WO2016098977A1 - Rotating electric machine - Google Patents

Rotating electric machine Download PDF

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Publication number
WO2016098977A1
WO2016098977A1 PCT/KR2015/007045 KR2015007045W WO2016098977A1 WO 2016098977 A1 WO2016098977 A1 WO 2016098977A1 KR 2015007045 W KR2015007045 W KR 2015007045W WO 2016098977 A1 WO2016098977 A1 WO 2016098977A1
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WO
WIPO (PCT)
Prior art keywords
case
coolant
electric machine
rotating electric
accommodation portion
Prior art date
Application number
PCT/KR2015/007045
Other languages
French (fr)
Inventor
Lyulhong MIN
Myeongki KIM
Sangwoo Park
Original Assignee
Lg Electronics Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lg Electronics Inc. filed Critical Lg Electronics Inc.
Publication of WO2016098977A1 publication Critical patent/WO2016098977A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/08—Arrangements for cooling or ventilating by gaseous cooling medium circulating wholly within the machine casing
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H02K5/207—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium with openings in the casing specially adapted for ambient air
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/25—Devices for sensing temperature, or actuated thereby
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H02K9/04—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
    • H02K9/06—Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/20909—Forced ventilation, e.g. on heat dissipaters coupled to components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present disclosure relates to a rotating electric machine, and particularly, to a rotating electric machine, which has a reduced size, and in which an increase in a temperature of a portion is suppressed.
  • a rotating electric machine includes a power generator converting mechanical energy into electrical energy and a motor converting electrical energy into mechanical energy.
  • the rotating electric machine includes a cooling unit for performing cooling when a temperature increases according to an operation of the rotating electric machine, to thus prevent a degradation of operational efficiency.
  • the cooling unit of the rotating electric machine is classified into an air cooling-type cooling unit for performing cooling using air and a water cooling-type cooling unit using a coolant.
  • a water jacket accommodating a coolant is so thick that a size and weight of the rotating electric machine increase to obstruct a compact configuration of the machine.
  • the inverter-integrated rotating electric machine may use a rotor including a rotor coil, but cooling of the inverter is not sufficient.
  • an aspect of the detailed description is to provide a rotating electric machine which has a reduced size and in which an increase in a temperature of some components is suppressed.
  • Another aspect of the detailed description is to provide a rotating electric machine capable of enhancing a cooling effect by selectively using different cooling fluids.
  • a rotating electric machine includes: a stator; a rotor disposed to be rotatable with respect to the stator; a case including a first case and a second case formed of a thermally conductible member and disposed to face each other, and disposed on outer side of the stator; a circuit unit installed in the first case or the second case; a cooling fan provided in the rotor; and a coolant accommodation portion formed to accommodate a coolant in a region of the first case or the second case in which the circuit unit is installed, and allowing the circuit unit to be cooled by the coolant.
  • a circuit unit installation unit in which the circuit unit is installed may be formed on an outer surface of the coolant accommodation portion.
  • the first case and the second case may each include a radial section portion disposed in a radial direction of the rotor and a circumferential section portion extending from the radial section portion in a circumferential direction, and the first case or the second case may include an intake hole allowing air to be intaken therethrough and a discharge hole allowing air to be discharged therethrough.
  • the coolant accommodation portion may be formed in the radial section portion of any one of the first case and the second case.
  • the circuit unit may include an inverter including a plurality of switching elements.
  • the case may further include a circuit unit case accommodating the circuit unit.
  • the rotor may include a rotor core and a rotor coil wound around the rotor core.
  • a power supply unit supplying power to the rotor coil may be disposed on one side of the coolant accommodation portion.
  • a plurality of cooling fans may be provided on both sides of the rotor.
  • the coolant accommodation portion may be formed in the radial section portion of the second case, the suction hole may be formed both in the radial section portion of the first case and in the circumferential section portion of the second case, and the discharge hole may be formed in the radial section portion or the circumferential section portion of the first case and in the circumferential section portion of the second case.
  • the intake hole formed in the circumferential section portion of the second case may be formed such that a length thereof in a circumferential direction is greater than a width thereof in an axial direction.
  • a plurality of intake holes formed in the circumferential section portion of the second case may be spaced apart from one another in the circumferential direction of the second case.
  • An air slot may be provided to be disposed in a radial direction within the coolant accommodation portion and communicate with the intake hole to allow air intaken through the intake hole formed in the circumferential section portion of the second case to move in a radial direction.
  • the second case may include a space portion temporarily accommodating air which has been moved along the air slot at an inner side of the coolant.
  • the second case may include an internal inlet formed to allow air of the space portion to be introduced to the interior of the second case.
  • the second case may include a rib provided between the coolant accommodation portion and the space portion to demarcate the coolant accommodation portion and the space portion.
  • the coolant accommodation portion may have a shape recessed inwardly in an axial direction from the circuit unit installation unit.
  • the circuit unit installation unit may include a heating element installation member in which a heating element is installed.
  • the coolant accommodation portion may be configured such that an opening thereof is blocked by the heating element installation member.
  • the air slot may penetrate through the coolant accommodation portion, and a coolant of the coolant accommodation portion may be in contact with a circumference (outer surface) of the air slot.
  • the cooling fan may include a first cooling fan and a second cooling fan provided on both sides of the rotor.
  • any one disposed to be adjacent to the coolant accommodation portion may be configured to have an air volume larger than that of the other.
  • the first case and the second case may be disposed to be spaced apart from one another in both end portions of the stator in an axial direction.
  • a region of the stator between the first case and the second case is exposed to the outside, and an uneven portion may be provided on an outer surface of the stator in order to increase a surface area.
  • Air may be intaken in an axial direction to the interior of the first case by the first cooling fan and may be discharged in a radial direction from the first case.
  • Air may be intaken in a radial direction to the interior of the second case by the second cooling fan and may be discharged in the radial direction from the second case.
  • the rotating electric machine may further include a coolant circulation unit communicating with the coolant accommodation portion and allowing the coolant to circulate by way of the coolant accommodation portion.
  • the coolant circulation unit may include a flow channel in which the coolant circulates; a pump configured to accelerate circulation of the coolant; and a switching valve (or an ON/OFF valve) configured to open and close the flow channel.
  • the coolant circulation unit may further include a coolant temperature sensing unit configured to sense a temperature of the coolant.
  • the rotating electric machine may further include a control unit configured to control the switching valve on the basis of a sensing result from the coolant temperature sensing unit.
  • the coolant accommodation portion may include an inlet through which the coolant is introduced to the interior and an outlet through which the coolant within the coolant accommodation portion flows out.
  • the coolant temperature sensing unit may be provided in the outlet.
  • the coolant accommodation portion cooling the cooling fan and the circuit unit is provided, an increase in a size and weight of the appearance may be suppressed and an increase in temperature of the circuit unit may be suppressed.
  • the circuit unit when a temperature of the circuit unit is relatively high, the circuit unit is cooled by the coolant, thereby suppressing a degradation of performance duel to an increase in temperature of the circuit unit.
  • the coolant circulation unit is driven to effectively cool the circuit unit.
  • FIG. 1 is a perspective view of a rotating electric machine according to an embodiment of the present disclosure.
  • FIG. 2 is a cross-sectional view of the rotating electric machine of FIG. 1.
  • FIG. 3 is a front view of the rotating electric machine of FIG. 1.
  • FIG. 4 is a right side view of the rotating electric machine of FIG. 3.
  • FIG. 5 is a rear perspective view of a second case of FIG. 1.
  • FIG. 6 is a rear view of the second case of FIG. 5.
  • FIG. 7 is a cross-sectional view illustrating a coupled state of a heating element installation member taken along line VII-VII of FIG. 6.
  • FIG. 8 is a cross-sectional view illustrating a coupled state of the heating element installation member taken along line VIII-VIII of FIG. 6.
  • FIG. 9 is a perspective view illustrating a state before a circuit unit case and the heating element installation member of FIG. 1 are coupled.
  • FIG. 10 is a perspective view illustrating an installation state of the heating element installation member of FIG. 9.
