CN112542924B - 机电一体型电力转换装置及电动汽车用驱动装置 - Google Patents
机电一体型电力转换装置及电动汽车用驱动装置 Download PDFInfo
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Abstract
本发明提供一种机电一体型电力转换装置及电动汽车用驱动装置,在动力驱动单元和电压转换器被收纳在单一的收纳箱的内部并被模块化的电力转换装置中,将搭载在电动机的壳体上的状态下的包括电动机在内的整体高度抑制得尽可能小。收纳箱(17)包括:箱体(18),其包括配置在电动机(11A)的壳体(13)的上方的箱体主部(18a)和与箱体主部的侧壁一体相连且垂下到壳体(13)的侧方的箱体剩余部(18b);上方盖部件(19),其在与箱体主部之间形成收纳动力驱动单元(28)的第一收纳室(21),并安装在箱体主部;侧方盖部件(20),其在与箱体剩余部之间形成收纳电压转换器(29)的第二收纳室(22),并安装在箱体剩余部的侧方开放端部。
Description
技术领域
本发明涉及将控制电动机的动作的动力驱动单元和电压转换器收纳在单一的收纳箱的内部并模块化而成的机电一体型电力转换装置、以及使用该机电一体型电力转换装置的电动汽车用驱动装置。
背景技术
在专利文献1中已知有如下结构:动力驱动单元和下转换器以层叠状态组装并一体化,由此构成高压电装模块体,该高压电装模块体配置在电动机及变速器的上方。
现有技术文献
专利文献
专利文献1:日本特开平7-156826号公报
发明内容
发明要解决的课题
在上述专利文献1所公开的结构中,高压电装模块体组装在电动机上的状态下的整体高度变大,在将电动机收纳在电动汽车的原动机室内的情况下,与发动机罩之间的间隙变小。
本发明是鉴于上述问题而提出的,其目的在于提供一种在搭载于电动机的壳体的状态下能够将包括电动机在内的整体高度抑制得尽可能小的机电一体型电力转换装置、以及适合使用该机电一体型电力转换装置的电动汽车用驱动装置。
用于解决课题的手段
为了实现上述目的,本发明提供一种机电一体型电力转换装置,其中,控制电动机的动作的动力驱动单元和电压转换器收纳在单一的收纳箱的内部并被模块化,其第一特征在于,所述收纳箱包括:箱体,其包括箱体主部和箱体剩余部,所述箱体主部配置在所述电动机的壳体的上方且向上方开放,所述箱体剩余部向侧方开放,并与所述箱体主部的侧壁一体相连且垂下到所述壳体的侧方;上方盖部件,其在与所述箱体主部之间形成收纳所述动力驱动单元的第一收纳室,并安装在所述箱体主部的上方开放端部;以及侧方盖部件,其在与所述箱体剩余部之间形成收纳所述电压转换器的第二收纳室,并安装在该箱体剩余部的侧方开放端部。
此外,本发明在第一特征的结构的基础上,其第二特征在于,由分隔所述第二收纳室的一部分并安装在所述箱体剩余部上的散热用盖体和所述箱体剩余部构成冷却套,所述电压转换器与所述散热用盖体接触并被收纳在所述第二收纳室内。
本发明在第一或第二特征的结构的基础上,其第三特征在于,所述箱体主部及所述箱体剩余部与所述壳体通过压铸一体成型而形成。
本发明在第三特征的结构的基础上,其第四特征在于,在所述电动机所具有的旋转轴的轴向的任意一端侧的所述壳体的端壁上,设置有所述电动机的定子用端子台,并且安装有检测所述旋转轴的旋转状态的旋转角度检测单元,所述壳体的在所述旋转轴的轴向上靠近所述端壁的上壁上,设有与所述第一收纳室连通的开口部,与三相引出线一起安装在所述定子用端子台上的动力线和与所述旋转角度检测单元相连的信号线贯通所述开口部而被导入所述第一收纳室内。
此外,本发明提供一种电动汽车用驱动装置,其具备第一至第四特征的结构中的任意一方的机电一体型电力转换装置的所述电动机作为驱动源,其第五特征在于,与所述电动机所具有的旋转轴联动且连结的变速器的至少一部分以该变速器所具有的输出轴的轴线与所述电动机的旋转轴线平行的方式并列配置在所述壳体的侧方,所述箱体剩余部及所述侧方盖部件在俯视时配置在所述变速器中的配置于所述壳体的侧方的部分与所述壳体之间。
另外,实施方式的电动发电机11A、11B对应于本发明的电动机,实施方式的第二冷却套32对应于本发明的冷却套,实施方式的旋变器41对应于本发明的旋转角度检测单元,实施方式的第四开口部50对应于本发明的开口部。
