JP7002621B1 - Control device integrated rotary electric machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To detect an abnormality in a cooling fluid passage and suppress abnormal heating of a generator motor in a rotary electric machine integrated with a control device. A rotary electric machine including a housing, a stator, and a rotor, and an inverter device provided on a rear bracket side and having a power module for controlling the rotary electric machine and a heat sink equipped with the power module are provided, and a cooling fluid for the heat sink is provided. A controller-integrated rotary electric machine in which a passage and a cooling fluid passage at the rear coil end of the stator winding are communicated, and are arranged around the fins of the heat sink to electrically connect the stator winding and the power module. A connecting board made of an insulating resin containing a bus bar for connection and a thermista attached to the connecting board are provided, and the operation of the power module is controlled based on the temperature of the thermista. [Selection diagram] Fig. 3

Description

The present application relates to a rotary electric machine integrated with a control device.

As a conventional rotary electric machine, a control in which an inverter device consisting of a DC / AC power mutual conversion circuit and a control circuit unit for controlling the DC / AC power mutual conversion circuit and a power generation / electric unit having a power generation function and an electric function are integrally configured. A device-integrated rotary electric machine is known.
As a stator of this type of rotary electric machine, a thermistor is installed around the stator winding to detect the temperature of the stator winding with high responsiveness and high accuracy (for example, Patent Document 1). reference).

Further, it is known that a thermistor is installed in an inverter module, and when overheating is determined and overheating is determined, the power generation action of the generator motor is suppressed or stopped (see, for example, Patent Document 2).

Japanese Unexamined Patent Publication No. 2008-131775 Japanese Unexamined Patent Publication No. 10-191691

However, although the fluid fluid of Patent Document 1 mounted on a vehicle can detect the temperature of the stator winding with high responsiveness and high accuracy, the cooling of the power conversion device in the fluid fluid motor integrated with the control device is used. In a structure in which the fluid passage and the cooling fluid passage of the stator winding portion are communicated with each other, the cooling fluid passage may be blocked by the hoisting of muddy water, gravel, pebbles, etc. by the automobile tire during use operation. In this case, it was not possible to determine the abnormality of the cooling fluid passage.

Further, in Patent Document 2, although it is possible to suppress or stop the driving or power generation action of the generator motor when it is determined to be overheated, it is determined that the cooling fluid passage is abnormal as in Patent Document 1. Was something that could not be done.

The present application has been made to solve the above-mentioned problems, and provides a controller-integrated rotary electric machine capable of detecting an abnormality in a cooling fluid passage and suppressing abnormal heating of a generator motor. The purpose is to do.

The controller-integrated rotary electric machine according to the present application has a housing composed of a front bracket and a rear bracket, a stator winding, a stator fixed to the housing, and rotatably supported by the housing to the stator. A heat sink equipped with a rotary electric machine composed of a stator to which a field winding and a rear fan are attached while facing each other, a power module provided on the rear bracket side and controlling the rotary electric machine, and the power module. A rotary electric machine integrated with a control device, wherein the cooling fluid passage of the heat sink and the cooling fluid passage of the rear side coil end of the stator winding are communicated with each other, and the outer periphery of the fin of the heat sink is provided. A connecting board made of an insulating resin, which is arranged in the stator winding and contains a bus bar for electrically connecting the power module, and a thermister attached to the connecting board are provided at the temperature of the thermista. It is characterized in that the operation of the power module is controlled based on the above.

According to the controller-integrated AC motor generator disclosed in the present application, it is possible to detect an abnormality in the cooling fluid passage, and it is possible to prevent abnormal heating of the generator motor.

It is sectional drawing which shows the structure of the control device integrated rotary electric machine which concerns on Embodiment 1. FIG. It is a circuit diagram which shows the structure of the electric system of the control device integrated rotary electric machine which concerns on Embodiment 1. FIG. It is a figure for demonstrating the cooling action in the control device integrated rotary electric machine which concerns on Embodiment 1. FIG. It is a top view which shows the main part structure of the control device integrated rotary electric machine which concerns on Embodiment 1. FIG. It is a perspective view which shows the structure of the stator in Embodiment 1. FIG. It is a top view which shows the main part structure of the control device integrated rotary electric machine which concerns on Embodiment 2. FIG. It is a top view which shows the main part structure of the control device integrated rotary electric machine which concerns on Embodiment 3. FIG.

