JP3556530B2 - Hybrid vehicle drive - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a hybrid vehicle driving apparatus that drives a vehicle by selectively using both or one of a driving force of an internal combustion engine and a driving force of an AC motor, and particularly relates to a hybrid vehicle driving device in which an AC motor is provided between an internal combustion engine and a transmission. The present invention relates to a hybrid vehicle drive device having a structure connected to a crankshaft.
[0002]
[Prior art]
For example, Japanese Patent Application Laid-Open No. 9-156388 discloses a method of driving a vehicle by selectively using both or one of a driving force of an internal combustion engine and a driving force of an AC motor as a driving method of a hybrid vehicle. The stator (stator) used in AC motors for hybrid vehicles is composed of a number of ring-shaped silicon steel plates with stator teeth protruding along the circumference from the inner peripheral end of the ring-shaped stator core toward the center. In general, a stator core is formed, and a stator coil (stator winding) is wound around a laminated portion of stator teeth.
[0003]
Here, in order to improve the linearity of the stator coil wound around the stator teeth, it is desirable that the stator coils be densely wound around each stator tooth. It is desirable to wind in. However, in the above-described conventional stator shape, since the stator teeth are fixedly arranged adjacent to each other, the stator winding cannot be densely wound around each stator tooth through the gap between the stator teeth, and a high linear product There was a problem that the rate could not be obtained.
[0004]
In order to solve such a problem, a stator core is formed by arranging stator pieces for a predetermined angle (for example, one slot) in a ring shape, and a stator coil is wound in advance for each stator piece. There is a possible configuration.
[0005]
[Problems to be solved by the invention]
However, even if the stator coils are wound on each stator piece, if the stator coils wound on the stator pieces of the same phase are continuously wound on the same conductor, for example, a plurality of stator pieces having the same phase may be used. If either of them is defective, only the defective stator piece cannot be replaced, and all the stator pieces in the same phase must be replaced or the defective part must be replaced after the stator coil is released. Was. Also, when assembling the stator pieces by arranging them in a ring shape, handling becomes difficult if the stator pieces of the same phase are connected to each other by a conductive wire.
[0006]
On the other hand, if the stator coil is separated for each stator piece so that each stator piece can be handled independently, it is necessary to separately connect the stator coils of the same phase to each other via another connection means. However, in such a configuration, since a non-insulated portion is exposed at a connection portion between each stator coil and the connection means, if water droplets, sludge, or the like adheres to the non-insulated portion during running of the vehicle, an electric leakage or a short circuit may be caused.
[0007]
SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the prior art, and in a configuration in which a plurality of independent stator coils are connected to each other via other connection means, a hybrid vehicle capable of preventing electric leakage and short circuit at each connection portion A drive device is provided.
[0008]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a hybrid vehicle drive device having a structure in which an AC motor is connected to a crankshaft between an internal combustion engine and a transmission, wherein the AC motor has a stator coil wound. A stator configured by arranging a plurality of independent stator pieces in a ring shape, a stator holding ring having an opening corresponding to the outer peripheral shape of the stator, and the stator being press-fitted and fixed to the opening, A plurality of first ring-shaped buses which are stacked and arranged along the outer circumference on one end side in the axial direction of the stator coil and connect one end of the stator coil wound on the stator piece of the same phase; A second ring-shaped bus arranged along the inner periphery on the side and connecting the other ends of the stator coils wound around the respective stator pieces; A coil is fixed so as to cover one end side in the axial direction and the first and second ring-shaped buses, a connecting portion between one end of each of the stator coils and the first ring-shaped bus, and a second end of each of the stator coils and the second. A stator cover having first and second openings for exposing a connection portion with the ring-shaped bus, and filling the stator from each of the first and second openings; It is characterized by comprising a connecting portion to the one ring-shaped bus, and a sealing member for sealing a connecting portion between the other end of each stator coil and the second ring-shaped bus.
[0009]
According to the above-described feature, the connection between one end of each stator coil and each first ring-shaped bus and the connection between the other end of each stator coil and the second ring-shaped bus are sealed by the filled seal member. Is completely isolated from the surrounding environment. Therefore, even if a plurality of independent stator coils are connected to each other via other connection means, it is possible to completely prevent a leakage or a short circuit at each connection portion.
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the drawings. FIG. 1 is a diagram schematically showing a hybrid vehicle V to which the hybrid vehicle drive device of the present invention is applied.
