JP5693642B2 - Rotating electric machine for vehicle and terminal connecting method of rotating electric machine for vehicle - Google Patents

Description

  The present invention relates to a rotating electrical machine for a vehicle in which a power conversion device is mounted on a rotating electrical machine main body, and more particularly to an improvement in a joint structure of a terminal portion and a terminal connection method.

2. Description of the Related Art Conventionally, an electromechanically integrated vehicular rotating electrical machine in which a power conversion device in which a power semiconductor module incorporating a switching element such as an IGBT (Insulated Gate Bipolar Transistor) is arranged around the central axis of the rotating electrical machine is arranged on the rear side of the rotating electrical machine Are known.
The P, N terminals and AC input / output terminals (AC terminals), which are the main terminals of the power semiconductor module, extend laterally from the side surface of the power semiconductor module and arc to the conductive bus bar structure adjacent to the power semiconductor module. Some were connected by welding or brazing. (For example, see Patent Document 1)
As another connection means, there is one in which terminals extending on the side surface of the power semiconductor module are connected by screw fastening. (For example, see Patent Document 2)

Japanese Patent No. 4391959 (paragraph [0004], FIG. 5 (a)) JP 2011-188560 (paragraph [0005], FIG. 6)

In the conventional power converter, since the main terminal and the AC terminal which are the power terminals of the power semiconductor module are arc-welded, a frequency of several thousand to several megahertz is provided between the welding electrode and the terminal which is the welded portion. A high frequency voltage of several thousand to several tens of thousands of volts is applied. There is a problem that the switching element of the power semiconductor module is damaged by the high-frequency voltage.
In addition, welding by brazing is not practical because there is a concern about heat effects on polymer materials such as plastics used in power conversion devices and electronic components including switching elements.
In addition, the connection by screws requires an area for fastening the screws as compared with welding, which becomes an obstacle to downsizing.

  The present invention has been made to solve the above-described problems, and by using two kinds of welding methods, the power semiconductor module power is joined by joining the terminals of the power semiconductor module to the conductor bus bar structure. It is an object of the present invention to obtain a rotating electrical machine for a vehicle in which a compact and highly efficient power conversion device is arranged in the rotating electrical machine without damaging the switching element.

A rotating electrical machine for a vehicle according to the present invention includes a transistor element that switches power supplied from a power source and a diode element that circulates power from a load, and the transistor element and the diode element have an input terminal and an output terminal. A plurality of power semiconductor modules having a plurality of power terminals and a signal terminal for driving the transistor element, and a mounting surface on which the plurality of power semiconductor modules are arranged so as to be arranged around the rotation axis of the rotating electrical machine And a power conversion device having a conductive bus bar structure having a terminal portion for connecting the power source or load and each of the power terminals, and the power terminal is connected to the power source side. An AC terminal for inputting and outputting an alternating current between the terminal, the N terminal, and the stator winding of the rotating electrical machine, and the power semiconductor module And the conductive bus bar structure has a portion that extends in a lateral direction from each side surface and protrudes in a direction parallel to the mounting surface, and a tip thereof is bent in a direction perpendicular to the mounting surface. The terminal portion of the body protrudes in a direction parallel to the portion bent in the vertical direction of the power terminal, and the portion bent in the vertical direction of the P terminal and the terminal portion of the conductive bus bar structure overlap each other. Are combined and touch-start TIG welded, the portion bent in the vertical direction of the N terminal and the AC terminal and the terminal portion of the conductive bus bar structure are overlapped and resistance welded , The terminal portion of the conductive bus bar structure connected to the P terminal is composed of a single conductor bus bar, a conductor having a plate thickness greater than that of the P terminal is used, and the N terminal and the AC terminal are connected to each other. Terminal portion of the conducting busbar structures are those in which each of the terminals and the plate thickness was set to be the same.

The terminal connection method for a rotating electrical machine for a vehicle according to the present invention includes a P terminal and an N terminal connected to the power supply side, an AC terminal for inputting / outputting an alternating current between the stator windings, and a signal terminal. and a power conversion device in which a plurality disposed around the rotating shaft power semiconductor module, a power supply or load and a method for connecting the conductive bus bar structure having a terminal portion for connecting the respective said power terminals, the P The terminal portion of the conductive bus bar structure connected to the terminal is used as one conductor bus bar in which a conductor having a plate thickness larger than that of the P terminal is used, and the P terminal and the terminal portion of the conductive bus bar structure are overlapped. as well as touch start TIG welding combined, in the above N terminal and the conducting busbar structure the terminal portions of each of the terminals and the plate thickness of the AC terminal is connected to the same, the N terminal and the upper Superposing the terminal portion of the AC terminal and the conductive bus bar structure is obtained by resistance welding.