  • FIG. 11 is a view illustrating a coolant circulation unit of the rotating electric machine of FIG. 1.
  • FIG. 12 is a control block diagram of the rotating electric machine of FIG. 1.
  • a rotating electric machine may include a stator 110, a rotor 120 rotatably disposed with respect to the stator 110, a case 140 including a first case 141 and a second case 142 formed as thermally conductive members and disposed to face each other, and disposed outside of the stator 110, a circuit unit 190 installed in the first case 141 or the second case 161, a cooling fan 130 provided in the rotor 120, and a coolant accommodation portion 175 formed in a region of the first case 141 or the second case 161 in which the circuit unit 190 is installed to accommodate a coolant to cool the circuit unit 190 by the coolant.
  • the stator 110 may include, for example, a stator core 111 and a stator coil 117 wound around the stator core 111.
  • the stator core 111 may include a rotor accommodation hole 114 for accommodating the rotor 120 therein, for example.
  • the stator core 111 may be formed by stacking a plurality of electrical sheets (or silicon steel sheets)112 with the rotor accommodation hole 114 formed in the center thereof, for example.
  • a pole and a slot may be alternately formed in the circumference of the rotor accommodation hole 114.
  • the stator core 111 may be configured such that an outer surface thereof has a circular shape, for example.
  • an irregular portion 116 may be formed on an outer circumferential surface of the stator core 111 such that a surface area thereof may increase.
  • the irregular portion 116 of the stator core 111 may be formed to be recessed in a radial direction and extend in an axial direction, for example.
  • a plurality of irregular portions 116 may be formed and spaced apart from one another in a circumferential direction of the stator core 111, for example.
  • the stator coil 117 may be inserted within the slot and wound around the pole.
  • the rotor 120 may include, for example, a rotor core 121 and a rotor coil 125 wound around the rotor core 121.
  • a shaft 127 may be provided in the center of the rotor core 121.
  • the rotor core 121 may be formed by stacking a plurality of electric steel sheets 122 each having a shaft hole 124 formed in a center thereof to allow the shaft 127 to be inserted therethrough, for example.
  • a pole and a slot may be alternately formed in the circumference of the shaft hole 124, for example.
  • the rotor coil 125 may be inserted within the slot and may be wound around the pole.
  • the rotor 120 may include a cooling fan 130 to intake air when rotated, for example.
  • the cooling fan 130 may be configured as a centrifugal fan intaking air in an axial direction and discharging air in a radial direction, for example.
  • the cooling fan 130 may include a first cooling fan 131 and a second cooling fan 132 provided in both end portions of the rotor 120 in an axial direction of the rotor 120.
  • the second cooling fan 132 may be configured to have an air volume greater than that of the first cooling fan 131, for example.
  • the second cooling fan 132 may include a blade having a width and/or length greater than that of the first cooling fan 131.
  • a power supply unit 128 supplying power to the rotor coil 125 may be provided in the shaft 127.
  • the power supply unit 128 may include, for example, a slip ring provided in the shaft 127 and a brush in contact with the slip ring.
  • a pulley 129 may be provided in one end portion of the shaft 127.
  • the other side of a transmission belt (not shown), one side of which is coupled to a pulley (not shown) of an engine of a vehicle, may be coupled to the pulley 129, for example.
  • the rotating electric machine of the present embodiment may serve as a starter for driving an engine of a vehicle when the vehicle starts, for example.
  • the rotating electric machine of the present embodiment may function as a generator producing electricity upon receiving power from the engine while the vehicle is driving.
  • the power supply unit 128 of the rotor 120 may be provided, for example.
  • stator core 111 may be configured to have circular shape in an outer surface thereof, for example.
  • the case 140 may be provided on outer side of the stator 110.
  • the case 140 may be configured to support the stator 110 and the rotor 120, for example.
  • the case 140 may include the first case 141 and the second case 161 disposed to face each other with the stator 110 interposed therebetween, for example.
  • the first case 141 and the second case 161 may be configured to be coupled to both end portions of the stator 110 along the axial direction, for example.
  • a central region of the stator 110 may be exposed to outside of the first case 141 and the second case 161 in the axial direction.
  • the first case 141 and the second case 161 may include coupling arms 146 and 166 protruding in a radial direction, respectively, for example.
  • Coupling bosses 150 and 170 may protrude from end portions of the coupling arm 146 of the first case 141 and the coupling arm 166 of the second case 161 in an axial direction, respectively.
  • End portions of the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161 may be configured to be in contact with each other.
  • Fastening member insertion holes 151 and 171 may penetrate through the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161, respectively, such that a fastening member (not shown) may be inserted thereinto.
  • the fastening member may be coupled to both the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161 so as to be coupled to an object (for example, a body of a vehicle) to fixedly couple the rotating electric machine to the object (for example, the body of the vehicle).
  • an object for example, a body of a vehicle
  • the first case 141 may be provided on one side (the left side in the drawing) of the stator 110, for example.
  • the first case 141 may be configured to have a cylindrical shape with one side opened, for example.
  • the first case 141 may be configured to include a radial section portion 142a disposed in a radial direction and a circumferential section portion extending from the radial section portion 142a in an axial direction.
  • the first case 141 may include a stator core coupling unit 147 to which an outer surface of the stator core 111 is insertedly coupled, for example.
  • the stator core coupling unit 147 of the first case 141 may be formed to allow the stator core 111 to be inserted therein by a predetermined depth.
  • the stator core coupling unit 147 of the first case 141 may include an extending portion 148 extending in a radial direction, compared with the circumferential section portion 142b and a cylindrical portion 149 extending from the extending portion 148 in an axial direction.
  • the extending potion 148 may come into contact with an end portion of the stator core 111 to limit insertion of the stator core 111.
  • the first case 141 may include a bearing coupling unit 144 allowing a bearing 145 rotatably supporting one side (left side in the drawing) of the shaft 127, for example, to be accommodated therein and coupled thereto.
  • the first case 141 may include, for example, an intake hole 152 allowing air to be intaken when the cooling fan 130 rotates.
  • the intake hole 152 may be formed in a radial section portion 142a of the first case 141.
  • the intake hole 152 of the first case 141 may be formed on an outer side of the bearing coupling unit 144 in the radial direction of the first case 141.
  • the first case 141 may include, for example, a discharge hole 142 allowing air to be discharged therethrough.
  • the discharge hole 154 may be formed on an outer side of the intake hole 152 of the first case 141 in the radial direction, for example.
  • the discharge hole 154 may be formed in the radial section portion 142a of the first case 141, for example.
  • the discharge hole 154 may be formed in the circumferential section portion 142b of the first case 141, for example.
  • the discharge hole 154 may be formed in both of the radial section portion 142a and the circumferential section portion 142b of the first case 141, for example.
  • the discharge hole 154 may be formed to have a reverse "L" shape over the radial section portion 142a and the circumferential section portion 142b of the first case 141, for example.
  • the discharge hole 154 may include a vertical section 155 formed in the radial section portion 142a of the first case 141 and a horizontal section 149 formed in the circumferential section portion 142b, for example.
  • the discharge hole 154 of the first case 141 may have an overall flow cross-sectional area greater than an overall flow cross-sectional area of the intake holes 152 of the first case 141 (the sum of the flow cross-sectional areas of a plurality of intake holes 152).
  • the second case 161 may be provided on the other side (right side in the drawing) of the stator 110.
  • the second case 161 may have a cylindrical shape with one side thereof opened.
  • the second case 161 may include a radial section portion 162a disposed in a radial direction and a circumferential section portion 162b extending from the radial section portion 162a in an axial direction.
  • the second case 161 may include, for example, a stator core coupling unit 167 to which an outer surface of the stator core 111 is insertedly coupled.
  • the stator core coupling unit 167 of the second case 161 may be formed such that the stator core 111 can be inserted therein to a predetermined depth.
  • the stator core coupling unit 167 of the second case 161 may include an extending portion 168 extending in a radial direction compared with the circumferential section portion 162b of the second case 161 and a cylindrical portion 169 extending from the extending portion 168 in the axial direction.