[0011]
The hybrid vehicle V of the present embodiment includes, for example, an internal combustion engine E that generates driving force by burning gasoline, a motor M that assists the output of the internal combustion engine E, a clutch mechanism C including a flywheel, A transmission T for transmitting the driving force generated by the internal combustion engine E and / or the motor M to the drive shaft 1;
[0012]
The motor M is a three-phase AC synchronous motor, which assists the output of the engine during acceleration or the like, and performs a regenerative braking function to charge the battery 3 during deceleration of the vehicle. The motor drive circuit 2 converts the output voltage (DC) of the battery 3 into an AC voltage and supplies the AC voltage to each phase of the AC motor M. The engine E is controlled by engine control means (not shown).
[0013]
FIG. 2 is a perspective view of the hybrid vehicle drive device, and the same reference numerals as those described above denote the same or equivalent parts. The internal combustion engine E having three cylinders includes an oil pan 25, a cylinder block 24, and a cylinder head 26, and a head cover 27 is mounted on the cylinder head 26.
[0014]
3 is a perspective view of the motor M alone viewed from the engine side, FIG. 4 is an assembly view of the motor M, and FIG. 5 is a cross-sectional view of a main part of the motor M. Represents the same or equivalent part.
[0015]
The motor M includes a stator assembly 50, a motor housing 60 that houses the stator assembly 50 and is connected to the engine E, a rotor 70 directly connected to a crankshaft of the engine, a transmission-side stator cover 80, and a stator assembly of the rotor 70. It comprises a rotation sensor 10 for detecting a rotation position with respect to 50, a terminal holder 30, a terminal cover 90, a grommet cover 40 and the like.
[0016]
A drain hole 61 for discharging water that has entered the motor M to the outside is formed inside the bottom of the motor housing 60, and the outside of the bottom of the motor housing 60 through which the drain hole 61 penetrates is formed. A drain chamber 62 is formed to allow the drainage while preventing flooding.
[0017]
FIG. 15 is a sectional view of the drain chamber 62, and FIG. 16 is a plan view of the drain chamber 62 as viewed from below the motor housing 60. Note that FIG. 16 shows a state in which a drain cover 63 to be described later is removed, and only the drain port 631 is shown by a broken line for easy understanding. A side view of the drain cover 63 is shown on the left side of FIG.
[0018]
The drain cover 63 includes a horizontal drain port 631 formed by cutting and raising a part of the plate-shaped body. The drain cover 63 is accommodated along an edge 632 formed on the inner side surface of the drain chamber 62. , And the bolt 622 so as to seal the inside of the drain chamber 62.
[0019]
In the ceiling surface of the drain chamber 62, two drain holes 651 communicating with the drain holes 61 are opened, and the edge portions are formed so as to surround a projection area of a drain port 631 formed in the drain cover 63. A “U” -shaped inundation prevention wall 656 is formed at the same height as 632. The U-shaped inundation prevention wall 656 prevents ingress of water from the drain port 631 into the drain chamber 62. Further, between the U-shaped inundation preventing wall 656 and the drain hole 651, a pair of inundation preventing walls 657 which are obliquely opposed at a predetermined angle have the same height as the edge 632 and the inundation preventing wall 656. Is further provided.
[0020]
According to the drain chamber 62 having such a configuration, the water that has entered the motor M is drained into the drain chamber 62 via the drain holes 61 and 651, and is further discharged from the drain port 631 of the drain cover 63 to the outside. Is discharged. On the other hand, flooding from the drain port 631 into the drain chamber 62 is firstly blocked by the U-shaped flooding prevention wall 656, and secondly, by a pair of flooding prevention walls 657. Therefore, drainage from the motor M becomes possible while preventing infiltration into the motor M from the outside.
[0021]
As shown in FIG. 6, the rotor 70 includes a rotor body 71, a plurality of N-pole and S-pole magnets 72 (72N, 72S) alternately arranged on the outer periphery of the rotor body 71, and the magnet 72. , And a plurality of cooling fins 71 a are provided on both side surfaces of the rotor main body 71.
[0022]
FIG. 7 is an assembly view of the stator assembly 50, and FIG. 8 is a perspective view showing an assembly method and a structure of a stator portion 501, which is a main configuration of the stator assembly 50.
[0023]
As shown in FIG. 8, the stator portion 501 is configured by arranging a plurality of (18 in the present embodiment) stator pieces 510 in a ring shape, and press-fitting the stator pieces 510 into openings of the stator holding ring 520. Is done.