According to the rotating electrical machine for a vehicle of the present invention, the terminal portion of the conductive bus bar structure that is overlapped with the P terminal and is touch-start TIG welded and joined to the terminal is configured by one conductor bus bar, Since a thick conductor is used, the current and voltage applied to the P terminal by touch start TIG welding are smaller than those of ordinary arc welding, which is sufficient without damaging the components of the power semiconductor module. According to the plate thickness, the terminal connection between the P terminal and the terminal portion of the conductive bus bar structure can be accurately performed, and the conductive bus bar structure composed of a single conductor bus bar using a conductor whose plate thickness is thicker than the P terminal. Conductive busbar structure that can reduce the amount of heat generated when a large current is passed through the terminal, and is resistance-welded by overlapping with the N and AC terminals The terminal part of each is configured to have the same plate thickness as each terminal, so that the terminal connection between the N terminal and the AC terminal and the terminal part of the conductive bus bar structure can be quickly performed by resistance welding. It is.
Further, according to the terminal connection method for a vehicular rotating electrical machine according to the present invention, the terminal portion of the conductive bus bar structure composed of one conductor bus bar in which a conductor having a plate thickness larger than that of the P terminal is overlapped with the P terminal. Since touch start TIG welding and terminal joining are combined, current and voltage applied to the P terminal are smaller than normal arc welding by touch start TIG welding, and damage the components of the power semiconductor module. The terminal portion of the conductive bus bar structure having the same plate thickness as that of the N terminal and the AC terminal can be accurately connected to the terminal portion of the P bus terminal and the terminal portion of the conductive bus bar structure. And the AC terminal and the terminal of the conductive bus bar structure by mutual resistance welding and terminal joining. If it is intended to quickly performed by resistance welding.

It is a longitudinal cross-sectional view which shows the rotary electric machine which concerns on Embodiment 1 of this invention. It is the figure which looked at the state before attachment of the control board of the power converter device in the rotary electric machine which concerns on Embodiment 1 of this invention from the rear side. It is an electric circuit diagram of the rotary electric machine which concerns on Embodiment 1 of this invention. FIG. 3 is a cross-sectional view taken along the arrow I-I in FIG. 2. It is the figure which looked at the state before attachment of the control board of the power converter device in the rotary electric machine which concerns on Embodiment 2 of this invention from the rear side.

Preferred embodiments of the present invention will be described below with reference to the drawings.
Embodiment 1 FIG.
1 is a longitudinal sectional view showing a rotating electrical machine according to Embodiment 1 of the present invention, and FIG. 2 is a diagram (a control board is shown) of a power conversion device in the rotating electrical machine according to Embodiment 1 of the present invention as viewed from the rear side. 3) FIG. 3 is an electric circuit diagram of the rotary electric machine according to Embodiment 1 of the present invention.
1 to 3, the rotating electrical machine 1 is an electromechanical integrated rotating electrical machine having a rotating electrical machine body 2 and a power conversion device 3 disposed in the rotating electrical machine body 2. In this example, the rotating electrical machine 1 is an AC generator motor (motor generator).
The rotating electrical machine main body 2 is disposed inside the cylindrical stator 4 and the stator 4, and a rotor 5 that can rotate with respect to the stator 4, and a case (support body) that supports the stator 4 and the rotor 5. ) 6.

The case 6 includes a front bracket 7 and a rear bracket 8 that sandwich the stator 4 in the axial direction of the rotor 5, and a plurality of fastening bolts 9 that tighten the space between the front bracket 7 and the rear bracket 8. The front bracket 7 and the rear bracket 8 are made of metal.
The stator 4 has a cylindrical stator core 10 fixed to each of the front bracket 7 and the rear bracket 8, and a stator winding (armature winding) 11 provided on the stator core 10. ing.
The rotor 5 includes a rotating shaft 12 disposed on the axis of the rotor 5, a rotor core 13 fixed to an intermediate portion of the rotating shaft 12, and a rotor winding (field) provided on the rotor core 13. Magnetic winding) 14.