Embodiment 1.
FIG. 1 is a cross-sectional view showing the structure of a rotary electric machine integrated with a control device according to the first embodiment.
In the figure, the rotary electric machine 1 integrated with a control device includes an inverter device 3 including a rotary electric machine 2 having a power generation function and an electric function, a DC AC power mutual conversion circuit, and a control circuit unit for controlling the DC AC power mutual conversion circuit. It is equipped with.

Here, the rotary electric machine 2 is housed in a housing 6 composed of a front bracket 4 and a rear bracket 5, and both ends of the rotary shaft 7 are attached to the front bracket 4 and the rear bracket 5 with a front bearing 8 and a rear bearing. A rotor 10 rotatably supported via 9 and a stator 11 provided around the rotor 10 on the outside of the rotor 10 and sandwiched and fixed to the front bracket 4 and the rear bracket 5. It is equipped with.
Further, the rotary electric machine 2 includes a rotation sensor 12 that detects the rotation state of the rotor 10 via the rotation shaft 7, a slip ring 13 provided at the tip of the rotation shaft 7 protruding from the rear bracket 5, and a brush holder. It is housed in 14, and is provided with a pair of brushes 15 whose tip surface is in sliding contact with the slip ring 13.

Further, the rotor 10 includes a field iron core 16 and a field winding 17 wound around the field iron core 16. A front fan 18a and a rear fan 18b for generating cooling air are attached to both end faces of the field core 16. Further, the field winding 17 is electrically connected to the slip ring 13 via a connecting wire 19, and a field current is supplied from the brush 15 to the field winding 17 via the slip ring 13.
Further, one end of the rotating shaft 7 protrudes from the front bracket 4, and a pulley 51 for transmitting and receiving torque in both directions to and from the engine (not shown) is attached to the tip of the rotating shaft 7 via a belt 52. ..

Further, the stator 11 is wound around the stator core 20 and the stator core 20, and is attached to the front coil end 21a of the stator 11 facing the front fan 18a of the rotor 10 and the rear fan 18b of the rotor 10. It comprises a stator winding 21 with a rear coil end 21b of the facing stator 11.

On the other hand, the inverter device 3 covered with the protective cover 36 provided on the outside of the housing 6 on the opposite side of the pulley 51 supplies alternating current to the stator winding 21 and direct current to the field winding 17. It is provided with a DC / AC power mutual conversion circuit unit that energizes the power supply and a control circuit unit that controls the operation of the DC / AC power mutual conversion circuit unit.
The DC / AC power mutual conversion circuit unit includes a power module 29 including a power circuit semiconductor switching element 28 that supplies AC power to the stator winding 21, and a field circuit that energizes the field winding 17 with a DC current. A field module 31 including a semiconductor switching element 30 for cooling, a cooling heat sink 34 to which a power module 29 and a field module 31 are mounted, and having fins 33, terminals 29a of the power module 29, and terminals of the field module 31. It has a terminal 32a electrically connected to each of the 31a and is insert-molded, and also has a case 32 for a power module and a case 37 for a field module. The heat sink 34 on which the power module 29 and the field module 31 are mounted is fixed to the rear bracket 5.

Further, the control circuit unit 35 includes control boards 38 and 39 electrically connected to the power module 29 and the field module 31 to form a control circuit for driving and controlling the power module 29 and the field module 31. ..
Further, a connecting board 40 is arranged on the radial outer periphery of the fin 33 in the heat sink 34, and the connecting board 40 includes a lead wire 22 of the stator winding 21 and a terminal 32a of the inverter device 3 as described later. It is a phase power interconnection component configured by covering the bus bar connecting the above with an insulating resin material, and is fixed to the rear bracket 5 by bolts.

