JP5754646B2 - Rotating electric machine for vehicles - Google Patents

Description

  The present invention relates to a vehicular rotating electrical machine mounted on a passenger car, a truck, or the like.

  2. Description of the Related Art Conventionally, there has been known a rotating electrical machine in which components such as switching elements constituting an electric module are sequentially assembled on a radiator (see, for example, Patent Document 1). Specifically, a plurality of electronic modules are mounted on a heat radiator, and a signal interconnection component is further mounted thereon.

Special table 2008-543266 gazette

  By the way, in the configuration disclosed in Patent Document 1 described above, since the electronic module and the signal interconnection component are mounted on the radiator, the exposed portion of the terminal of the electronic module is sealed with a thermosetting sealing material. Then, it is necessary to heat the whole including the heat radiator having a large heat capacity together to maintain a constant temperature, and there is a problem that it takes time to manufacture.

  In addition, multiple wires and base plates are individually attached to input / output signals between electronic modules or with other parts, resulting in a large number of parts and complicated assembly work. . Further, the positioning of the electronic module is performed using positioning pins or the like, and there is a problem that the structure and the assembling process are complicated because a dedicated component for positioning is required to increase the positioning accuracy of the module.

  The present invention was created in view of the above points, and an object of the present invention is to provide a vehicular rotating electrical machine that can shorten the time required for manufacturing by shortening the thermosetting time of the sealing material of the module. It is to provide. Another object of the present invention is to provide a rotating electrical machine for a vehicle that can easily increase the positioning accuracy of a module, can reduce the number of parts, and can simplify the structure and assembly process.

In order to solve the above-described problems, a rotating electrical machine for a vehicle according to the present invention includes a rotor that is magnetized by energization of a field winding, a stator that is disposed to face the rotor, a rotor and a stator, The frame that holds the stator and the alternating current induced in the stator winding provided in the stator is converted into a direct current and supplied to the battery, or the direct current supplied from the battery is converted into an alternating current and the stator In a rotating electrical machine for a vehicle that includes a power converter that supplies a winding, the power converter connects a plurality of switching modules each having a switching element and the switching module to each other and connects the switching module to other components. The switching module has a plurality of connection terminals for connecting to other components, and one of the plurality of connection terminals. There are exposed from the side face of the module body, when assembled with the switching module to the terminal block, a recess formed in the side surface and part of the surface of the terminal block of the module body, thermosetting sealing When the sealing material is filled, a recess is formed that defines a closed space in which the sealing material can be held before curing. After the switching module is assembled to the terminal block, bonding between them and filling and curing of the sealing material are performed. As a result, an assembly of the power converter is formed in a state where a part of the plurality of connection terminals exposed from the side surface of the module body is covered with the sealing material, and the assembly is assembled to the frame.

  Since the sealing material can be heat-cured in an assembly that combines the terminal block and the switching module, it is not necessary to heat the heat-dissipating member or frame with a large heat capacity at the same time. The time required for manufacturing the converter and the rotating electrical machine for the vehicle can be shortened. Moreover, since the power converter can be prepared as one part as an assembly in which the switching module and the terminal block are combined, the number of parts can be reduced and the structure and assembly process of the rotating electrical machine for the vehicle can be simplified. Can be realized.

  Further, when the switching module described above is assembled to the terminal block, it is desirable that the module main body be positioned by bringing a part of the terminal block into contact with a part of the module main body. This eliminates the need for separate positioning components when positioning the switching module, and simplifies the structure and assembly process of the power converter. In addition, when the switching module is assembled to the terminal block, positioning can be easily performed by simply contacting a part thereof, and stable positional accuracy can be ensured.

  In addition, by placing a part of the terminal block in contact with a part of the module body, the module body is positioned and a recess is formed, and a part of the connection terminal in the module body is exposed inside the recess. It is desirable that the surface is arranged. By adopting a shape that serves both as a positioning structure and a sealing structure, the structure can be simplified and a terminal block having a shape that is easy to manufacture can be realized.