  • the extending portion 169 may come into contact with an end portion of the stator core 111 to limit insertion of the stator core 111, for example.
  • the second case 161 may include a bearing coupling unit 164 in which the bearing 145 rotatably supporting the other side (right side in the drawing) of the shaft 127 is accommodated and coupled, for example.
  • a circuit unit installation unit 173 in which the circuit unit 190 is installed may be formed on an outer surface of the second case 161, for example.
  • a coolant accommodation portion 175 accommodating a coolant to cool the circuit unit 190 may be provided in the circuit unit installation unit 173.
  • the circuit unit 190 may include an inverter including a plurality of heating elements 192 and a printed circuit board 194, for example.
  • the plurality of heating elements 192 may include a switching element called an insulted gate bipolar transistor (IGBT), for example.
  • IGBT insulted gate bipolar transistor
  • the coolant accommodation portion 175 may be formed in the radial section portion 162a of the second case 161, for example.
  • the coolant accommodation portion 175 may be formed in the radial section portion 162a of the second case 161, for example.
  • the coolant accommodation portion 175 may be recessed inwardly from the circuit unit installation unit 173 in an axial direction, for example.
  • the coolant accommodation portion 175 may be configured such that the interior there of is hermetically closed with respect to the outside when a heating element installation member 210 (to be described hereinafter) is coupled to the circuit unit 173 of the second case 161.
  • the coolant accommodation portion 175 may be positioned on outer side of the bearing accommodation unit 164 in a radial direction, for example.
  • the coolant accommodation portion 175 may have a circular ring (tube) shape, for example.
  • an inlet 176 may be provided in the second case 161 to allow a coolant to be introduced to the interior of the coolant accommodation portion 175.
  • the inlet 176 may outwardly protrude in a radial direction of the second case 161 and bent to extend in an axial direction.
  • An outlet 177 may be formed in the second case 161 to allow a coolant within the coolant accommodation portion 175 to flow out therethrough.
  • the outlet 177 may protrude in a radial direction from an outer surface of the circumferential section portion 162b of the second case 161 and bent to extend in an axial direction.
  • the second case 161 may include intake holes 172 allowing air to be intaken therethrough to the interior when the cooling fan 130 rotates.
  • the intake holes 172 of the second case 161 may be formed in the circumferential section portion 162b of the second case, for example.
  • each of the intake holes 172 formed in the circumferential section portion 162b of the second case 161 may have a length L1 extending in a circumferential direction compared with a width W1 thereof in an axial direction.
  • a contact area (heat exchange) in which air intaken through the intake holes 172 is heat-exchanged with the circuit unit installation unit 173 increases to accelerate cooling of the circuit unit 190.
  • the intake holes 172 formed in the circumferential section portion 162b of the second case 161 may be spaced apart from one another in the circumferential direction.
  • the intake holes 172 formed in the circumferential section portion 162b of the second case 161 may be spaced apart from one another at equal intervals on the same circumference.
  • Air flow channels or air slots 178 may be formed in the coolant accommodation portion 175 to allow air intaken through the intake holes 172 of the second case 161 to move therealong so as to be heat-exchanged with a coolant.
  • the air slots 178 may be formed to be connected to the intake holes 172 of the second case 161, respectively.
  • four intake holes 172 are formed in the second case 161, and four air slots 187 are formed to correspond to the number of intake hole 172, but the numbers of the intake holes 172 and the air slots 178 may be appropriately adjusted in consideration of the size and/or a heating value of the circuit unit installation unit 173.
  • the air slots 178 may be formed in a radial direction of the second case 161, for example.
  • each of the air slots 178 may pass through the interior of the coolant accommodation portion 175.
  • each of the air slots 178 may have a circumferential surface (outer wall) having a rectangular pipe shape.
  • Each of the air slots 178 may be configured such that the circumferential surface thereof is entirely in contact with the coolant.
  • the air slots 178 may be formed such that a flow cross-sectional area thereof gradually decreases inwardly in a radial direction of the second case 161.
  • a space portion 180 may be formed in an outer central region of the radial section portion 162a of the second case 161.
  • the space portion 180 is configured to be demarcated with respect to the coolant accommodation portion 175 by a circular outer wall or a rib 181.
  • a lower end of each of the air slots 178 may be connected to and communicate with the space portion.
  • An internal inlet 179 may be formed in a penetrating manner in the space portion 180 to allow air of the space portion 180 to be introduced to the interior of the second case 161.
  • a plurality of internal inlets 179 may be formed to be spaced apart in a circumferential direction on the circumference of the bearing coupling unit 164 of the second case 161, for example.
  • cooling of the bearing 145 may be accelerated.
  • Discharge holes 182 may be formed in the second case 161 to allow internal air to be discharged to the outside.
  • the discharge holes 182 of the second case 161 may be formed on one side of the intake hole 172 of the second case 161 in an axial direction, for example.
  • the discharge holes 182 of the second case 161 may be formed on an outer side of a coil end of the stator coil 117, for example.
  • the discharge holes 182 of the second case 161 may have a length L2 longer in the axial direction than a width W2 in the circumferential direction, for example.
  • the discharge holes 182 of the second case 161 may be formed to be spaced apart from one another at preset intervals in the circumferential direction of the second case 161.
  • the discharge holes 182 of the second case 161 may have an overall flow cross-sectional area greater than that of the intake holes 172 of the second case 161.
  • an air flow may be smoothly performed to increase a cooling effect.
  • the circuit unit installation unit 173 of the second case 161 may include a heating element installation member 210 in which the heating elements 192 are installed, for example.
  • an opening of the coolant accommodation portion 175 may be blocked.
  • the heating elements 192 having a high heating value is rapidly cooled, heat having a high temperature generated by the heating elements 192 is restrained from being spread to the vicinity within the accommodation space of the circuit unit 190, thus suppressing generation of a bad influence on a peripheral circuit component due to the heat having a high temperature.
  • the heating element installation member 210 may be formed as a plate-shape member, and may be coupled to be in contact with an outer surface of the second case 161, that is, with one plate surface of the circuit unit installation unit 173.
  • a sealing member 211 may be provided between the circuit unit installation unit 173 and the heating element installation member 210 in order to maintain airtightness of the coolant accommodation portion 175.
  • the sealing member 211 may be provided between an outer edge and an inner edge (rib 181) of the coolant accommodation portion 175 and the heating element installation member 210 to prevent leakage of the coolant.
  • the heating elements 192 may be coupled to the other plate surface (outer surface) of the heating element installation member 210.
  • three heating elements may be formed and spaced apart from one another.
  • a plurality of bosses 220 may be formed on the other plate surface of the heating element installation member 210 and protrude outwardly from the plate surface.
  • the heating element installation member 210 may include a protrusion portion 212 protruding to one side in a radial direction of the second case 161, for example.
  • a connector lead out hole 214 may be formed in the protrusion portion 212 to allow a connector 195, to which a power source (an input power source and/or an output power source) is connected, to be led out therethrough.
  • a ground unit lead out hole 215 may be formed in the protrusion portion to allow a grounding unit 197 to be led out therethrough.
  • the PCB 194 may be coupled to and supported by the bosses 220.
  • the connector 195 and the grounding unit 197 may be provided on one side of the PCB 194, for example.
  • a circuit unit case 225 for covering the circuit unit 190 may be provided in the circuit unit installation unit 173 of the second case 161.
  • the circuit unit case 225 may be configured to correspond to a shape of the heating element installation member 210 and have a container-like shape opened toward the heating element installation member 210.
  • the circuit unit case 225 may be coupled to be in contact with the heating element installation member 210 to form a hermetically closed accommodation space of the circuit unit 190.
  • the coolant accommodation portion 175 may be connected to a coolant circulation unit 230.
  • the coolant circulation unit 230 may include a flow channel 232 in which the coolant circulates, a pump 234 accelerating circulation of the coolant, and a switching valve (or an ON/OFF valve) 236 opening and closing the flow channel 232.