The rotating shaft 12 passes through the front bracket 7 and the rear bracket 8. The rotating shaft 12 is rotatably supported by the front bracket 7 and the rear bracket 8 via bearings 15.
The outer peripheral portion of the rotor core 13 faces the inner peripheral portion of the stator 4. The rotor core 13 is provided with a cooling fan 16 for blowing air that is rotated integrally with the rotor 5.
A pulley 17 is fixed to the end of the rotating shaft 12 on the front bracket 7 side. The pulley 17 is wound around a transmission belt (not shown) that interlocks with the rotating shaft of the engine. Further, on the rear bracket 8 side of the rotary shaft 12, a rotational position detection sensor 18 that generates a signal corresponding to the rotational position of the rotary shaft 12 and a plurality of slip rings 19 electrically connected to the rotor winding 14. Is provided. The slip ring 19 is an annular conductive member that surrounds the outer periphery of the rotating shaft 12.

  The slip ring 19 is in contact with a conductive brush 20 for supplying a field current for generating a magnetic field in the rotor 5 to the slip ring 19. The rear bracket 8 is provided with a brush holder 21 that guides the brush 20 in a direction in which the brush 20 comes in contact with or separates from each slip ring 19. The brush holder 21 is provided with a pressing spring 22 that individually biases each brush 20 in a direction in contact with each slip ring 19. Each brush 20 is pressed against the slip ring 19 by the urging force of the pressing spring 22. When the rotor 5 is rotated, the slip ring 19 is slid with respect to the brush 20.

The power converter 3 is supported by the rear bracket 8 and is covered with a cover 39 made of insulating resin.
The power converter 3 is electrically connected to the stator winding 11 and adjusts the power from the power semiconductor module 23 and the battery 30 (DC power supply) and supplies the field current to the rotor winding 14 as a field current. A control board 25 for controlling each of the module 24, a heat sink 29 having cooling fins 34 on which the modules are disposed, and a conductive bus bar structure 31, a power semiconductor module 23 and a field module 24 to which the modules are connected; Have.
The field module 24 is manufactured by molding a group of semiconductor elements 32 through which a field current is passed. The field module 24 includes a battery terminal 24 a, a ground terminal 24 b, a field winding connection terminal 24 c, and a signal terminal 24 d. It is fixed.
The power semiconductor module 23 is fixed to the heat sink 29 similarly to the field module 24.

In addition, the power semiconductor module 23 is manufactured by molding an element pair in which two switching elements 36 for passing a stator current are connected in series, and connected to a P terminal 23a, an N terminal 23b, and a stator winding. AC terminal 23c which is an alternating current input / output and a signal terminal 23d. The P terminal 23a, the N terminal 23b, and the AC terminal 23c constitute a power terminal. The signal terminal 23 d is a terminal connected to the contact point between the source of one semiconductor element 36 and the drain of the other semiconductor element 36 connected in series, and a terminal connected to the gate electrode of each semiconductor element 36.
A control board 25 for controlling the power semiconductor module 23 is disposed above the power semiconductor module flat surface on the side opposite to the heat sink 29. The control board 25 includes a signal terminal 23d of the power semiconductor module 23, a field The signal terminal 24d of the magnetic module, the signal terminal 18a of the rotational position detection sensor 18, the signal terminal of the external connection connector 27, and the like are electrically connected.
The conductive bus bar structure 31 is manufactured by molding a power input / output terminal 26 to which each power semiconductor module 23 is connected, an N terminal 28 to which an N terminal 23b is connected, and an AC terminal 33 to which an AC terminal 23c is connected. ing.

  That is, a power converter of a rotating electrical machine for a vehicle that is an object of the present invention includes a transistor element that switches power supplied from a power source and a diode element that circulates power from a load, and the transistor element and The diode element includes a plurality of power semiconductor modules having a plurality of main terminals serving as input terminals and output terminals and a signal terminal for driving the transistor elements, and the plurality of power semiconductor modules are arranged around the rotation axis of the rotating machine. A mounting portion having a mounting surface to be mounted; and a conductive bus bar structure having a terminal portion for connecting the power source or load and each of the main terminals.

Next, operation | movement of the power converter device 3 is demonstrated.
In the control board 25, the field module 24 and the power are controlled based on the rotational position signal of the rotor 5 from the rotational position detection sensor 18 and signal information from an external device (for example, an engine control unit) through the external connector 27. The semiconductor module 23 is controlled.
When the engine is started, DC power from the battery 30 is supplied to each of the power semiconductor module 23 and the field module 24. In the field module 24, an operation for adjusting the DC power from the battery 30 to the field current is performed under the control of the control board 25. The field current from the field module 24 is supplied to the rotor winding 14 via the brush 20 and the slip ring 19. As a result, a DC magnetic field is generated in the rotor 5.