  Moreover, it is desirable that the terminal block described above is integrally formed including a wiring terminal corresponding to each of a battery terminal connected to the battery and a control signal terminal where at least one of input and output of the control signal is performed. By including one terminal block and wiring with a battery terminal or the like in the terminal block, the number of parts can be reduced and the structure and assembly process can be simplified, thereby realizing a significant cost reduction.

It is a figure which shows the structure of the generator for vehicles of one Embodiment. It is a figure which shows the structure of a switching module. It is the external appearance perspective view which looked at the generator for vehicles from the rear side slanting back. It is the figure which looked at the generator for vehicles from the rear side. It is the external appearance perspective view which looked at the generator for vehicles which removed the rear cover from the rear side slanting back. It is the figure which looked at the generator for vehicles which removed the rear cover from the rear side. It is a fragmentary sectional view of the rear side of the generator for vehicles. It is a top view which shows the mounting state inside a switching module. It is a top view of a switching module. It is a perspective view of a switching module. It is a perspective view of a switching module. It is a partial expanded side view of a switching module. It is a top view of a terminal block. It is a reverse view of a terminal block. It is a perspective view of a terminal block. It is a reverse view of a power converter. It is a top view of a rear frame. It is a perspective view of a rear frame.

  Hereinafter, a vehicular generator according to an embodiment to which a vehicular rotating electrical machine of the present invention is applied will be described with reference to the drawings. FIG. 1 is a diagram illustrating a configuration of a vehicle generator according to an embodiment. As shown in FIG. 1, the vehicle generator 1 according to the present embodiment includes two stator windings 2 and 3, a field winding 4, two switching module groups 5 and 6, a power generation control device 7, and a terminal block. 10 is comprised.

  One stator winding 2 is a multiphase winding (for example, a three-phase winding composed of an X-phase winding, a Y-phase winding, and a Z-phase winding), and is wound around a stator core (not shown). It is disguised. Similarly, the other stator winding 3 is a multi-phase winding (for example, a three-phase winding composed of a U-phase winding, a V-phase winding, and a W-phase winding). The stator winding 2 is wound at a position shifted by 30 degrees in terms of electrical angle. In the present embodiment, a stator 20 (FIG. 3) is constituted by these two stator windings 2 and 3 and the stator core.

  The field winding 4 is wound around a field pole (not shown) disposed opposite to the inner peripheral side of the stator core to constitute a rotor. The rotor and the stator 20 are concentrically opposed to each other. By passing an exciting current through the field winding 4, the field pole is magnetized. The stator windings 2 and 3 generate an alternating voltage by a rotating magnetic field generated when the field pole is magnetized.

  One switching module group 5 is connected to one stator winding 2 to form a three-phase full-wave rectifier circuit (bridge circuit) as a whole, and the alternating current induced in the stator winding 2 is converted into direct current. Convert to current. The switching module group 5 includes a number of switching modules 5X, 5Y, and 5Z corresponding to the number of phases of the stator winding 2 (three in the case of a three-phase winding). The switching module 5 </ b> X is connected to the X-phase winding included in the stator winding 2. The switching module 5Y is connected to the Y-phase winding included in the stator winding 2. The switching module 5Z is connected to the Z-phase winding included in the stator winding 2.

  The other switching module group 6 is connected to the other stator winding 3 to form a three-phase full-wave rectifier circuit (bridge circuit) as a whole, and the alternating current induced in the stator winding 3 is converted into direct current. Convert to current. The switching module group 6 includes a number of switching modules 6U, 6V, and 6W corresponding to the number of phases of the stator winding 3 (three in the case of a three-phase winding). The switching module 6U is connected to a U-phase winding included in the stator winding 3. The switching module 6V is connected to a V-phase winding included in the stator winding 3. Switching module 6 </ b> W is connected to a W-phase winding included in stator winding 3.