  • one end portion of the flow channel 232 may be connected to the inlet 176, and the other end portion of the flow channel 232 may be connected to the outlet 177.
  • the flow channel 232 may be configured to pass through a heat exchanging unit 238 such that the coolant may be heat-exchanged.
  • the heat exchanging unit may be, for example, a radiator of a vehicle.
  • the coolant of the coolant accommodation portion 175 may be discharged through the outlet 177 and moves along the flow channel 232 so as to be cooled by the heat exchanging unit 238, and moves again along the flow channel 232 so as to be introduced to the interior of the coolant accommodation portion 175 through the inlet 176, and by repeatedly performing this process, the second case 161 and the circuit unit 190 may be cooled.
  • the rotating electric machine may include a control unit 240 implemented as a microprocessor including a control program.
  • control unit 240 may be configured to sense a temperature of the coolant and control the switching valve 236 on the basis of the sensing result.
  • a coolant temperature sensing unit 245 for sensing a temperature of the coolant may be connected to the control unit 240 such that a sensing signal may be transmitted.
  • the coolant temperature sensing unit 245 may be provided in the outlet 177 of the coolant accommodation portion 175, for example.
  • the switching valve 236 for opening and closing the flow channel 232 may be connected to the control unit 240 such that the switching valve 236 may be controlled.
  • control unit 240 may be configured to control the switching valve 236 to open the flow channel 232 when a sensing result of the coolant temperature sensing unit 245 is equal to or higher than a preset temperature,.
  • the preset temperature may be, for example, 100.
  • control unit 240 may control the switching valve 236 to close the flow channel 232.
  • the preset temperature of the coolant may be differently set.
  • the rotor 120 may rotate around the shaft 127 according to interaction between the stator coil 117 and the rotor coil 125.
  • Temperatures of the stator 110 and the rotor 120 may increase as the stator coil 117 and the rotor coil 125 are heated.
  • air intaken in the axial direction through the intake hole 152 of the first case 141 may be changed in direction so as to move in a radial direction and may be discharged to the outside through the discharge hole 154 formed across the radial section portion 142a and the circumferential section portion 142b of the first case 141.
  • portions (left end portions) of the rotor 120 and the stator 110 are cooled, and in particular, cooling of a coil end of the rotor coil 125 and a coil end of the stator coil 117 having a relatively high heating value may be accelerated.
  • stator 110 is substantially exposed to the outside and is in direct contact with ambient air, and thus, heat dissipation thereof may be further accelerated.
  • each intake hole 172 of the second case 161 may move to the space portion 180 along each air slot 178 and may be introduced to the interior of the second case 161 through the internal inlet 179.
  • the air introduced to the interior of the second case 161, while moving in the radial direction, may cool the coil end of the rotor coil 125 and the coil end of the stator coil 117 and may be discharge to the outside through the discharge hole 182.
  • the coolant within the coolant accommodation portion 175 is cooled and the circuit unit 190 may be cooled by the cooled coolant.
  • the stator core 111 is in contact with the first case 141 and the second case 161 by the stator core coupling units 147 and 167 such that the stator core 111 is thermally conducted, and thus, heat of the stator core 111 having a relatively high temperature may be thermally conducted to the first case 141 and the second case 161, accelerating cooling of the stator core 111.
  • control unit 240 may sense a temperature of the coolant.
  • control unit 240 may control the switching valve 236 to open the flow channel 232.
  • the control unit 240 may control the pump 234 to be driven to accelerate circulation of the coolant.
  • the coolant flowing out through the outlet 177 may be heat-exchanged in the heat-exchanging unit 238 so as to be cooled, and move along the flow channel 232.
  • the cooled coolant may be introduced to the coolant accommodation portion 175 through the inlet 176, move along the interior of the coolant accommodation portion 175 to cool the second case 161, and discharged to the outside of the coolant accommodation portion 175 through the outlet 177.
  • This circulation process is repeatedly performed to cool the second case 161 and the circuit unit 190.
  • control unit 240 may control the pump 234 to be stopped from driving.

Abstract

A rotating electric machine includes a stator; a rotor disposed to be rotatable with respect to the stator; a case including a first case and a second case formed of a thermally conductible member and disposed to face each other, and disposed on outer side of the stator; a circuit unit installed in the first case or the second case; a cooling fan provided in the rotor, and a coolant accommodation portion formed to accommodate a coolant in a region of the first case or the second case in which the circuit unit is installed, and allowing the circuit unit to be cooled by the coolant. An increase in size and weight of an appearance due to a cooling unit may be suppressed, and an increase in temperature of some components may be suppressed.

Description

ROTATING ELECTRIC MACHINE
The present disclosure relates to a rotating electric machine, and particularly, to a rotating electric machine, which has a reduced size, and in which an increase in a temperature of a portion is suppressed.
As known, a rotating electric machine includes a power generator converting mechanical energy into electrical energy and a motor converting electrical energy into mechanical energy.
The rotating electric machine includes a cooling unit for performing cooling when a temperature increases according to an operation of the rotating electric machine, to thus prevent a degradation of operational efficiency.
The cooling unit of the rotating electric machine is classified into an air cooling-type cooling unit for performing cooling using air and a water cooling-type cooling unit using a coolant.
In the related art rotating electric machine, when the air cooling-type cooling unit is used, a cooling effect is not sufficient in terms of the characteristics of air, and thus, a temperature of some components may increase.
Also, in case of using a water cooling-type cooling unit, it is not easy to cool a rotor, and thus, there is a limitation in cooling a rotating electric machine including a rotor having a rotor coil generating a relatively large amount of heat.
Also, in case of using the water cooling-type cooling unit, a water jacket accommodating a coolant is so thick that a size and weight of the rotating electric machine increase to obstruct a compact configuration of the machine.
In particular, in a case in which an inverter-integrated rotating electric machine uses a water cooling-type cooling unit, a water jacket for cooling a stator and a water jacket for cooling the inverter should be separately provided, increasing the size in appearance and weight of the machine, and the water cooling-type cooling unit is not appropriate for a rotor having a rotor coil generating a relatively large amount of heat, and thus, there is a limitation in using the water cooling-type cooling unit.
Also, in a case in which the inverter-integrated rotating electric machine uses an air cooling-type cooling unit, since a size of an appearance thereof does not increase relatively, allowing for a compact configuration, the inverter-integrated rotating electric machine may use a rotor including a rotor coil, but cooling of the inverter is not sufficient.
Therefore, an aspect of the detailed description is to provide a rotating electric machine which has a reduced size and in which an increase in a temperature of some components is suppressed.
Another aspect of the detailed description is to provide a rotating electric machine capable of enhancing a cooling effect by selectively using different cooling fluids.
To achieve these and other advantages and in accordance with the purpose of this specification, as embodied and broadly described herein, a rotating electric machine includes: a stator; a rotor disposed to be rotatable with respect to the stator; a case including a first case and a second case formed of a thermally conductible member and disposed to face each other, and disposed on outer side of the stator; a circuit unit installed in the first case or the second case; a cooling fan provided in the rotor; and a coolant accommodation portion formed to accommodate a coolant in a region of the first case or the second case in which the circuit unit is installed, and allowing the circuit unit to be cooled by the coolant.
A circuit unit installation unit in which the circuit unit is installed may be formed on an outer surface of the coolant accommodation portion.
The first case and the second case may each include a radial section portion disposed in a radial direction of the rotor and a circumferential section portion extending from the radial section portion in a circumferential direction, and the first case or the second case may include an intake hole allowing air to be intaken therethrough and a discharge hole allowing air to be discharged therethrough.
The coolant accommodation portion may be formed in the radial section portion of any one of the first case and the second case.
The circuit unit may include an inverter including a plurality of switching elements.
The case may further include a circuit unit case accommodating the circuit unit.
The rotor may include a rotor core and a rotor coil wound around the rotor core.
A power supply unit supplying power to the rotor coil may be disposed on one side of the coolant accommodation portion.