FIG. 2 is a circuit diagram showing a configuration of an electric system in the controller-integrated rotary electric machine according to the first embodiment.
In the figure, the power module 29 and the field module 31 are supplied with electric power from a battery and their operating states are controlled by a control circuit.
Here, the power module 29 has a configuration in which six sets of upper arms and lower arms are connected in series, and the ground of the lower arms is electrically connected to the rear bracket 5 via the heat sink 34. Similarly, the ground of the arm of the field module 31 is also electrically connected to the rear bracket 5 via the heat sink 34.
The stator winding 21 is composed of two sets of three-phase Y-connections in which neutral points are connected, and each of the two sets of three-phases is a U-phase, a V-phase, a W-phase, and an X-phase. , Y phase and Z phase are arranged in parallel, and each phase is electrically connected to 6 sets of upper arm and lower arm.

Next, the operation of the control device integrated rotary electric machine 1 as described above will be described.
First, when the engine is started, DC power is sent from the battery to the power module 29 of the inverter device 3, the DC power is converted into three-phase AC power, and the three-phase AC power is supplied to the stator winding 21. On the other hand, the field current controlled by the field module 31 is supplied to the brush 15, the slip ring 13, the connection line 19, and the field winding 17, and a rotating magnetic field is applied to the field winding 17 of the rotor 10. The rotor 10 is rotationally driven. The rotational torque of the rotor 10 is transmitted to the engine via the rotary shaft 7, the pulley 51, and the belt 52, and the engine is started.

When the engine is started, the rotational torque of the engine is transmitted to the rotary electric machine 2 via the crank pulley, the belt 52 and the pulley 51. As a result, the rotor 10 is rotated, and a three-phase AC voltage is induced in the stator winding 21. This three-phase AC voltage is rectified into DC power by the power module 29 and supplied to the battery and the electric load.

Next, the cooling mechanism in the control device integrated rotary electric machine 1 as described above will be described with reference to FIG.
First, when the rotor 10 is rotationally driven, the front fan 18a and the rear fan 18b are driven, and as shown by the arrow in FIG. 3, on the front side, the first provided on the inner peripheral side in the axial direction of the front bracket 4. Outside air is sucked from one intake hole, bent in the centrifugal direction by the front fan 18a, and provided on the radial outer peripheral side of the front bracket 4 while cooling the front coil end 21a and the front bracket 4 of the stator winding. It is discharged from the exhaust hole.
Further, on the rear side, outside air is sucked from a second intake hole provided on the radial outer periphery of the protective cover 36, and between the base surface of the heat sink 34 and the fin 33 existing between the rear end surface of the rear bracket 5. After passing through the ventilation holes provided on the outer periphery of the holding portion of the rear bearing 9 of the rear bracket 5, the rear bracket 5 is bent in the centrifugal direction by the rear fan 18b, and the rear coil end 21b of the stator winding and the rear bracket 5 are moved. While cooling, the air is discharged from the exhaust hole provided on the radial outer peripheral side of the rear bracket 5.

That is, the cooling fluid flowing through the second cooling fluid passage on the rear side passes through the fins 33 of the heat sink 34 of the inverter device 3, so that the heat of the heat sink 34 can be absorbed and the heat sink 34 can be cooled, and the heat sink 34 can be cooled. It is possible to suppress the temperature rise of the power module 29 and the field module 31 thermally coupled to the heat sink.

FIG. 4 is a plan view showing a main configuration of a rotary electric machine integrated with a control device according to the first embodiment, and is viewed from the front bracket 4 side at a position A between the rear bracket 5 and the fin 33 of FIG. Is.
In the figure, a plurality of fins 33 are arranged so as to be radial in the circumferential direction of the fins 33 of the heat sink 34, and a passage through which the cooling fluid passes from the outer diameter side to the inner diameter side is formed between the adjacent fins 33. This is considered to further reduce the temperature of the power module 29 and the field module 31. Here, in order to improve the cooling efficiency, the thickness of the fins 33 in the circumferential direction is set to 2 mm, and the width of the cooling passage between the adjacent fins 33 is set to 4 mm on the outer diameter side and 3 mm on the inner diameter side.