The power generation control device 7 is an excitation control circuit that controls the excitation current that flows in the field winding 4 connected via the F terminal, and adjusts the excitation current to adjust the output voltage of the vehicle generator 1 (each output voltage) V _B of switching module is controlled to be regulated voltage Vreg. For example, the power generation controller 7 stops the supply of the exciting current to the field winding 4 when the output voltage V _B is higher than the regulated voltage Vreg, it is lower than the regulated voltage Vreg output voltage V _B When the exciting current is supplied to the field winding 4 at this time, the output voltage V _B is controlled to become the adjustment voltage Vreg. Further, the power generation control device 7 determines the number of rotations of the rotor based on the voltage of one of the stator windings connected to the P terminal (detection terminal for phase voltage detection) (for example, W phase). The excitation current supplied to the field winding 4 when the rotation stop is detected is stopped or reduced. Furthermore, the power generation control device 7 is connected to the ECU 8 (external control device) via an ERR terminal as a control signal terminal and a communication line, and bidirectional serial communication with the ECU 8 (for example, LIN (Local Interconnect)). LIN communication using the Network) protocol) and transmitting or receiving communication messages such as error information.

  The terminal block 10 connects the switching modules 5X, 5Y, and 5Z, connects the switching modules 6U, 6V, and 6W, and connects the switching module 5X and other components (for example, the power generation control device 7). . A specific example of the terminal block 10 will be described later. The terminal block 10 and the two switching module groups 5 and 6 constitute a power converter 11.

  The vehicular generator 1 according to the present embodiment has such a configuration. Next, details of the switching module 5X and the like will be described.

  FIG. 2 is a diagram illustrating a configuration of the switching module 5X. The other switching modules 5Y, 5Z, 6U, 6V, and 6W have the same configuration. As shown in FIG. 2, the switching module 5 </ b> X includes two MOS transistors 50 and 51 and a control circuit 54.

  The MOS transistor 50 has a source connected to the X-phase winding of the stator winding 2 via the P terminal, and a drain connected to the electrical load 18 and the positive terminal of the battery 9 via the BATT terminal (battery terminal). This is a switching element of the upper arm (high side). The MOS transistor 51 is a lower-arm (low-side) switching element whose drain is connected to the X-phase winding via the P terminal and whose source is connected to the negative terminal (earth) of the battery 9 via the GND terminal. . A series circuit composed of these two MOS transistors 50 and 51 is arranged between the positive terminal and the negative terminal of the battery 9, and an X-phase winding is connected to the connection point of these two MOS transistors 50 and 51. A diode is connected in parallel between the source and drain of each of the MOS transistors 50 and 51. This diode is realized by a parasitic diode (body diode) of the MOS transistors 50 and 51, but a diode as another component may be further connected in parallel. Note that at least one of the upper arm and the lower arm may be configured using a switching element other than a MOS transistor.

  The control circuit 54 determines the timing for starting and ending the rectifying operation, setting the on / off timing of the MOS transistors 50 and 51 for performing the rectifying operation, the MOS transistor 50 corresponding to the on / off timing, 51, a self-diagnosis operation for judging the presence or absence of abnormality by monitoring the driving operation, voltage, current or temperature.

  For example, the F terminal as a control signal terminal provided in the switching module 5X is connected to the F terminal of the power generation control device 7, and the control circuit 54 supplies the field winding 4 from the F terminal of the power generation control device 7. The presence or absence of the PWM signal (excitation current) is monitored, and when the output of the PWM signal continues for a predetermined time (for example, 30 μsec), the MOS transistors 50 and 51 are turned on / off to start the rectification operation. The control circuit 54 turns off the MOS transistors 50 and 51 when the output of the PWM signal supplied from the F terminal of the power generation control device 7 to the field winding 4 is interrupted for a predetermined time (for example, 1 second). The rectifying operation is terminated. Further, when an abnormality occurs, the control circuit 54 outputs a signal notifying the occurrence of an abnormality from an ERR terminal (error terminal) as a control signal terminal. For example, the ERR terminal of each switching module 5X or the like is connected to one common signal line, and when a signal notifying the occurrence of abnormality is output from any one of the switching modules 5X or the like to the power generation control device 7 performs a predetermined process (for example, notification to the ECU 8) in response to the occurrence of an abnormality.

