by the rotor shaft 6.
As shown in FIG. 2, the power circuit case 25 is made of resin and includes an annular outer case portion 251 and an annular inner case portion 252. An inner wall 255 surrounding the through hole 254 is formed in the inner case portion 252. The inner wall 255 constitutes the inner wall of the power circuit case 25.

The power circuit case 25 is fixed to the rear surface of the heat sink 23 described above. As a result, a power module housing portion 257 surrounded by the outer case portion 251 and the inner case portion 252 of the power circuit case 25 and the rear side surface of the heat sink 23 is formed.
As shown in FIG. 2, the six power modules 21 described above are housed in a power module housing portion 257 and are arranged in a U shape with a space therebetween. In addition, a control circuit board connection part 260 connected to the control circuit board 40 is inserted in the power module housing part 257. The control circuit board connecting portion 260 is for supplying a gate signal from the control circuit formed on the control circuit board 40 to the gate of the semiconductor switching element of each power module 21.

The power circuit waterproofing resin 28 is filled in a power module housing portion 257 that houses the power module 21 and the control circuit board connecting portion 260. As a result, the power module 21 and the control circuit board connecting portion 260 are embedded in the power circuit waterproof resin 28 and protected by the power circuit waterproof resin 28.
The B terminal 24 as a terminal electrically connected to the positive electrode of the external battery is molded in the inner case portion 252 and the case connecting portion 253 of the power circuit case 25. The B terminals 24 are electrically and mechanically connected to the terminals 22a of the six power modules 21 and the terminals 260a of the control circuit board connection portion 260 by welding or soldering, respectively. The B terminal 24 is exposed on the upper surface of the case connecting portion 253 of the power circuit case 25.

A bus bar (hereinafter referred to as B bus bar) 30 electrically connected to the positive electrode of an external battery is fixed to the heat sink 23 by screws 31 and 32 on both sides of the power input / output terminal bolt 11. Here, FIG. 1 and FIG. 4 have different cut surfaces. In FIG. 4, the B bus bar 30 is provided on the back side of the drawing. The B terminal 24 is disposed between the power module 21 and the heat sink 23. The B terminal 24 is formed of a copper metal member.
As shown in FIG. 4, the formed female screw is fixed to the heat sink 23 via the case connecting portion 253 by screwing with the screw 31 inserted through the insulating material 33 from the rear surface of the heat sink 23. Has been.
The B terminal 24 provided in the case coupling portion 253 of the power circuit case 25 is electrically connected to the power input / output terminal bolt 11 through the spacer 42 by the tightening force of the nut 36.

Specifically, as shown in FIG. 4, the power input / output terminal bolt 11 has a head abutting against a bolt fixing member and penetrating through a through hole provided in the B terminal 24. The power input / output terminal bolt 11 is screwed into the nut 36, fixed to the B terminal 24 via the spacer 42, and press-fitted into the plate 43 embedded in the case connecting portion 253.
In the controller-integrated rotating electrical machine 100 according to Embodiment 1 of the present invention configured as described above, the power input / output terminal bolt 11 is provided on the positive electrode side of the battery provided outside the controller-integrated rotating electrical machine 100. Is electrically connected via a battery harness or the like (not shown). The pulley 12 is connected to a pulley (not shown) on the internal combustion engine side provided on the output shaft of the internal combustion engine via a belt.

If the controller-integrated rotating electrical machine 100 is operated as an electric motor, a gate signal from a control circuit provided in the control circuit board 40 is operated so that the power conversion circuit configured by each power module 21 is operated as an inverter. Thus, switching control of the semiconductor switching element of each power module 21 is performed.
Thus, the DC power input from the battery to the terminal 22a of each power module 21 through the power input / output terminal bolt 11, the B terminal 24 and the B bus bar 30 is converted into a six-phase AC by the inverter configured by the power module 21. It is converted into electric power and supplied to the windings of each phase of the six-phase stator winding 300 via the terminal 22b of each power module 21. As a result, the rotor 13 is driven by the interaction between the rotating magnetic field generated by the stator winding 300 and the magnetic field generated by the rotor winding (field winding) 7 provided on the rotor 13, and the pulley Power is transmitted from 12 to the internal combustion engine via the belt.