发明的效果
根据本发明的第一特征,由于动力驱动单元和电压转换器分散配置在电动机的上方和电动机的侧方,因此在搭载于电动机的壳体的状态下能够将包括电动机在内的整体高度抑制得尽可能地小,并且由于动力驱动单元和电压转换器收纳在单一的收纳箱内,因此还能够抑制部件数量的增加。
另外,根据本发明的第二特征,由于电压转换器与散热用盖体接触并被收纳在第二收纳室内,所述散热用盖体与箱体剩余部共同构成冷却套,所以所述动力驱动单元、所述电压转换器以及冷却套可以在不增大电力转换装置的整体高度的情况下高效地收纳在单一的收纳箱内,并且可以高效地冷却电压转换器。
根据本发明的第三特征,由于箱体主部以及箱体剩余部通过与壳体的压铸一体成型而形成,所以壳体的上壁兼作收纳动力驱动单元的第一收纳室的底部,省略了紧固螺钉、气密部件等而抑制了部件数量的增加,并且能够实现包括电动机的电力转换装置的轻量化。
根据本发明的第四特征,与电动机的三相引出线相连的动力线和与转速检测单元相连的信号线贯通设置在壳体的上壁上的开口部而被导入箱体主部和上方盖部件之间的第一收纳室,因此高压的动力线不会暴露在外部,难以发生在电动汽车遭遇碰撞事故的状况下的意外的漏电事故,能够提高安全性,另外,由于不需要防水连接器等,所以能够实现低成本化。
另外,根据本发明的第五特征,由于变速器的至少一部分与电动机并列配置,在电动机和变速器中的配置于电动机侧方的部分之间配置有箱体剩余部和侧方盖部件,因此,尽管电压转换器配置在电动机的侧方,也能够实现电动汽车用驱动装置的紧凑化。
附图说明
图1是第一实施方式的电动汽车用驱动装置的分解立体图。
图2是从箱体拆下了上方盖部件及侧方盖部件的状态下的主要部分分解立体图。
图3是在拆下了端部盖的状态下剖开壳体的一部分进行表示的电动发电机的局部剖开主视图。
图4是冷却系统的系统图。
图5是第二实施方式的冷却系统的系统图。
标号说明
11A、11B:作为电动机的电动发电机;
12:变速器;
13:壳体;
13a:端壁;
14:旋转轴;
15:输出轴;
17:收纳箱;
18:箱体;
18a:箱体主部;
18b:箱体剩余部;
19:上方盖部件;
20:侧方盖部件;
21:第一收纳室;
22:第二收纳室;
28:动力驱动单元;
29:电压转换器;
31:散热用盖体;
32:冷却套;
40:定子用端子台;
41:作为旋转角度检测单元的旋变器;
42、43、44:引出线;
45、46、47:动力线;
50:开口部;
51:信号线。
具体实施方式
参照附图,对本发明的实施方式进行说明。
参照图1~图4对本发明的第一实施方式进行说明,首先,在图1中,该机电一体型的电动汽车用驱动装置搭载于电动汽车(电动车辆),具备:电动发电机11A,其是作为发挥驱动动力的驱动源而起作用的电动机;和变速器12,其被传递来自该电动发电机11A的动力。
在所述电动发电机11A的壳体13内设置有未图示的电动机冷却部,电动机11A的旋转轴14由所述壳体13旋转自如地支承。所述变速器12具有减速齿轮机构,该减速齿轮机构具有与所述旋转轴14的轴线即所述电动发电机11A的旋转轴线平行的一对输出轴15,所述变速器12与所述旋转轴14的一端部联动、连结。该变速器12所具有的变速箱16在所述旋转轴14的一端侧与所述电动发电机11A的壳体13连续设置。所述变速箱16具备与所述壳体13连续设置的内侧箱半体16a和在所述旋转轴14的一端侧覆盖所述内侧箱半体16a的开放端的外侧箱半体16b,所述内侧箱半体16a具有接近配置于所述壳体13的侧方的突出部分16aa。
在所述内侧箱半体16a的所述突出部分16aa,为了将所述电动发电机11A的动力分别分配给车辆的左右一对驱动轮,与所述一对输出轴15相连地收纳有未图示的差动齿轮机构(差动齿轮),所述突出部分16aa与所述电动发电机11A并列配置。
一对所述输出轴15中的一个输出轴15以使其一部分面对所述内侧箱半体16a中的所述突出部分16aa的突出端的方式旋转自如地支承在所述变速箱16上,另一个所述输出轴15与所述一个输出轴15同轴地,以使其一部分从所述外侧箱半体16b面对外部的方式旋转自如地支承在所述变速箱16上。在这些输出轴15上连结有用于向驱动轮侧传递动力的驱动轴(未图示),该驱动轮借助未图示的悬架装置以能够上下摆动的方式悬架在车辆上。