  Next, specific structures of the vehicle generator 1, the power converter 11, and the switching module 5X will be described. The switching modules 5Y, 5Z, 6U, 6V, and 6W other than the switching module 5X have the same structure, and detailed description thereof is omitted.

  FIG. 3 is an external perspective view of the vehicular generator 1 as viewed obliquely from the rear side. FIG. 4 is a view of the vehicle generator 1 as seen from the rear side. FIG. 5 is an external perspective view of the vehicular generator 1 with the rear cover removed, as viewed from the rear side obliquely rearward. FIG. 6 is a view of the vehicle generator 1 with the rear cover removed as seen from the rear side. FIG. 7 is a partial cross-sectional view of the rear side of the vehicle generator 1.

  As shown in these figures, the vehicle generator 1 includes a stator 20, a rotor 30 (FIG. 7), a front frame 22, a rear frame 24, a rear cover 26, a power generation control device 7, a power converter 11, and a brush device. 12 is comprised.

  The front frame 22 and the rear frame 24 hold the stator 20 sandwiched from both sides, and accommodate a rotor 30 that is disposed facing the inner side of the stator 20 so as to be rotatably supported. The brush device 12 supplies an excitation current from the battery 9 or the power converter 11 to the field winding 4 of the rotor 30.

  The rear cover 26 covers and protects the power generation control device 7, the power converter 11, and the brush device 12 that are attached to the outside of the rear frame 24. In the rear cover 26, a plurality of air inlets 27 arranged radially and concentrically at positions facing the power converter 11 on the axial end surface are positions corresponding to the brush device 12 (example shown in FIG. 4). Then, an intake port 28 is formed at a position adjacent to the brush device 12 and at an intermediate position between the brush device 12 and the voltage control device 7.

  Further, the power converter 11 is mounted on the end face in the axial direction of the rear frame 24 in a state in which the opposing surface is in direct contact, and the rear frame 24 is used as a heat radiating member that radiates heat generated by the power converter 11. . For this reason, the axial direction end surface of the rear frame 24 is formed in a shape suitable for heat dissipation, and details thereof will be described later.

  The rotor 30 includes a cooling fan 32 on an end surface in the axial direction. When the cooling fan 32 rotates together with the rotor 30, cooling air is taken in from a plurality of air intakes 27 provided in the rear cover 26 and gaps between the rear cover 26 and the rear frame 24. The cooling air passes between the rear frame 24 and the power converter 11 (recess 242), and is then introduced into the rear frame 24 through the air inlet 246 formed on the inner diameter side of the recess 242, and is wound by the stator. After the wires 2 and 3 are cooled, they are discharged to the outside of the rear frame 24. When the cooling fan 32 rotates together with the rotor 30, the cooling air is taken into the rear cover 26 from the intake port 28 provided in the rear cover 26. Since this cooling air flows in the vicinity of the brush device 12 and the voltage control device 7, these can be efficiently cooled, and when the brush wear powder is discharged using the cooling air, the discharge effect can be enhanced. .

  Next, details of the structure of the switching module 5X and the like will be described. FIG. 8 is a plan view showing a mounting state inside the switching module 5X. FIG. 9 is a plan view of the switching module 5X. 10 and 11 are perspective views of the switching module 5X. FIG. 12 is a partially enlarged side view of the switching module 5X. The reference numerals (P, BATT, GND, F, ERR) attached to the terminals shown in FIGS. 8 to 12 correspond to the terminals assigned the same reference numerals in FIG.