[0024]
The respective stator pieces 510 are opposed to each other so as to sandwich the teeth of the stator core teeth 512 and are fitted to each other with the stator core teeth 512 formed by stacking silicon steel sheets punched into a substantially “T” shape. It comprises a pair of bobbin insulators 511 and 513 and a stator coil 514 wound around the teeth of the stator core teeth 512 via the bobbin insulators 511 and 513. The stator holding ring 520 and the stator core teeth 512 are formed of the same material or materials having substantially the same thermal expansion coefficients so that the fitted state of the two does not loosen due to heat generated by the engine E during operation.
[0025]
A semi-circular convex portion 512a and a semi-circular concave portion 512b are formed along the rotation axis on both end surfaces of the outer periphery of the stator core teeth 512 functioning as a stator core when the stator pieces 510 are arranged in a ring shape. . The convex portions 512a and the concave portions 512b of the T-shaped stator core teeth 512 arranged adjacent to each other engage with each other (see FIG. 10), thereby preventing the displacement of each stator piece 510 in the axial center direction.
[0026]
Further, when the stator pieces 510 are arranged in a ring shape and fixed by press-fitting into the opening of the stator holding ring 520, if the relative positional relationship between them is not proper, the excitation timing of each stator piece 510 will be shifted. Therefore, in this embodiment, as shown in FIG. 9, at least one portion of the end surface of the opening of the stator holding ring 520, as shown in FIG. 9, the row of stators arranged in a ring shape (18 stator pieces; ) And a stator engaging ring 520 are formed with a protruding engagement portion 520c for regulating the relative positional relationship between the stator holding ring 520 and the stator holding ring 520, and formed in a longitudinal shape along the axial direction (perpendicular to the paper surface).
[0027]
Further, as shown in FIG. 10, a concave engaging portion 512c which engages with the convex engaging portion 520c is formed on a curved surface which becomes an outer peripheral end surface when the stator core teeth 512 are arranged in a ring shape. It is formed longitudinally along the direction. In FIG. 10, illustration of the bobbin type insulators 511 and 513, the stator coil 514, and the like of the stator piece 510 is omitted for easy understanding.
[0028]
The stator rows (stators) arranged in a ring shape in advance are such that the concave engaging portion 512c formed on the outer peripheral end face of any of the stator pieces 510 has a convex shape formed on the opening end face of the stator holding ring 520. It is positioned and press-fitted with respect to the stator holding ring 520 so as to engage with the engagement portion 520c.
[0029]
As described above, in this embodiment, since the engagement means 512c and 520c that engage with each other are provided on both the stator side and the stator holding ring 520, the positioning of both can be performed simply and accurately.
[0030]
As described above, when the press-fitting of the stator row into the stator holding ring 520 is completed and the stator portion 501 is completed, the other ends 514b of the respective stator coils 514 described later are connected to each other as shown in FIG. Bus ring 530 (second ring-shaped bus) for supplying an exciting current to all the stator coils 514U wound on the U-phase stator piece (first ring). Bus 532U for supplying an exciting current to all the stator coils 514V wound around the V-phase stator pieces, and all the stator coils 514W wound around the W-phase stator pieces. A bus ring 532W for supplying an exciting current is set on an end face of the bobbin type insulator 513 as shown in FIG.
[0031]
As shown in FIGS. 5 and 13, a plurality of partition plates 513a are provided upright on the engine-side end surface of the bobbin type insulator 513, and each of the bus rings 532U, 532V, 532W is formed by the partition plate 513a. It is set so as to be stacked at a predetermined position. Each of the bus rings 532U, 532V, and 532W is provided with a power supply terminal 537 (537U, 537V, 537W), as shown in FIGS. Each power supply terminal 537 is guided to the terminal holder 30 via a bus bar 531 (531U, 531V, 531W) for supplying a drive current to each of the bus rings 532U, 532V, 532W. Each of the power supply terminals 537 and the bus bar 531 are fastened together by bolts 602 to a stator cover 535 described later.
[0032]
In the terminal holder 30, the terminal 121 of the power supply line 122 and one end of the bus bar 531 are fastened together by a bolt 123. The opening of the terminal holder 30 is covered by the terminal cover 90.
[0033]
As shown in FIG. 7, a plurality of projecting terminals 533U, 533V, 533W are formed in the center direction at the inner peripheral end of each of the bus rings 532U, 532V, 532W. A plurality of protruding terminals 534 are formed in the radial direction from the outer peripheral end of 530. An insulating resin is uniformly applied to the exposed surfaces of the bus rings 532 and 530 except for the main parts of the projecting terminals 533 and 534. As the insulating resin material, not only a function as an insulating film but also a fluorine-based resin is preferable because of its low frictional resistance and high film strength.