A plurality of cooling fans may be provided on both sides of the rotor.
The coolant accommodation portion may be formed in the radial section portion of the second case, the suction hole may be formed both in the radial section portion of the first case and in the circumferential section portion of the second case, and the discharge hole may be formed in the radial section portion or the circumferential section portion of the first case and in the circumferential section portion of the second case.
The intake hole formed in the circumferential section portion of the second case may be formed such that a length thereof in a circumferential direction is greater than a width thereof in an axial direction.
A plurality of intake holes formed in the circumferential section portion of the second case may be spaced apart from one another in the circumferential direction of the second case.
An air slot may be provided to be disposed in a radial direction within the coolant accommodation portion and communicate with the intake hole to allow air intaken through the intake hole formed in the circumferential section portion of the second case to move in a radial direction.
The second case may include a space portion temporarily accommodating air which has been moved along the air slot at an inner side of the coolant.
The second case may include an internal inlet formed to allow air of the space portion to be introduced to the interior of the second case.
The second case may include a rib provided between the coolant accommodation portion and the space portion to demarcate the coolant accommodation portion and the space portion.
The coolant accommodation portion may have a shape recessed inwardly in an axial direction from the circuit unit installation unit.
The circuit unit installation unit may include a heating element installation member in which a heating element is installed.
The coolant accommodation portion may be configured such that an opening thereof is blocked by the heating element installation member.
The air slot may penetrate through the coolant accommodation portion, and a coolant of the coolant accommodation portion may be in contact with a circumference (outer surface) of the air slot.
The cooling fan may include a first cooling fan and a second cooling fan provided on both sides of the rotor.
Among the first cooling fan and the second cooling fan, any one disposed to be adjacent to the coolant accommodation portion may be configured to have an air volume larger than that of the other.
The first case and the second case may be disposed to be spaced apart from one another in both end portions of the stator in an axial direction.
A region of the stator between the first case and the second case is exposed to the outside, and an uneven portion may be provided on an outer surface of the stator in order to increase a surface area.
Air may be intaken in an axial direction to the interior of the first case by the first cooling fan and may be discharged in a radial direction from the first case.
Air may be intaken in a radial direction to the interior of the second case by the second cooling fan and may be discharged in the radial direction from the second case.
The rotating electric machine may further include a coolant circulation unit communicating with the coolant accommodation portion and allowing the coolant to circulate by way of the coolant accommodation portion.
The coolant circulation unit may include a flow channel in which the coolant circulates; a pump configured to accelerate circulation of the coolant; and a switching valve (or an ON/OFF valve) configured to open and close the flow channel.
The coolant circulation unit may further include a coolant temperature sensing unit configured to sense a temperature of the coolant.
The rotating electric machine may further include a control unit configured to control the switching valve on the basis of a sensing result from the coolant temperature sensing unit.
The coolant accommodation portion may include an inlet through which the coolant is introduced to the interior and an outlet through which the coolant within the coolant accommodation portion flows out.
The coolant temperature sensing unit may be provided in the outlet.
Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from the detailed description.
As described above, according to the embodiments of the present invention, since the coolant accommodation portion cooling the cooling fan and the circuit unit is provided, an increase in a size and weight of the appearance may be suppressed and an increase in temperature of the circuit unit may be suppressed.
Also, when a temperature of the circuit unit is relatively high, the circuit unit is cooled by the coolant, thereby suppressing a degradation of performance duel to an increase in temperature of the circuit unit.
Also, when a temperature of the circuit unit is relatively high, the coolant circulation unit is driven to effectively cool the circuit unit.
In addition, an increase in temperature of the rotor (rotor coil) can be effectively suppressed by cooling the rotor by the cooling fan.
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a perspective view of a rotating electric machine according to an embodiment of the present disclosure.
FIG. 2 is a cross-sectional view of the rotating electric machine of FIG. 1.
FIG. 3 is a front view of the rotating electric machine of FIG. 1.
FIG. 4 is a right side view of the rotating electric machine of FIG. 3.
FIG. 5 is a rear perspective view of a second case of FIG. 1.
FIG. 6 is a rear view of the second case of FIG. 5.
FIG. 7 is a cross-sectional view illustrating a coupled state of a heating element installation member taken along line VII-VII of FIG. 6.
FIG. 8 is a cross-sectional view illustrating a coupled state of the heating element installation member taken along line VIII-VIII of FIG. 6.
FIG. 9 is a perspective view illustrating a state before a circuit unit case and the heating element installation member of FIG. 1 are coupled.
FIG. 10 is a perspective view illustrating an installation state of the heating element installation member of FIG. 9.
FIG. 11 is a view illustrating a coolant circulation unit of the rotating electric machine of FIG. 1.
FIG. 12 is a control block diagram of the rotating electric machine of FIG. 1.
Hereinafter, embodiments will be described in detail with reference to the accompanying drawings such that they can be easily practiced by those skilled in the art to which the present invention pertains. In describing the present invention, a detailed description of known techniques associated with the present invention unnecessarily obscure the gist of the present invention, it is determined that the detailed description thereof will be omitted.
As illustrated in FIGS. 1 and 2, a rotating electric machine according to an embodiment of the present disclosure may include a stator 110, a rotor 120 rotatably disposed with respect to the stator 110, a case 140 including a first case 141 and a second case 142 formed as thermally conductive members and disposed to face each other, and disposed outside of the stator 110, a circuit unit 190 installed in the first case 141 or the second case 161, a cooling fan 130 provided in the rotor 120, and a coolant accommodation portion 175 formed in a region of the first case 141 or the second case 161 in which the circuit unit 190 is installed to accommodate a coolant to cool the circuit unit 190 by the coolant.
The stator 110 may include, for example, a stator core 111 and a stator coil 117 wound around the stator core 111.
The stator core 111 may include a rotor accommodation hole 114 for accommodating the rotor 120 therein, for example.
The stator core 111 may be formed by stacking a plurality of electrical sheets (or silicon steel sheets)112 with the rotor accommodation hole 114 formed in the center thereof, for example.
Although not shown specifically, in the stator core 110, a pole and a slot may be alternately formed in the circumference of the rotor accommodation hole 114.
The stator core 111 may be configured such that an outer surface thereof has a circular shape, for example.
As illustrated in FIG. 4, an irregular portion 116 may be formed on an outer circumferential surface of the stator core 111 such that a surface area thereof may increase.
Accordingly, heat dissipation of the stator 110 may be accelerated.
The irregular portion 116 of the stator core 111 may be formed to be recessed in a radial direction and extend in an axial direction, for example.
A plurality of irregular portions 116 may be formed and spaced apart from one another in a circumferential direction of the stator core 111, for example.
The stator coil 117 may be inserted within the slot and wound around the pole.
The rotor 120 may include, for example, a rotor core 121 and a rotor coil 125 wound around the rotor core 121.
A shaft 127 may be provided in the center of the rotor core 121.
The rotor core 121 may be formed by stacking a plurality of electric steel sheets 122 each having a shaft hole 124 formed in a center thereof to allow the shaft 127 to be inserted therethrough, for example.
Although not shown, in the rotor core 121, a pole and a slot may be alternately formed in the circumference of the shaft hole 124, for example.
The rotor coil 125 may be inserted within the slot and may be wound around the pole.
The rotor 120 may include a cooling fan 130 to intake air when rotated, for example.
The cooling fan 130 may be configured as a centrifugal fan intaking air in an axial direction and discharging air in a radial direction, for example.
The cooling fan 130 may include a first cooling fan 131 and a second cooling fan 132 provided in both end portions of the rotor 120 in an axial direction of the rotor 120.
The second cooling fan 132 may be configured to have an air volume greater than that of the first cooling fan 131, for example.
In detail, for example, the second cooling fan 132 may include a blade having a width and/or length greater than that of the first cooling fan 131.
A power supply unit 128 supplying power to the rotor coil 125 may be provided in the shaft 127.
Although not shown in detail, the power supply unit 128 may include, for example, a slip ring provided in the shaft 127 and a brush in contact with the slip ring.