On the other hand, the power semiconductor module 23 performs a switching operation under the control of the control board 25. Thereby, the DC power from the battery 30 is converted into AC power. The AC power converted by the power semiconductor module 23 is supplied to the stator winding 11. Thereby, a rotating magnetic field is generated in the stator 4 and the rotor 5 is rotated. The pulley 17 is rotated by the rotation of the rotor 5 and the engine is started.
After the engine is started, the rotational power from the engine is transmitted to the pulley 17. As a result, the rotor 5 is rotated and AC power is induced in the stator winding 11. At this time, the power semiconductor module 23 performs a switching operation under the control of the control board 25. Thereby, AC power induced in the stator winding 11 is converted into DC power. Thereafter, the DC power from the power semiconductor module 23 is charged in the battery 30.

Next, a wiring structure between power semiconductor module 23 and conductive bus bar structure 31 in the first embodiment of the present invention will be described with reference to FIG.
4 is a cross-sectional view taken along the line II in FIG. 2 and shows details of the terminal structure of the power semiconductor module 23.

The P terminal 23a of the power semiconductor module 23 extends laterally from the side surface, protrudes in a direction parallel to the power semiconductor module mounting surface, and is bent in a direction perpendicular to the mounting surface. In the touch start TIG welding, the wide surface of the P terminal 23a and the surface of the terminal portion of the power input / output terminal 26 of the conductive bus bar structure 31 are overlapped, and the electrode tip of the welding torch is brought into contact with the welded portion and then separated. It is joined and used as a joint part (welded part).
On the other hand, the N terminal 23b and the AC terminal 23c of the power semiconductor module 23 extend laterally from the side surface in the same manner as the P terminal 23a, and protrude in a direction parallel to the power semiconductor module mounting surface. The N terminal 23b and the AC terminal 23c are widened and the terminal surfaces of the N terminal 28 and the AC terminal 33 of the conductive bus bar structure 31 are sandwiched. It is resistance welding that is energized and heated.
4 shows the AC terminal 23c, the N terminal 23b has the same configuration.

According to the first embodiment, the following effects can be obtained.
First, the P terminal 23a and the current input / output terminal 26 of the conductive bus bar structure 31 will be described. Since the P terminal 23a is joined by touch start TIG welding, the current and voltage flowing through the P terminal 23a are smaller than those of normal arc welding, and the switching element is hardly damaged.
The current input / output terminal 26 is composed of one bus bar, and the P terminals 23a of the plurality of power semiconductor modules 23 are connected to the one bus bar, so that the plate thickness is thicker than the P terminal 23a (thicker). ) A conductor can be used, and the calorific value of the conductor through which a large current flows can be reduced.
Furthermore, since the P terminal 23a is disposed on the inner peripheral side of the rotating shaft 12 of the rotor 5, the length of the current input / output terminal 26 is short, and the resistance value of the conductor can be lowered.

Next, the N terminal 23b and the N terminal 28 of the conductive bus bar structure 31 will be described. Since the N terminal 28 includes a plurality of bus bars, and the N terminals 23b of the plurality of power semiconductor modules 23 are connected to the plurality of bus bars, a conductor having the same thickness as that of the N terminal 23b can be used.
Further, since it is a conductor having the same thickness as that of the N terminal 23b, it is disposed on the outer peripheral side of the rotor 5 away from the rotating shaft 12, and unlike the welding of the P terminal 23a, the difference in the heat capacity of the welded portion is small. By employing welding, the joining time can be made shorter than the time for joining the P terminals 23a.
Next, the AC terminal 23c and the AC terminal 33 of the conductor bus bar structure 31 will be described. The AC terminal 33 includes a plurality of bus bars, and the AC terminals 23c of the plurality of power semiconductor modules 23 are connected to the plurality of bus bars. Therefore, a conductor having the same plate thickness as that of the AC terminals 23c can be used.
Moreover, since it is a conductor having the same thickness as that of the AC terminal 23c, disposed on the outer peripheral side of the rotor 5 away from the rotating shaft 12, resistance welding can be performed, and the joining time can be made shorter than the time for joining the P terminal 23a. .