[0034]
As shown in FIG. 11, one end of a terminal 550 as a connection terminal is swaged to each protruding terminal 533U of the bus ring 532U, and the other end of the terminal 550 is wound around a U-phase stator piece. One end 514a of the stator coil 514U is swaged. Therefore, one end 514a of each of the stator coils 514U wound on each of the U-phase stator pieces disposed every third one is commonly connected via the bus ring 532U.
[0035]
Similarly, one end 514a of each stator coil 514V wound around each V-phase stator piece is commonly connected via a bus ring 532V (and terminal 550), and wound around each W-phase stator piece. One end 514a of each stator coil 514W is commonly connected via bus ring 532W (and terminal 550).
[0036]
On the other hand, as shown in FIG. 11, one end of the terminal 550 is swaged to each protruding terminal 534 of the bus ring 530 for middle point connection, and the other end of the terminal 550 is wound around the stator piece of each phase. The other end 514b of the turned stator coil is swaged. Therefore, the other ends 514b of the respective stator coils 514 wound around all the stator pieces are commonly connected via the bus ring 530 (and the terminal 550). That is, the bus ring 530 corresponds to a neutral point of the star connection.
[0037]
As described above, in the present embodiment, the stator is configured by arranging the stator pieces 510 in a ring shape, the stator coils 514 wound around the respective stator pieces are also independent, and the stator wound around the stator pieces of the same phase. The coils are connected by a first bus ring 532. Therefore, each stator piece 510 can be handled independently including the stator coil 514, and its handling and productivity when assembling into a stator are improved.
[0038]
Further, in the present embodiment, the bus ring 532 as a power supply line to each phase is disposed outside and the second bus ring as a neutral point of each phase is disposed inside, so that the power supply line and the neutral point The wires do not cross, and wiring can be easily routed.
[0039]
When the connection of the stator coil is completed as described above, the coil is covered with the stator cover 535, and this is screwed to the stator assembly 50. Further, the stator assembly 50 is screwed to the motor housing 60 with bolts 601 as shown in FIG.
[0040]
As described above, in the present embodiment, the stator and the stator holding ring 520 fitted by press-fitting have substantially the same coefficient of thermal expansion, so that even if the motor is heated by the heat generated by the internal combustion engine during the operation of the vehicle. In addition, looseness does not occur at the joint between the stator and the stator holding ring. Since the stator holding ring 520 and the motor housing 60 are fixed by screws, the stator of the motor used in a high-temperature environment can be easily and reliably fixed to the housing 60.
[0041]
As shown in FIG. 7, the stator cover 535 includes a plurality of first elongated holes 541 arranged in a circumferential direction in order from an outer peripheral portion, and a plurality of first elongated holes 541 arranged in the circumferential direction inside the first elongated hole. And a plurality of second elongated holes 543 arranged circumferentially inside the round hole.
[0042]
FIG. 12 is a diagram showing a relative positional relationship between the long holes 541, 543 and the round hole 542 of the stator cover 535 and the stator piece 510, and the terminal 550 extends from the first long hole 541. The connection between the terminal 550 of each bus ring 532 and one end 514a of the stator coil is exposed, and the terminal 550, the terminal 534 of the bus ring 530 and the other end 514b of the stator coil are exposed from the second elongated hole. And the connection part is exposed.
[0043]
In the present embodiment, as shown in the cross-sectional view of FIG. 13 and the partially cutaway plan view of FIG. 14, the sealant 201 is filled into the stator from each of the long holes 541 and 543, and each of the connection parts (caulking part) Is sealed. As the sealant 201, for example, a thermosetting silicone resin can be used, and after filling, the sealant 201 is cured by heating in an electric furnace or the like.
[0044]
In the present embodiment, as shown in FIG. 12, projections 241 and 242 are provided upright on the back surfaces of both ends of the long holes 541 and 543 of the stator cover 535 along the circumferential direction. The protrusions 241 and 242 prevent the sealing agent 201 filled from the long holes 541 and 543 from flowing in the circumferential direction. Further, as shown in FIG. 13, the radiation and the loss toward the center are prevented by the plurality of partition plates 513 a erected on the engine-side end surface of the insulator 513 and the end surface of the stacked bus ring 532. .