  In FIG. 8, the high-side MOS transistor 50 and the low-side MOS transistor 51 are formed in the same size by the same manufacturing method. Each of the MOS transistors 50 and 51 and the control circuit 54 are mounted on a lead frame, and a heat sink 56 for heat dissipation is provided immediately below the MOS transistors 50 and 51 that generate a large amount of heat. The switching module 5X is formed as a semiconductor package in which all components other than the heat sink 56 are sealed with a mold resin. From the module body 60 attached with the heat sink 56 exposed, a P terminal, a BATT terminal, and a GND terminal A part of the connection terminal 58 corresponding to the F terminal and the ERR terminal protrudes. Among them, the connection terminal 58 corresponding to the GND terminal has the same terminal shape as the heat sink 56, and is screwed at the same time when the heat sink 56 is screwed to the rear frame 24 to be electrically connected to the rear frame 24. Connection is made.

  As shown in FIG. 10 or FIG. 11, in addition to the connection terminal 58, a plurality of electrodes 59 are exposed on the side surface of the module body 60 (hereinafter, these electrodes 59 are referred to as “exposed electrodes”). . When the connection terminal 58 is insert-molded, an electrode protruding from the module main body 60 is used for positioning and fixing, and a trace of cutting the protruding portion after the resin molding ends remains as a part of the exposed electrode 59. In addition, when the switching module 5X is manufactured, an electrode protruding from the module main body 60 is used to perform a function test or the like, and a trace of cutting the protruding portion after the test ends remains as another exposed electrode 59.

  Incidentally, the connection terminal 58 corresponding to the P terminal protruding from the module main body 60 has a shape that relieves stress generated by connecting the lead wire 55 drawn from the X-phase winding of the stator winding 2. Hereinafter, the connection terminal 58 corresponding to the P terminal will be described as “connection terminal 58P” in order to distinguish it from other connection terminals 58.

  As shown in FIGS. 9 to 12, the connection terminal 58 </ b> P includes a connection portion 580 for connecting to a lead wire 55 as a lead portion drawn from the X-phase winding of the stator winding 2, and the connection portion 580. It has the connection part 582 which connects these between the module main bodies 60. The connecting portion 580 and the connecting portion 582 include a portion embedded in the module main body 60 and are formed by press-molding a metal plate material.

  The connecting portion 580 has a wide rectangular shape in which the length along the extending direction of the lead wire 55 is longer in the direction perpendicular to the extending direction. In FIG. 12, when the height direction of the connecting portion 58 is “vertical direction” and the direction perpendicular to the height direction is “horizontal direction”, the direction along the extending direction of the lead line 55 is the vertical direction. The part 580 has a horizontally long rectangular shape. The length in the horizontal direction of the connection portion 580 is set to a value longer than a plurality of times the width of the lead line 55. Further, the flat connecting portion 580 having a horizontally long rectangular shape is folded back in the middle in the longitudinal direction to sandwich the lead wire 55, and then the space between them is welded.

  The connecting portion 582 has a rectangular shape connected to a part of the connecting portion 580, and includes a bend structure that is bent in an S shape along the longitudinal direction. By providing the bend structure, it is possible to absorb and relieve repetitive stress mainly applied in the extending direction of the lead wire 55.

  The above-described process of welding the lead wire 55 to the connection terminal 58P is performed when the power converter 11 is assembled to the rear frame 24 after the switching module 5X and the like are assembled to the terminal block 10 to complete the power converter 11. Done.

  Next, a detailed example of the terminal block 10 and a specific example in which the switching module 5X and the like are assembled to the terminal block 10 will be described. FIG. 13 is a plan view of the terminal block 10. FIG. 14 is a rear view of the terminal block 10. FIG. 15 is a perspective view of the terminal block 10. FIG. 16 is a rear view of the power converter 11 and shows the power converter 11 as an assembly in which six switching modules 5X and the like are assembled to the terminal block 10 shown in FIG.

  The terminal block 10 has six storage recesses 100 for storing six switching modules 5X, 5Y, 5Z, 6U, 6V, and 6W on one side (rear power converter on the rear frame 24). 11 on the side facing the axial end surface of the rear frame 24). Further, from the terminal block 10, one wiring terminal 102 protrudes from the inner diameter side and two wiring terminals 104 protrude from the bottom surface of the housing recess 100 corresponding to each switching module 5 </ b> X and the like.