A pulley 129 may be provided in one end portion of the shaft 127.
The other side of a transmission belt (not shown), one side of which is coupled to a pulley (not shown) of an engine of a vehicle, may be coupled to the pulley 129, for example.
The rotating electric machine of the present embodiment may serve as a starter for driving an engine of a vehicle when the vehicle starts, for example.
Also, the rotating electric machine of the present embodiment may function as a generator producing electricity upon receiving power from the engine while the vehicle is driving.
In the other end portion (the right end portion in the drawing) of the shaft 127, the power supply unit 128 of the rotor 120 may be provided, for example.
Meanwhile, the stator core 111 may be configured to have circular shape in an outer surface thereof, for example.
The case 140 may be provided on outer side of the stator 110.
The case 140 may be configured to support the stator 110 and the rotor 120, for example.
The case 140 may include the first case 141 and the second case 161 disposed to face each other with the stator 110 interposed therebetween, for example.
The first case 141 and the second case 161 may be configured to be coupled to both end portions of the stator 110 along the axial direction, for example.
For example, a central region of the stator 110 may be exposed to outside of the first case 141 and the second case 161 in the axial direction.
The first case 141 and the second case 161 may include coupling arms 146 and 166 protruding in a radial direction, respectively, for example.
Coupling bosses 150 and 170 may protrude from end portions of the coupling arm 146 of the first case 141 and the coupling arm 166 of the second case 161 in an axial direction, respectively.
End portions of the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161 may be configured to be in contact with each other.
Fastening member insertion holes 151 and 171 may penetrate through the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161, respectively, such that a fastening member (not shown) may be inserted thereinto.
The fastening member may be coupled to both the coupling boss 150 of the first case 141 and the coupling boss 170 of the second case 161 so as to be coupled to an object (for example, a body of a vehicle) to fixedly couple the rotating electric machine to the object (for example, the body of the vehicle).
The first case 141 may be provided on one side (the left side in the drawing) of the stator 110, for example.
The first case 141 may be configured to have a cylindrical shape with one side opened, for example.
The first case 141 may be configured to include a radial section portion 142a disposed in a radial direction and a circumferential section portion extending from the radial section portion 142a in an axial direction.
The first case 141 may include a stator core coupling unit 147 to which an outer surface of the stator core 111 is insertedly coupled, for example.
The stator core coupling unit 147 of the first case 141 may be formed to allow the stator core 111 to be inserted therein by a predetermined depth.
As illustrated in FIG. 2, the stator core coupling unit 147 of the first case 141 may include an extending portion 148 extending in a radial direction, compared with the circumferential section portion 142b and a cylindrical portion 149 extending from the extending portion 148 in an axial direction.
For example, the extending potion 148 may come into contact with an end portion of the stator core 111 to limit insertion of the stator core 111.
The first case 141 may include a bearing coupling unit 144 allowing a bearing 145 rotatably supporting one side (left side in the drawing) of the shaft 127, for example, to be accommodated therein and coupled thereto.
The first case 141 may include, for example, an intake hole 152 allowing air to be intaken when the cooling fan 130 rotates.
The intake hole 152 may be formed in a radial section portion 142a of the first case 141.
For example, as illustrated in FIG. 3, the intake hole 152 of the first case 141 may be formed on an outer side of the bearing coupling unit 144 in the radial direction of the first case 141.
The first case 141 may include, for example, a discharge hole 142 allowing air to be discharged therethrough.
The discharge hole 154 may be formed on an outer side of the intake hole 152 of the first case 141 in the radial direction, for example.
The discharge hole 154 may be formed in the radial section portion 142a of the first case 141, for example.
The discharge hole 154 may be formed in the circumferential section portion 142b of the first case 141, for example.
The discharge hole 154 may be formed in both of the radial section portion 142a and the circumferential section portion 142b of the first case 141, for example.
The discharge hole 154 may be formed to have a reverse "L" shape over the radial section portion 142a and the circumferential section portion 142b of the first case 141, for example.
The discharge hole 154 may include a vertical section 155 formed in the radial section portion 142a of the first case 141 and a horizontal section 149 formed in the circumferential section portion 142b, for example.
The discharge hole 154 of the first case 141 may have an overall flow cross-sectional area greater than an overall flow cross-sectional area of the intake holes 152 of the first case 141 (the sum of the flow cross-sectional areas of a plurality of intake holes 152).
Thus, air may smoothly flow to increase a cooling effect.
Meanwhile, the second case 161 may be provided on the other side (right side in the drawing) of the stator 110.
The second case 161 may have a cylindrical shape with one side thereof opened.
As illustrated in FIG. 5, the second case 161 may include a radial section portion 162a disposed in a radial direction and a circumferential section portion 162b extending from the radial section portion 162a in an axial direction.
The second case 161 may include, for example, a stator core coupling unit 167 to which an outer surface of the stator core 111 is insertedly coupled.
The stator core coupling unit 167 of the second case 161 may be formed such that the stator core 111 can be inserted therein to a predetermined depth.
The stator core coupling unit 167 of the second case 161 may include an extending portion 168 extending in a radial direction compared with the circumferential section portion 162b of the second case 161 and a cylindrical portion 169 extending from the extending portion 168 in the axial direction.
The extending portion 169 may come into contact with an end portion of the stator core 111 to limit insertion of the stator core 111, for example.
The second case 161 may include a bearing coupling unit 164 in which the bearing 145 rotatably supporting the other side (right side in the drawing) of the shaft 127 is accommodated and coupled, for example.
Meanwhile, as illustrated in FIG. 5, a circuit unit installation unit 173 in which the circuit unit 190 is installed may be formed on an outer surface of the second case 161, for example.
A coolant accommodation portion 175 accommodating a coolant to cool the circuit unit 190 may be provided in the circuit unit installation unit 173.
The circuit unit 190 may include an inverter including a plurality of heating elements 192 and a printed circuit board 194, for example.
The plurality of heating elements 192 may include a switching element called an insulted gate bipolar transistor (IGBT), for example.
The coolant accommodation portion 175 may be formed in the radial section portion 162a of the second case 161, for example.
The coolant accommodation portion 175 may be formed in the radial section portion 162a of the second case 161, for example.
The coolant accommodation portion 175 may be recessed inwardly from the circuit unit installation unit 173 in an axial direction, for example.
The coolant accommodation portion 175 may be configured such that the interior there of is hermetically closed with respect to the outside when a heating element installation member 210 (to be described hereinafter) is coupled to the circuit unit 173 of the second case 161.
The coolant accommodation portion 175 may be positioned on outer side of the bearing accommodation unit 164 in a radial direction, for example.
The coolant accommodation portion 175 may have a circular ring (tube) shape, for example.
Meanwhile, an inlet 176 may be provided in the second case 161 to allow a coolant to be introduced to the interior of the coolant accommodation portion 175.
The inlet 176 may outwardly protrude in a radial direction of the second case 161 and bent to extend in an axial direction.
An outlet 177 may be formed in the second case 161 to allow a coolant within the coolant accommodation portion 175 to flow out therethrough.
The outlet 177 may protrude in a radial direction from an outer surface of the circumferential section portion 162b of the second case 161 and bent to extend in an axial direction.
The second case 161 may include intake holes 172 allowing air to be intaken therethrough to the interior when the cooling fan 130 rotates.
The intake holes 172 of the second case 161 may be formed in the circumferential section portion 162b of the second case, for example.
As illustrated in FIG. 4, each of the intake holes 172 formed in the circumferential section portion 162b of the second case 161 may have a length L1 extending in a circumferential direction compared with a width W1 thereof in an axial direction.
Thus, a contact area (heat exchange) in which air intaken through the intake holes 172 is heat-exchanged with the circuit unit installation unit 173 increases to accelerate cooling of the circuit unit 190.
The intake holes 172 formed in the circumferential section portion 162b of the second case 161 may be spaced apart from one another in the circumferential direction.
The intake holes 172 formed in the circumferential section portion 162b of the second case 161 may be spaced apart from one another at equal intervals on the same circumference.