[0045]
As described above, in the present embodiment, the partition plate 513a erected on the bobbin-shaped insulator 513 is used to stop the flow of the sealant 201, so that the flow-out of the filler can be efficiently prevented without increasing the number of parts. .
[0046]
【The invention's effect】
According to the present invention, the following effects are achieved.
(1) The connection between one end of each stator coil and each first ring-shaped bus, and the connection between the other end of each stator coil and the second ring-shaped bus are sealed by a seal member and completely shut off from the surrounding environment. Is done. Therefore, even if a plurality of independent stator coils are connected to each other via other connection means, it is possible to completely prevent a leakage or a short circuit at each connection portion.
(2) To prevent the flow of the filler, the partition plate erected on the bobbin-shaped insulator, the projection provided on the stator cover, and a part of the laminated end surface of the plurality of first ring-shaped buses are used. Without increasing the amount of filler.
[Brief description of the drawings]
FIG. 1 is a diagram schematically showing a hybrid vehicle V to which a hybrid vehicle drive device of the present invention is applied.
FIG. 2 is a perspective view of a hybrid vehicle drive device.
FIG. 3 is a perspective view of the motor M alone viewed from the engine side.
FIG. 4 is an assembly view of the motor M.
FIG. 5 is a sectional view of a main part of the motor M.
FIG. 6 is a perspective view showing a structure of a rotor.
FIG. 7 is an assembly view of the stator assembly.
FIG. 8 is a perspective view showing an assembling method and a structure of a stator unit.
FIG. 9 is a plan view of a stator holding ring.
FIG. 10 is a diagram showing a method of positioning a stator piece with respect to a stator holding ring.
FIG. 11 is a plan view of a stator assembly.
FIG. 12 is a diagram showing a connection method between a stator coil and a bus ring.
FIG. 13 is a sectional view of a main part of the stator assembly.
FIG. 14 is a partially broken plan view of the stator assembly.
FIG. 15 is a sectional view of a drain chamber.
FIG. 16 is a plan view of the inside of the drain chamber.
[Explanation of symbols]
50 ... stator assembly, 60 ... motor housing, 70 ... rotor, 80 ... stator cover, 201 ... sealant, 510 ... stator piece, 511, 513 ... bobbin-shaped insulator, 512 ... stator core teeth, 514 ... stator coil, 520 ... stator Retaining ring, 530: Bus ring for connecting a middle point, 532: Bus ring, 533, 534: Projecting terminal, 550: Terminal

Claims (2)

In a hybrid vehicle drive device having a structure in which an AC motor is connected to a crankshaft between an internal combustion engine and a transmission,
The AC motor,
A stator configured by arranging a plurality of independent stator pieces wound with stator coils in a ring shape,
A stator holding ring having an opening corresponding to the outer peripheral shape of the stator, wherein the stator is press-fitted and fixed to the opening;
A plurality of first ring-shaped buses that are arranged along the outer periphery at one axial end of the stator coil and that connect one end of the stator coil wound around the stator piece of the same phase;
A second ring-shaped bus which is arranged along the inner periphery at one axial end of the stator coil and serves as a midpoint by connecting the other ends of the stator coils wound around the respective stator pieces;
The one end of each of the stator coils is fixed so as to cover one end side in the axial direction of the stator coil and the first and second ring-shaped buses, and the connecting portion between one end of each of the stator coils and the first ring-shaped bus, and the other end of each of the stator coils. A stator cover having first and second openings that respectively expose connection portions with the second ring-shaped bus;
The stator is filled from each of the first and second openings, and at least a connection portion between one end of each of the stator coils and the first ring-shaped bus, and a connection portion between the other end of each of the stator coils and the second ring-shaped bus. A hybrid vehicle drive device comprising: a seal member for sealing a connection portion. A pair of protrusions are respectively provided on the back surfaces of both ends in the circumferential direction of the first and second openings opened in the stator cover,
A stator coil is wound around the stator piece via a bobbin-shaped insulator,
The connecting portion between one end of each of the stator coils and the first ring-shaped bus is a partition plate provided upright on the bobbin-shaped insulator, the pair of protrusions, and a stacked end surface of the stacked plurality of first ring-shaped buses. Sealed by the seal member in a space surrounded by a part,
A connecting portion between the other end of each of the stator coils and the second ring-shaped bus is surrounded by a partition plate erected on the bobbin-shaped insulator, the pair of protrusions, and a part of an end face of the second ring-shaped bus. The hybrid vehicle drive device according to claim 1, wherein the seal member is sealed in the closed space by the seal member.

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