Next, the electrical connection relationship between the lead wire 22 of the stator winding 21 and the power module 29 of the inverter device 3 will be described. The connecting board 40 arranged between the rear bracket 5 and the inverter device 3 is located on the outer peripheral side of the first connection portion 41a connected to the lead wire 22 of the stator winding 21 and the first connection portion 41a thereof. Six sets of bus bars 41 having a second connecting portion 41b connected to the terminal 32a of the case 32 of the inverter device 3 are arranged separately from each other and covered with an insulating resin material to be integrally formed. It is fixed to the rear bracket 5 by three bolts 42. The terminal 32a of the case 32 of the inverter device 3 is electrically connected to the terminal 29a of the power module 29 by welding.

By the way, as shown in FIG. 5, in the stator 11, 96 slots are arranged in the circumferential direction on the inner peripheral side of the stator core 20, and in each slot, a straight portion of a continuous conductor wire having an insulating coating (a straight portion (a straight portion). It is configured to include a stator winding 21 formed by arranging six slot accommodating portions) in a row in the radial direction. The number of magnetic poles of the rotor 10 is 16 poles.

In the stator winding 21 configured in this way, the stator windings 21 extend from the stator core 20 and the turn portions of the continuous conductor wires form three rows in an annular shape in the circumferential direction, so that the front side coil end 21a and the rear side coil end 21a are formed. 21b is configured, and it is known that the amount of heat generated increases due to the denseness of the continuous conductor wires at the portions of the coil ends 21a and 21b.

When the rotary electric machine 1 with an integrated control device as described above is mounted on an automobile, the second cooling fluid passage may be blocked by the hoisting of muddy water, gravel, pebbles, etc. by the automobile tire when the automobile is used and operated. If the second cooling fluid passage is blocked, the power module 29 and the field module 31 may overheat abnormally, resulting in failure.
Further, the stator winding 21 prevents short-circuiting of adjacent windings in the slot by the insulating coating, but when the cooling fluid passage is blocked, the insulating coating abnormally overheats and reaches the dielectric breakdown temperature. This may cause a failure that causes a short circuit between the phases.

Therefore, in the first embodiment, the connecting board 40, the power module 29, and the stator winding 21 are arranged in the second cooling fluid passage in the order in which the cooling fluid flows, and the heat sink 34 on which the power module 29 is mounted is arranged. The connecting board 40 is arranged on the outer diameter side of the fin 33, and the thermistor 43 is provided on the bus bar 41 in the connecting board 40. The thermistor 43 is protected by an insulating resin and is connected to the control circuit of the inverter device 3.

That is, when the second cooling fluid passage is normal, the amount of heat of the rear side coil end 21b provided near the discharge port of the cooling fluid passage is transferred to the bus bar 41 of the connecting board 40 via the lead wire 22. , The temperature of the thermistor 43 rises.
On the other hand, the cooling fluid is sucked directly above the bus bar 41 of the connecting board 40 provided near the suction port of the second cooling fluid passage, the bus bar 41 of the connecting board 40 is cooled, and the temperature of the thermistor 43 is lowered. This temperature rising action and temperature lowering action are canceled out, and the temperature is settled at a certain level.

Here, when the second cooling fluid passage is blocked by winding up muddy water, gravel, pebbles, etc., the amount of heat of the rear side coil end 21b provided near the discharge port of the cooling fluid passage increases, and the temperature of the thermistor 43 increases. Will rise further.
Further, the degree of decrease in the temperature of the thermistor 43 is reduced by reducing the flow rate of the cooling fluid directly above the bus bar 41 of the connecting board 40 provided near the suction port of the second cooling fluid passage.
By reducing the degree of cancellation between the temperature rise action and the temperature lowering action, the thermistor 43 reaches a higher temperature than in the normal state, and this high temperature state is detected and the generator motor is detected via the control circuit of the inverter device 3. It is possible to control the drive or power generation to be suppressed or stopped.

That is, by closing the space between the heat sink 34, which is the inlet of the second cooling fluid passage, and the opening of the rear bracket 5, the temperature of the thermista 43 provided at the inlet of the second cooling fluid passage becomes high, and the temperature of the thermista 43 becomes high. By closing the rear side coil end 21b of the stator 11 and the opening of the rear bracket 5, which are the outlets of the second cooling fluid passage, the rear side coil end 21b becomes hot and the amount of heat thereof is connected. Heat is transferred from the stator winding 21 to the bus bar 41 built in the connecting board 40 by the lead wire of the child 11, and the temperature of the thermista 43 becomes high. Therefore, it is possible to determine that the second cooling fluid passage is blocked by displaying the high temperature state of the thermistor 43.