Air flow channels or air slots 178 (hereinafter, referred to as "air slots 178") may be formed in the coolant accommodation portion 175 to allow air intaken through the intake holes 172 of the second case 161 to move therealong so as to be heat-exchanged with a coolant.
The air slots 178 may be formed to be connected to the intake holes 172 of the second case 161, respectively.
In the present embodiment, as illustrated in FIG. 6, for example, four intake holes 172 are formed in the second case 161, and four air slots 187 are formed to correspond to the number of intake hole 172, but the numbers of the intake holes 172 and the air slots 178 may be appropriately adjusted in consideration of the size and/or a heating value of the circuit unit installation unit 173.
The air slots 178 may be formed in a radial direction of the second case 161, for example.
As illustrated in FIG. 5, each of the air slots 178 may pass through the interior of the coolant accommodation portion 175.
As illustrated in FIG. 8, each of the air slots 178 may have a circumferential surface (outer wall) having a rectangular pipe shape.
Each of the air slots 178 may be configured such that the circumferential surface thereof is entirely in contact with the coolant.
Thus, heat exchange between air moving along the air slots 178 and the coolant in contact with the circumferential surface of each of the air slots 178 may be accelerated.
For example, the air slots 178 may be formed such that a flow cross-sectional area thereof gradually decreases inwardly in a radial direction of the second case 161.
A space portion 180 may be formed in an outer central region of the radial section portion 162a of the second case 161.
As illustrated in FIG. 5, for example, the space portion 180 is configured to be demarcated with respect to the coolant accommodation portion 175 by a circular outer wall or a rib 181.
A lower end of each of the air slots 178 may be connected to and communicate with the space portion.
Thus, air intaken through each of the intake holes 172 and moving along each of the air slots 178 may join in the space portion 180.
An internal inlet 179 may be formed in a penetrating manner in the space portion 180 to allow air of the space portion 180 to be introduced to the interior of the second case 161.
A plurality of internal inlets 179 may be formed to be spaced apart in a circumferential direction on the circumference of the bearing coupling unit 164 of the second case 161, for example.
According to this configuration, cooling of the bearing 145 may be accelerated.
Discharge holes 182 may be formed in the second case 161 to allow internal air to be discharged to the outside.
The discharge holes 182 of the second case 161 may be formed on one side of the intake hole 172 of the second case 161 in an axial direction, for example.
The discharge holes 182 of the second case 161 may be formed on an outer side of a coil end of the stator coil 117, for example.
Thus, cooling of the coil end of the stator coil 117 may be accelerated.
The discharge holes 182 of the second case 161 may have a length L2 longer in the axial direction than a width W2 in the circumferential direction, for example.
The discharge holes 182 of the second case 161 may be formed to be spaced apart from one another at preset intervals in the circumferential direction of the second case 161.
The discharge holes 182 of the second case 161 may have an overall flow cross-sectional area greater than that of the intake holes 172 of the second case 161.
Accordingly, an air flow may be smoothly performed to increase a cooling effect.
Meanwhile, the circuit unit installation unit 173 of the second case 161 may include a heating element installation member 210 in which the heating elements 192 are installed, for example.
Thus, an opening of the coolant accommodation portion 175 may be blocked.
According to this configuration, heat exchange between the heating elements 192 having a relatively high heating value and the coolant is accelerated to rapidly cool the heating elements 192.
Also, since the heating elements 192 having a high heating value is rapidly cooled, heat having a high temperature generated by the heating elements 192 is restrained from being spread to the vicinity within the accommodation space of the circuit unit 190, thus suppressing generation of a bad influence on a peripheral circuit component due to the heat having a high temperature.
The heating element installation member 210 may be formed as a plate-shape member, and may be coupled to be in contact with an outer surface of the second case 161, that is, with one plate surface of the circuit unit installation unit 173.
As illustrated in FIG. 7, a sealing member 211 may be provided between the circuit unit installation unit 173 and the heating element installation member 210 in order to maintain airtightness of the coolant accommodation portion 175.
For example, the sealing member 211 may be provided between an outer edge and an inner edge (rib 181) of the coolant accommodation portion 175 and the heating element installation member 210 to prevent leakage of the coolant.
The heating elements 192 may be coupled to the other plate surface (outer surface) of the heating element installation member 210.
For example, as illustrated in FIGS. 9 and 10, three heating elements may be formed and spaced apart from one another.
In this embodiment, the case in which three heating elements 192 are provided is illustrated as an example, but the number of the heating elements may be appropriately adjusted.
A plurality of bosses 220 may be formed on the other plate surface of the heating element installation member 210 and protrude outwardly from the plate surface.
The heating element installation member 210 may include a protrusion portion 212 protruding to one side in a radial direction of the second case 161, for example.
A connector lead out hole 214 may be formed in the protrusion portion 212 to allow a connector 195, to which a power source (an input power source and/or an output power source) is connected, to be led out therethrough.
A ground unit lead out hole 215 may be formed in the protrusion portion to allow a grounding unit 197 to be led out therethrough.
The PCB 194 may be coupled to and supported by the bosses 220.
The connector 195 and the grounding unit 197 may be provided on one side of the PCB 194, for example.
A circuit unit case 225 for covering the circuit unit 190, for example, may be provided in the circuit unit installation unit 173 of the second case 161.
For example, the circuit unit case 225 may be configured to correspond to a shape of the heating element installation member 210 and have a container-like shape opened toward the heating element installation member 210.
The circuit unit case 225 may be coupled to be in contact with the heating element installation member 210 to form a hermetically closed accommodation space of the circuit unit 190.
Meanwhile, the coolant accommodation portion 175 may be connected to a coolant circulation unit 230.
For example, as illustrated in FIG. 11, the coolant circulation unit 230 may include a flow channel 232 in which the coolant circulates, a pump 234 accelerating circulation of the coolant, and a switching valve (or an ON/OFF valve) 236 opening and closing the flow channel 232.
For example, one end portion of the flow channel 232 may be connected to the inlet 176, and the other end portion of the flow channel 232 may be connected to the outlet 177.
The flow channel 232 may be configured to pass through a heat exchanging unit 238 such that the coolant may be heat-exchanged.
The heat exchanging unit may be, for example, a radiator of a vehicle.
The coolant of the coolant accommodation portion 175 may be discharged through the outlet 177 and moves along the flow channel 232 so as to be cooled by the heat exchanging unit 238, and moves again along the flow channel 232 so as to be introduced to the interior of the coolant accommodation portion 175 through the inlet 176, and by repeatedly performing this process, the second case 161 and the circuit unit 190 may be cooled.
Meanwhile, the rotating electric machine may include a control unit 240 implemented as a microprocessor including a control program.
As illustrated in FIG. 12, for example, the control unit 240 may be configured to sense a temperature of the coolant and control the switching valve 236 on the basis of the sensing result.
A coolant temperature sensing unit 245 for sensing a temperature of the coolant may be connected to the control unit 240 such that a sensing signal may be transmitted.
The coolant temperature sensing unit 245 may be provided in the outlet 177 of the coolant accommodation portion 175, for example.
The switching valve 236 for opening and closing the flow channel 232 may be connected to the control unit 240 such that the switching valve 236 may be controlled.
For example, the control unit 240 may be configured to control the switching valve 236 to open the flow channel 232 when a sensing result of the coolant temperature sensing unit 245 is equal to or higher than a preset temperature,.
Here, the preset temperature may be, for example, 100.
When a temperature of the coolant is lower than the preset temperature (for example, 100) the control unit 240 may control the switching valve 236 to close the flow channel 232.
In order to open and close the flow channel 232, the preset temperature of the coolant may be differently set.
Through such a configuration, when power is supplied to the stator 110 and the rotor 120, the rotor 120 may rotate around the shaft 127 according to interaction between the stator coil 117 and the rotor coil 125.
Temperatures of the stator 110 and the rotor 120 may increase as the stator coil 117 and the rotor coil 125 are heated.