  On the other hand, when the controller-integrated rotating electrical machine 100 is operated as a generator, the power of the internal combustion engine is transmitted to the pulley 12 via the belt, and the rotor 13 is driven. The semiconductor switching element of each power module 21 is switching-controlled by a gate signal from a control circuit provided on the control circuit board 40 so that the configured power conversion circuit is operated as a converter. The AC power induced in each phase winding of the stator winding 300 is applied to each power module 21 via the terminal 22b of each power module 21, and is converted into DC power by the converter configured by each power module 21. Thus, the battery 22 is supplied from the terminal 22a of each power module 21 to the battery via the B bus bar 30, the terminal 24, the spacer 42, and the nut 36.

Since the controller-integrated rotating electrical machine 100 according to Embodiment 1 of the present invention is configured as described above, salt water enters from the head of the power input / output terminal bolt 11 and the plate 43 dissolves during electrolytic corrosion. However, since the bus bar 30 has a structure that is difficult to dissolve, power can be supplied to the power module 21. The plate 43 is formed of a metal member such as aluminum. If the plate (AL) is made of a material that has a higher ionization tendency than the bus bar (Cu) and a metal having a high ionization tendency such as aluminum is kept in contact with the copper material, the aluminum will be corroded sacrificially to corrode the copper bus bar. Can be suppressed. Aluminum corrodes first and discharge | releases an electron, An electron is supplied to copper and an anticorrosion effect is acquired by preventing the electron emission of copper. Further, as a selection of the plate material, iron or zinc which is a metal having a higher ionization tendency than copper may be used in addition to aluminum.
In the present invention, the embodiments can be appropriately modified and omitted within the scope of the invention.

  1: Front bracket, 2: Rear bracket, 3: Stator iron core, 4: Rotor iron core, 5: Stator, 6: Rotor shaft, 7: Rotor winding, 8: Slip ring, 9: Brush, 10 : Magnetic pole position detection sensor, 11: Terminal bolt for power input / output, 12: Pulley, 13: Rotor, 20: Power circuit section, 21: Power module, 22a: Terminal, 22b: Terminal, 23: Heat sink, 24: B Terminal: 25: Power circuit case, 28: Power circuit waterproof resin, 30: B bus bar, 31: Screw, 32: Screw, 33: Insulating material, 36: Nut, 40: Control circuit board, 41: Board storage case, 42: Spacer, 43: Plate, 51: Front side cooling fan, 52: Rear side cooling fan, 61: Front side 62: Rear side bearing, 90: Brush holder, 100: Rotating electric machine with integrated control device, 101: Bolt, 102: Main body of rotating electric machine, 111: Sensor rotor, 112: Sensor stator, 113: Sensor winding, 231: Through hole, 251: Outer case part, 252: Inner case part, 253: Case connection part, 254: Through hole, 257: Power module housing part, 260: Control circuit board connection part, 300: Stator winding

Claims (4)

A power circuit section provided between the external power source and the stator winding of the rotating electrical machine body;
A terminal bolt for power input / output provided in the power circuit unit and electrically connected to the external power source;
A plate press-fitted into the terminal bolt for power input / output;
A power input / output conductor in contact with the plate;
A bus bar connected to the power input / output conductor;
A power module connected to the bus bar and the stator winding;
A case coupling portion of the power circuit portion fixed to a heat sink for cooling the power module,
The power input / output terminal bolt is penetrated through a through hole provided in the power input / output conductor with its head abutting against a bolt fixing member,
The power input / output terminal bolt is screwed with a nut, fixed to the power input / output conductor via a spacer, and press-fitted into the plate embedded in the case connecting portion,
The controller-integrated dynamoelectric machine, wherein the power input / output terminal bolt and the bus bar are separated from each other.   The controller-integrated rotating electrical machine according to claim 1, wherein the plate is made of a metal having a higher ionization tendency than the bus bar.   The controller-integrated rotating electrical machine according to claim 1, wherein the plate is made of any one of aluminum, iron, and zinc.   4. The controller-integrated dynamoelectric machine according to claim 1, wherein the power input / output conductor is formed so as to be exposed on an upper surface of the case connecting portion. 5.

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