  As described above, the connection terminal 58 corresponding to the P terminal, BATT terminal, GND terminal, F terminal, and ERR terminal protrudes from the module body 60 such as the switching module 5X, and the connection terminal 58 corresponding to the BATT terminal is provided. A connection terminal 58 connected to the wiring terminal 102 and corresponding to the F terminal and the ERR terminal is connected to each of the two wiring terminals 104. These connections are made by welding, but some may be made by soldering.

  By the way, the switching module 5X and the like are assembled to the terminal block 10 after the module main body 60 is assembled in each storage recess 100, the corresponding connection terminal 58 and the wiring terminals 102 and 104 are joined, and further formed around the module main body 60. The filling recess is filled with a thermosetting sealing material and cured.

  As shown in FIG. 14, each storage recess 100 of the terminal block 10 has three locations where a part of the module main body 60 comes into contact when the module main body 60 such as the switching module 5 </ b> X is incorporated in the storage recess 100. Positioning portions S1, S2, and S3 are included. These three positioning portions S 1, S 2, S 3 abut against a part of the module main body 60, so that the position of the module main body 60 in the housing recess 100 is constrained. As a result, the connection terminal 58 to be joined and the wiring terminals 102 and 104 are aligned, and welding or the like in the next process becomes easy.

  Further, in the state in which the module main body 60 is incorporated in the storage recess 100 in this way, as shown in FIG. 16, the filling recesses 106 and 108 are formed at two locations by the side surface of the module main body 60 and the side surface of the storage recess 100. Is formed. The two filling recesses 106 and 108 are formed when the three positioning portions S 1, S 2 and S 3 of the terminal block 10 are brought into contact with a part of the module main body 60.

  The internal space of one filling recess 106 includes an F terminal protruding from one side of the module body 60, a connection terminal 58 corresponding to the ERR terminal, and an exposed electrode 59 (FIG. 11). In this filling recess 106, a closed space in which the sealing material can be held before curing is formed by the side surface of the module body 60 and the side surface of the housing recess 100, and is heated after filling the sealing material. Thus, both the exposed portion including the joint portion between the connection terminal 58 and the wiring terminals 102 and 104 and the exposed electrode 59 are covered with the sealing material.

  The other filling recess 108 includes an exposed electrode 59 (FIG. 10) protruding from the other side surface of the module body 60. The filling recess 108 is similar to the filling recess 106 in that a closed space capable of holding the sealing material before curing is formed by the side surface of the module body 60 and the side surface of the storage recess 100. The exposed electrode 59 is covered with a sealing material by heating and curing after filling with the stopper.

  In this manner, the power converter 11 is formed by assembling the six switching modules 5X and the like to the terminal block 10. After the power converter 11 is assembled to the rear frame 24, the lead wires 55 drawn from the phase windings of the stator windings 2 and 3 are connected to the connection terminals 58 corresponding to the P terminals of the switching modules 5X and the like. The

  In the above description, all the switching modules 5X and the like are wired in the same way, but actually, the P terminal of the switching module 6W arranged at the end as shown in FIG. Connection is made. Specifically, the terminal block 10 includes three wiring terminals 101A, 101B, and 101C that are mutually connected inside. Among these, the wiring terminal (third connection terminal) 101 </ b> A is connected to a lead wire 55 drawn from the W-phase winding of the stator winding 6. The wiring terminal (first connection terminal) 101B is arranged at a position corresponding to the connection terminal 58 corresponding to the P terminal of the switching module 6W, and is connected to the connection terminal 58. Furthermore, the wiring terminal 101C (second connection terminal) is connected to the P terminal of the power generation control device 7 when the power generation control device 7 is assembled.