When the cooling fan 130 starts to rotate together with the rotor 120, air may be intaken to the interior through the intake holes 152 and 172 of the first case 141 and the second case 161, respectively.
In detail, air intaken in the axial direction through the intake hole 152 of the first case 141 may be changed in direction so as to move in a radial direction and may be discharged to the outside through the discharge hole 154 formed across the radial section portion 142a and the circumferential section portion 142b of the first case 141.
During this process, portions (left end portions) of the rotor 120 and the stator 110 are cooled, and in particular, cooling of a coil end of the rotor coil 125 and a coil end of the stator coil 117 having a relatively high heating value may be accelerated.
Also, a central portion of the stator 110 is substantially exposed to the outside and is in direct contact with ambient air, and thus, heat dissipation thereof may be further accelerated.
Meanwhile air intaken through each intake hole 172 of the second case 161 may move to the space portion 180 along each air slot 178 and may be introduced to the interior of the second case 161 through the internal inlet 179.
The air introduced to the interior of the second case 161, while moving in the radial direction, may cool the coil end of the rotor coil 125 and the coil end of the stator coil 117 and may be discharge to the outside through the discharge hole 182.
As air moves along the air slot 178, the coolant within the coolant accommodation portion 175 is cooled and the circuit unit 190 may be cooled by the cooled coolant.
The stator core 111 is in contact with the first case 141 and the second case 161 by the stator core coupling units 147 and 167 such that the stator core 111 is thermally conducted, and thus, heat of the stator core 111 having a relatively high temperature may be thermally conducted to the first case 141 and the second case 161, accelerating cooling of the stator core 111.
Meanwhile, on the basis of the sensing signal sensed through the coolant temperature sensing unit 245, the control unit 240 may sense a temperature of the coolant.
When the sensed temperature of the coolant is equal to or higher than the preset temperature, for example, 100, the control unit 240 may control the switching valve 236 to open the flow channel 232.
The control unit 240 may control the pump 234 to be driven to accelerate circulation of the coolant.
When the pump 234 is driven, movement of the coolant along the flow channel 232 may be accelerated, and as soon as the coolant flows into the coolant accommodation portion 175 through the inlet 176, the coolant flows out through the outlet 177.
The coolant flowing out through the outlet 177 may be heat-exchanged in the heat-exchanging unit 238 so as to be cooled, and move along the flow channel 232.
The cooled coolant may be introduced to the coolant accommodation portion 175 through the inlet 176, move along the interior of the coolant accommodation portion 175 to cool the second case 161, and discharged to the outside of the coolant accommodation portion 175 through the outlet 177. This circulation process is repeatedly performed to cool the second case 161 and the circuit unit 190.
When a temperature of the coolant is lower than the preset temperature (100), the control unit 240 may control the pump 234 to be stopped from driving.
The foregoing embodiments and advantages are merely exemplary and are not to be considered as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
As the present features may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be considered broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims.

Claims (20)

  1. A rotating electric machine comprising:
    a stator;
    a rotor disposed to be rotatable with respect to the stator;
    a case including a first case and a second case formed of a thermally conductible member and disposed to face each other, and disposed on outer side of the stator;
    a circuit unit installed in the first case or the second case;
    a cooling fan provided in the rotor; and
    a coolant accommodation portion formed to accommodate a coolant in a region of the first case or the second case in which the circuit unit is installed, and allowing the circuit unit to be cooled by the coolant.
  2. The rotating electric machine of claim 1, wherein a circuit unit installation unit in which the circuit unit is installed is formed on an outer surface of the coolant accommodation portion.
  3. The rotating electric machine of claim 1, wherein the first case and the second case each include a radial section portion disposed in a radial direction of the rotor and a circumferential section portion extending from the radial section portion in a circumferential direction, and
    the first case or the second case includes an intake hole allowing air to be intaken therethrough and a discharge hole allowing air to be discharged therethrough.
  4. The rotating electric machine of claim 3, wherein the coolant accommodation portion is formed in the radial section portion of any one of the first case and the second case.
  5. The rotating electric machine of claim 4, wherein the circuit unit includes an inverter including a plurality of switching elements, and
    the case further includes a circuit unit case accommodating the circuit unit.
  6. The rotating electric machine of claim 5, wherein the rotor includes a rotor core and a rotor coil wound around the rotor core, and
    a power supply unit supplying power to the rotor coil is disposed on one side of the coolant accommodation portion.
  7. The rotating electric machine of claim 6, wherein a plurality of cooling fans are provided on both sides of the rotor.
  8. The rotating electric machine of claim 7, wherein
    the coolant accommodation portion is formed in the radial section portion of the second case,
    the suction hole is formed both in the radial section portion of the first case and in the circumferential section portion of the second case, and
    the discharge hole is formed in the radial section portion or the circumferential section portion of the first case and in the circumferential section portion of the second case.
  9. The rotating electric machine of claim 7, wherein
    the intake hole formed in the circumferential section portion of the second case is formed such that a length thereof in a circumferential direction is greater than a width thereof in an axial direction, and
    a plurality of intake holes formed in the circumferential section portion of the second case are spaced apart from one another in the circumferential direction of the second case.
  10. The rotating electric machine of claim 7, wherein an air slot is provided to be disposed in a radial direction within the coolant accommodation portion and communicates with the intake hole to allow air intaken through the intake hole formed in the circumferential section portion of the second case to move in a radial direction.
  11. The rotating electric machine of claim 10, wherein the second case comprises:
    a space portion temporarily accommodating air which has been moved along the air slot at an inner side of the coolant; and
    an internal inlet formed to allow air of the space portion to be introduced to the interior of the second case.
  12. The rotating electric machine of claim 11, wherein the second case includes a rib provided between the coolant accommodation portion and the space portion to demarcate the coolant accommodation portion and the space portion.
  13. The rotating electric machine of claim 11, wherein
    the coolant accommodation portion has a shape recessed inwardly in an axial direction from the circuit unit installation unit,
    the circuit unit installation unit includes a heating element installation member in which a heating element is installed, and
    the coolant accommodation portion is configured such that an opening thereof is blocked by the heating element installation member.
  14. The rotating electric machine of claim 11, wherein the air slot penetrates through the coolant accommodation portion, and a coolant of the coolant accommodation portion is in contact with a circumference of the air slot.
  15. The rotating electric machine of claim 11, wherein
    the cooling fan includes a first cooling fan and a second cooling fan provided on both sides of the rotor, and
    among the first cooling fan and the second cooling fan, any one disposed to be adjacent to the coolant accommodation portion is configured to have an air volume larger than that of the other.
  16. The rotating electric machine of claim 15, wherein
    the first case and the second case are disposed to be spaced apart from one another in both end portions of the stator in an axial direction,
    air is intaken in an axial direction to the interior of the first case by the first cooling fan and is discharged in a radial direction from the first case, and
    air is intaken in a radial direction to the interior of the second case by the second cooling fan and is discharged in the radial direction from the second case.
  17. The rotating electric machine of any one of claims 1 to 16, further comprising:
    a coolant circulation unit communicating with the coolant accommodation portion and allowing the coolant to circulate by way of the coolant accommodation portion.
  18. The rotating electric machine of claim 17, wherein the coolant circulation unit comprises:
    a flow channel in which the coolant circulates;
    a pump configured to accelerate circulation of the coolant; and
    a switching valve configured to open and close the flow channel.
  19. The rotating electric machine of claim 18, wherein
    the coolant circulation unit further includes a coolant temperature sensing unit configured to sense a temperature of the coolant, and
    the rotating electric machine further comprising:
    a control unit configured to control the switching valve on the basis of a sensing result from the coolant temperature sensing unit.
  20. The rotating electric machine of claim 19, wherein
    the coolant accommodation portion includes an inlet through which the coolant is introduced to the interior and an outlet through which the coolant within the coolant accommodation portion flows out, and
    the coolant temperature sensing unit is provided in the outlet.
PCT/KR2015/007045 2014-12-16 2015-07-08 Rotating electric machine WO2016098977A1 (en)

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