Therefore, in contrast to the conventional technical idea of installing the thermistor around the stator winding, according to the first embodiment of the present application, the cooling state of the thermistor 43 at the suction port of the second cooling fluid passage is detected. Therefore, the abnormality determination of the second cooling fluid passage can be easily performed. Also. To detect the combined temperature of the thermal element of the connecting board 40 which is the tip of the intake port of the second cooling fluid passage and the thermal element of the rear side coil end 21b which is the rear end of the exhaust port of the cooling fluid. Therefore, it is possible to determine the presence or absence of blockage in all of the second cooling fluid passage from the intake port to the discharge port.
Further, by installing the thermistor 43 at the inlet of the second cooling fluid passage, it is possible not only to prevent the stator winding 21 from overheating but also to prevent the electronic components constituting the inverter device 3 from overheating. ..

Embodiment 2.
FIG. 6 is a plan view showing a main structure of a rotary electric machine integrated with a control device according to a second embodiment.
In the figure, the controller-integrated rotary electric machine according to the second embodiment is characterized in that a plurality of fins 44 are formed on the connecting board 40, and other configurations are the same as those of the first embodiment. Therefore, the description is omitted.
These fins 44 are projected toward the inner diameter side in a state where a part of the flat plate-shaped bus bar 41 is connected, and the protruding portion is bent in an L shape and twisted in the radial direction, and the surface is surrounded by an insulating resin. It is composed of things. These fins 44 are on the outer diameter side of the fins 33 of the heat sink 34, and are located between the plurality of fins 33, that is, the fins 33 and the fins 44 are arranged in a staggered manner in the circumferential direction about the rotation axis. Has been done.

By providing the connecting board 40 with the plurality of fins 44 in this way, the cooling performance of the bus bar 41 of the connecting board 40 can be improved, and the temperature rise of the bus bar 41 of the connecting board 40 can be suppressed.
Further, by arranging the fins 33 and 44 in a staggered pattern, the cooling performance of the fins 33 of the heat sink 34 can be improved as follows.
Since the cooling air has an air volume corresponding to the rotation speed of the rotor 10 by the fan 18b, the cross-sectional area of the fluid passage is reduced due to the staggered arrangement, and as a result, the air volume = (wind speed) X (cross-sectional area). If the air volume is the same, the wind speed will increase. As a result, the cooling performance of both the connecting board 40 and the fins 33 of the heat sink 34 is improved. Further, since the fins 33 of the heat sink 34 are located between the fins 44 of the connecting board 40 due to the staggered arrangement, the cooling air collides with the outer peripheral portion of the fins 33 of the heat sink 34 in the outer diameter direction, so that the heat sink 34 The cooling property of the fin 33 will be improved.

Since the fins 44 on the connecting board 40 and the fins 33 on the heat sink 34 are arranged in a staggered pattern, the cooling fluid passages are dense, so that muddy water, gravel, pebbles, etc. are used during use operation. Since the cooling fluid passage due to winding is likely to be blocked, it is effective to detect the temperature of the cooling fluid passage by the thermista 43 of the connecting board 40 arranged on the outer periphery of the fin 33 of the heat sink 34.

Further, by connecting the fins 44 on the connecting board 40 to the bus bar 41 made of an aluminum metal plate, the heat dissipation of the bus bar 41 can be improved, and by covering the surface of the fins 44 with an insulating resin, it is used for automobiles. It is possible to prevent electrolytic corrosion caused by the intrusion of salt water or the like by the tire.
Further, by filling the insulating resin material with a filler such as alumina, the thermal conductivity can be improved, and as a result, the heat dissipation of the bus bar 41 can be improved.