  By using such wiring terminals 101A, 101B, 101C, the phase voltage of the W phase of the stator winding 6 can be taken into both the switching module 6W and the power generation control device 7, and the terminal of the switching module 6W. The shape and arrangement can be made the same as other switching modules 5X and the like, and the number of parts can be reduced.

  Next, the shape suitable for heat dissipation of the axial end surface of the rear frame 24 to which the power converter 11 is assembled will be described. FIG. 17 is a plan view of the rear frame 24. FIG. 18 is a perspective view of the rear frame 24. As shown in these drawings, the rear frame 24 includes six convex portions 240 arranged at predetermined intervals in the circumferential direction, and a concave portion 242 formed between two convex portions 240 adjacent in the circumferential direction. The rib-shaped portion 244 formed on the bottom surface of the recess 242 is provided on the end surface in the axial direction.

  When the power converter 11 is assembled, the flat top surface portion of the convex portion 240 contacts the heat sinks 56 such as the six switching modules 5X so as to face the entire surface. Moreover, the recessed part 242 is arrange | positioned between the two switching modules 5X etc. which adjoin the circumferential direction. The recess 242 is used as a passage for cooling air generated by the cooling fan 32 (FIG. 7). By disposing the rib-shaped portion 244 in the passage, the surface area of the rear frame 24 in the passage is increased. The convex part 240, the concave part 242 and the rib-shaped part 244 described above are arranged so that the extending direction is radial with the rotation axis (FIG. 7) of the rotor 30 as the center. By arranging the convex portions 240 radially, the bearing housing portion 248 of the rear frame 24 that houses the bearing 36 that rotatably supports the rotor 30 is firmly supported by using the respective convex portions 240. Further, it is desirable that the convex portions 240 are arranged at equal intervals on an arc centered on the rotation axis of the rotor 30.

  As described above, in the vehicular generator 1 according to the present embodiment, the sealing material can be thermoset in an assembled state in which the terminal block 10 and the switching module 5X are combined. It is not necessary to heat the rear frame 24 at the same time, and the time required for manufacturing the power converter 11 and the vehicle generator 1 can be shortened by shortening the time for thermosetting. Moreover, since the power converter 11 can be prepared as one component as an assembly in which the switching module 5X and the like and the terminal block 10 are combined, the number of components can be reduced and the structure of the vehicle generator 1 can be reduced. And the assembly process can be simplified. Furthermore, by using the power converter 11 as an assembly that is a separate part from the brush device 12 and the power generation control device 7, this power can be obtained in the same assembly process as that of the rectifier used in a conventional vehicle AC generator. The converter 11 can be assembled, and the assembly process of the power converter 11, the brush device 12, and the power generation control device 7 can be simplified.

  Further, since the module body 60 is positioned by bringing a part of the terminal block 10 into contact with a part of the module body 60 when the switching module 5X or the like is assembled to the terminal block 10, the switching module 5X When positioning such as, no separate parts for positioning are required, and the structure and assembly process of the power converter 11 can be simplified. In addition, when the switching module 5X or the like is assembled to the terminal block 10, positioning can be easily performed by simply contacting a part thereof, and stable positional accuracy can be ensured.

  Also, by positioning a part of the terminal block 10 against a part of the module main body 60, the module main body 60 is positioned and the filling recesses 106 and 108 are formed. In addition, the module body 60 has a surface where a part of the connection terminal 58 is exposed, and has a shape that simplifies the structure and is easy to manufacture by adopting a shape that combines the positioning structure and the sealing structure. A terminal block can be realized.

  Further, the terminal block 10 is integrally formed including wiring terminals 102 and 104 corresponding to the battery terminal connected to the battery 9 and the control signal terminal to which at least one of the input and output of the control signal is performed, By including the terminal block 10 in one and including the wiring terminals 102 and 104 therein, the number of parts can be reduced and the structure and assembly process can be simplified, and a significant cost reduction can be realized.