Embodiment 2. FIG.
FIG. 5 is a view (control board not shown) of power converter 3 in rotary electric machine 1 according to Embodiment 2 of the present invention viewed from the rear side.
As shown in FIG. 5, the power semiconductor module 23 in the second embodiment is arranged in a substantially U shape around the rotation axis of the rotating electrical machine, and accordingly, the terminal junction position of the power semiconductor module 23 is also a center. A letter shape is formed. That is, the current input / output terminal 26 connected to the P terminal 23a is arranged in a substantially square shape, the field module 24 is disposed on one side thereof, and the power semiconductor module 23 is formed in a substantially U shape on the other three sides. Is arranged. By adopting such a configuration, the N terminal 23b and the AC terminal 23c arranged on the outside can also be arranged linearly.
Thus, in the configuration of the second embodiment, the welding positions and the torch are less moved and the workability can be improved by arranging the joining positions in a straight line.

DESCRIPTION OF SYMBOLS 1 Rotating electrical machine, 2 Rotating electrical machine main body, 3 Power converter, 4 Stator, 5 Rotor, 6 Case (support), 7 Front bracket, 8 Rear bracket, 9 Fastening bolt, 10 Stator iron core, 11 Stator winding Wire, 12 Rotating shaft, 13 Rotor core, 14 Rotor winding, 15 Bearing, 16 Cooling fan, 17 Pulley, 18 Rotation position detection sensor, 18a Signal terminal, 19 Slip ring, 20 Brush, 21 Brush holder, 22 Press Spring, 23 power semiconductor module, 23a P terminal, 23b N terminal, 23c AC terminal, 23d signal terminal, 24 field module, 24a battery terminal, 24b ground terminal, 24c field winding connection terminal, 24d signal terminal, 25 control PCB, 26 Current input / output terminal 26a, terminal surface, 27 connector, 28 N terminal, 29 heat sink, 30 battery, 31 conductive bus bar structure, 32 semiconductor element (field module), 33 AC terminal, 34 cooling fin, 36 semiconductor element (power semiconductor) module).

Claims (4)

A transistor element that switches power supplied from a power source and a diode element that circulates power from a load, and the transistor element and the diode element include a plurality of power terminals and transistor elements serving as an input terminal and an output terminal. A plurality of power semiconductor modules having signal terminals for driving; a mounting portion having a mounting surface for mounting the plurality of power semiconductor modules so as to be arranged around the rotation axis of the rotating electrical machine; and the power source or the load. And a conductive bus bar structure having a terminal portion for connecting each of the power terminals and the power terminals, wherein the power terminals include a P terminal and an N terminal connected to the power supply side, and fixing of the rotating electric machine. AC terminal that inputs and outputs alternating current to and from the slave windings, laterally from each side of the power semiconductor module Extending and projecting in a direction parallel to the mounting surface, a tip portion thereof is bent in a direction perpendicular to the mounting surface, and the terminal portion of the conductive bus bar structure includes the power terminal. Projecting in a direction parallel to the portion bent in the vertical direction, and the portion bent in the vertical direction of the P terminal and the terminal portion of the conductive bus bar structure are overlapped and touch start TIG welded, The portion bent in the vertical direction of the N terminal and the AC terminal and the terminal portion of the conductive bus bar structure are overlapped and resistance-welded, and the conductive bus bar connected to the P terminal The terminal portion of the structure is composed of one conductor bus bar, a conductor having a plate thickness larger than that of the P terminal is used, and the conductive bus bar structure to which the N terminal and the AC terminal are connected is used. Rotating electrical machine for a vehicle, wherein the child unit has respective terminals and the plate thickness is the same.   2. The vehicle according to claim 1, wherein the power semiconductor module is disposed on a heat sink so as to surround a rotating shaft, and a P terminal is disposed closer to the inner periphery, and an N terminal and an AC terminal are disposed closer to the outer periphery. Rotating electric machine.   3. The rotating electrical machine for a vehicle according to claim 1, wherein the power semiconductor module is disposed in a substantially U-shape so as to surround the rotating shaft. Power conversion in which a plurality of power semiconductor modules having a P terminal and an N terminal connected to the power source side, an AC terminal for inputting / outputting an alternating current between the stator windings, and a signal terminal are arranged around the rotation axis It is a method of connecting a device and a conductive bus bar structure having a terminal part for connecting a power source or a load and each of the power terminals, the terminal part of the conductive bus bar structure connected to the P terminal As one conductor bus bar in which a conductor having a plate thickness larger than that of the P terminal is used, the P terminal and the terminal portion of the conductive bus bar structure are overlapped and subjected to touch start TIG welding, and the N terminal and the AC and terminal portions of the conducting busbar structure terminal is connected to the respective terminals and the plate thickness same, and a terminal portion of the N terminal and said AC terminal and the conductive bus bar structure Terminal connecting method of a vehicular rotary electric machine, characterized in that the resistance welding combined ne.

Images