Embodiment 3.
FIG. 7 is a plan view showing a main structure of a rotary electric machine integrated with a control device according to the third embodiment.
In the figure, the controller-integrated rotary electric machine according to the third embodiment is characterized in that two thermistors 43 are arranged at positions that are rotationally symmetric with respect to the rotation axis on the connecting board 40, and the other Since the configuration is the same as that of the first embodiment, the description thereof will be omitted.
By arranging the two thermistors 43 at the rotation target positions in this way, even if one of the thermistors 43 fails, the other thermistor 43 can detect the blockage of the cooling fluid passage.

Further, when the control device integrated rotary electric machine 1 is attached to the vehicle by arranging it at a symmetrical position of 180 degrees with respect to the rotation axis, one of the two thermistors 43 is on the ground side. Therefore, it is not necessary to consider the rotation position when mounting the vehicle on a vehicle, and the degree of freedom of mounting can be increased.
Furthermore, since the cooling fluid passage on the ground side is likely to be blocked by the hoisting of muddy water, gravel, pebbles, etc. by the automobile tire, the cooling fluid passage is compared by comparing the temperatures of the two thermistors 43 on the top direction side and the ground direction side. The abnormality can be easily determined.
The thermistor 43 is not limited to the embodiment in which only two thermistors 43 are provided at positions that are rotationally symmetric as shown in FIG. 7, and at least two or more thermistors 43 are provided to detect abnormal overheating of any of the thermistors 43. It may be configured as follows.

Although various exemplary embodiments and examples are described in the present application, the various features, embodiments, and functions described in one or more embodiments are specific embodiments. It is not limited to the application of, but can be applied to the embodiment alone or in various combinations.
Therefore, innumerable variations not exemplified are envisioned within the scope of the techniques disclosed in the present application. For example, it is assumed that at least one component is modified, added or omitted, and further, at least one component is extracted and combined with the components of other embodiments.

1: Control device integrated rotary electric machine, 2: Rotary electric machine, 3: Inverter device,
4: Front bracket, 5: Rear bracket, 6: Housing,
10: Rotor, 11: Stator, 12: Rotor sensor, 17: Field winding,
18a: Front fan, 18b: Rear fan, 21: Stator winding,
21a: front coil end, 21b: rear coil end,
29: Power module, 31: Field module, 33: Fins,
34: Heat sink, 40: Connecting board, 41: Bus bar,
43: Thermistor, 44: Fin

Claims (8)

It has a housing consisting of a front bracket and a rear bracket, and a stator winding. A stator fixed to the housing, rotatably supported by the housing, arranged facing the stator, and a field winding. A rotating electric machine consisting of a rotor with wires and a rear fan attached,
A power module for controlling the rotary electric machine and an inverter device having a heat sink on which the power module is mounted are provided on the rear bracket side.
A controller-integrated rotary electric machine in which the cooling fluid passage of the heat sink and the cooling fluid passage of the coil end on the rear side of the stator winding are communicated with each other.
A connecting board made of an insulating resin, which is arranged on the outer periphery of the fins of the heat sink and contains a bus bar for electrically connecting the stator winding and the power module.
Equipped with a thermistor attached to this connecting board,
A controller-integrated rotary electric machine characterized in that the operation of the power module is controlled based on the temperature of the thermistor. The rotary electric machine integrated with a control device according to claim 1, wherein the connecting board is provided with cooling fins exposed to the cooling fluid passage. The controller-integrated rotary electric machine according to claim 2, wherein the fins on the connecting board side are provided at positions staggered with respect to the fins on the heat sink on the power module side. The controller-integrated rotary electric machine according to claim 2 or 3, wherein the bus bar and the fins in the connecting board are surrounded by an insulating resin. The controller-integrated rotary electric machine according to claim 4, wherein the insulating resin contains a filler. The controller-integrated rotary electric machine according to any one of claims 1 to 5, wherein the thermistor is provided with at least two of them. The controller-integrated rotary electric machine according to claim 6, wherein the two thermistors are arranged at positions that are rotationally symmetric with respect to the rotation axis of the rotor. The controller-integrated rotary electric machine according to claim 6 or 7, wherein the temperatures of the plurality of thermistors are compared and it is determined that the cooling fluid passage is blocked when the temperature difference is equal to or larger than a predetermined threshold value.

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