  In addition, this invention is not limited to the said embodiment, A various deformation | transformation implementation is possible within the range of the summary of this invention. For example, in the above-described embodiment, the two stator windings 2 and 3 and the two switching module groups 5 and 6 are provided. However, the vehicle including one stator winding 2 and one switching module group 5 is provided. The present invention can also be applied to power generators. In the above-described embodiment, three switching modules are included in each of the two switching module groups 5 and 6, but the number of switching modules may be other than three. In the above-described embodiment, the vehicle generator 1 including the two Y-connected stator windings 2 and 3 has been described. However, the vehicle generator including the Δ-connected stator winding is also described. The present invention can be applied.

  In the above-described embodiment, the case where the rectifying operation (power generation operation) is performed using each switching module 5X or the like has been described. However, by applying the on / off timing of the MOS transistors 50 and 51, the voltage is applied from the battery 9. The present invention can be applied to a vehicular rotating electrical machine that converts a direct current to be converted into an alternating current and supplies it to the stator windings 2 and 3 to perform an electric operation.

  In the above-described embodiment, the switching module 5X and the like are assembled to the terminal block 10 to form the power converter 11 as an assembly, and the power converter 11 is assembled to the axial end surface of the rear frame 24. The present invention can also be applied to the case where another heat radiating member such as a heat radiating plate is interposed between the power converter 11 and the rear frame 24.

  As described above, according to the present invention, since the sealing material can be thermoset in an assembled state in which the terminal block and the switching module are combined, it is necessary to heat the heat dissipation member and the frame having a large heat capacity at the same time. In addition, the time required for manufacturing the power converter and the rotating electrical machine for the vehicle can be shortened by shortening the time for thermosetting.

DESCRIPTION OF SYMBOLS 1 Vehicle generator 2, 3 Stator winding 4 Field winding 5, 6 Switching module group 5X, 5Y, 5Z, 6U, 6V, 6W Switching module 7 Power generation control apparatus 9 Battery 10 Terminal block 11 Power converter 12 Brush device 24 Rear frame 26 Rear cover 27, 28, 246 Air inlet 30 Rotor 32 Cooling fan 50, 51 MOS transistor 54 Control circuit 55 Lead wire 56 Heat sink 58 Connection terminal 60 Module body 100 Recess for storage 102, 104 Wiring terminal 106, 108 filling recess 580 connecting portion 582 connecting portion

Claims (4)

A rotor magnetized by energization of a field winding; a stator disposed opposite to the rotor; a frame for holding the rotor and the stator; and a stator winding provided in the stator A vehicle comprising: a power converter that converts an alternating current induced in a wire into a direct current and supplies the battery, or converts a direct current supplied from the battery into an alternating current and supplies the alternating current to the stator winding In rotating electrical machines,
The power converter includes a plurality of switching modules each having a switching element, and a terminal block for connecting the switching modules to each other and connecting the switching modules to each other.
The switching module has a plurality of connection terminals for connecting to other components, and a part of the plurality of connection terminals is exposed from the side surface of the module body,
When assembled with the switching module to the terminal block, a recess formed between the side surface and the terminal block part of the surface of the module body, when the thermosetting sealing material is filled The concave portion that defines a closed space that can hold the sealing material before curing is formed,
After assembling the switching module to the terminal block, bonding between them and filling and curing of the sealing material, a part of the plurality of connection terminals exposed from the side surface of the module body An assembly of the power converter is formed in a state covered with a sealing material ,
A rotating electrical machine for a vehicle, wherein the assembly is assembled to the frame. In claim 1,
When the switching module is assembled to the terminal block, the module main body is positioned by bringing a part of the terminal block into contact with a part of the module main body. . In claim 2,
By positioning a part of the terminal block against a part of the module body, the module body is positioned and the recess is formed,
A rotating electrical machine for a vehicle, wherein a surface of the module body from which a part of the connection terminal is exposed is disposed inside the recess. In any one of Claims 1-3,
The vehicle is characterized in that the terminal block includes a wiring terminal corresponding to each of a battery terminal connected to the battery and a control signal terminal for performing at least one of input and output of a control signal. Rotating electric machine.

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