另外,在所述电动发电机11A的所述壳体13配备有收纳箱17。该收纳箱17包括与所述壳体13连续设置的箱体18、和安装在该箱体18上的上方盖部件19及侧方盖部件20,所述箱体18包括配置在所述壳体13的上方的箱体主部18a、和向侧方开放并与所述箱体主部18a的侧壁一体相连且垂下到所述壳体13的侧方的箱体剩余部18b。
在所述箱体主部18a的上方开放端部,安装有在与该箱体主部18a之间形成第一收纳室21的所述上方盖部件19,在所述箱体剩余部18b的侧方开放端部,安装有在与该箱体剩余部18b之间形成第二收纳室22的所述侧方盖部件20。
由所述箱体主部18a及箱体剩余部18b构成的箱体18优选通过例如将熔融的铝合金材料注入模具而成型的所谓压铸法,与所述壳体13一体成型。此时,壳体13的上壁兼作收纳后述的动力驱动单元28等的第一收纳室21的底部,与将作为与壳体13分离的部件的箱体安装到壳体13的情况相比,可以简化紧固螺钉、气密部件等,从而可以减少部件的数量,并且可以减轻电力转换装置的重量。
一并参照图2,在所述第一收纳室21中收纳有动力驱动单元28,该动力驱动单元28具有:功率模块25,其具有承担电力转换的半导体元件组;ECU26,其控制该功率模块25;以及电容器模块27,其在车辆的电池(未图示)和所述功率模块25之间使直流电力平滑化,并且该动力驱动单元28通过所述功率模块25的电力转换,控制所述电动发电机11A的动作,在所述第二收纳室22中,收纳有用于将直流电力降压而向所述ECU26等供给的电压转换器29。
在所述箱体主部18a的底部(即,在该实施方式中为所述壳体13的上壁)安装有第一冷却套30,该第一冷却套30具有:冷却液流通部30a,其在下表面具有能够使冷却液流通的冷却液导入口及冷却液导出口;和载置台部30b,其与该冷却液流通部30a相连,在该第一冷却套30中的所述冷却液流通部30a上安装有所述功率模块25,所述ECU26配设在该功率模块25上。另外,所述电容器模块27安装在所述第一冷却套30的所述载置台部30b上。
在所述箱体剩余部18b上安装有分隔所述第二收纳室22的一部分的金属薄板状的散热用盖体31,由该散热用盖体31和所述箱体剩余部18b构成第二冷却套32,该第二冷却套32收纳在所述第二收纳室22中。所述电压转换器29与所述散热用盖体31接触并固定在该散热用盖体31上,并且被收纳在所述第二收纳室22内。
关注图1,在所述箱体主部18a的侧壁中的位于所述第二冷却套32的上方且将所述第一收纳室21与所述第二收纳室22之间隔开的部分,设有使所述第一收纳室21与所述第二收纳室22之间连通的第一、第二及第三开口部33、34、35,该第一、第二及第三开口部33、34、35在所述电动发电机11A的旋转轴线方向上从所述变速器12侧依次隔开间隔地设置。
在所述第一开口部33中贯插有12V的电力供给用母线36,该电力供给用母线36连接在与未图示的电池连接且设置于所述壳体13的电源用正极侧端子和所述电压转换器29之间。另外,在所述第二开口部34中贯插有一对高电压用母线37、38,该一对高电压用母线37、38连接在收纳于所述第一收纳室21内的所述电容器模块27与所述电压转换器29之间。进而,在所述第三开口部35中贯插有导线39,该导线39将来自所述电压转换器29的12V的电力供给到收纳于所述第一收纳室21中的所述ECU26。
在图3中,在所述电动机11A所具备的所述旋转轴14的轴向的任意一端侧,在本实施方式中是一端部与所述变速器12的减速齿轮机构联动地连结的所述旋转轴14的轴向另一端侧,在所述壳体13的端壁13a上,设置有所述电动发电机11A的定子用端子台40,并且安装有检测所述旋转轴14的旋转状态的作为旋转角度检测单元的旋变器41。在所述定子用端子台40上安装有三相引出线42、43、44和三相动力线45、46、47。在所述端壁13a安装有覆盖所述旋转轴14的轴向另一端部及所述旋变器41的端子罩48,在所述壳体13的所述端壁13a与所述端子罩48之间形成有收纳所述定子用端子台40及所述旋变器41的第三收纳室49。
在所述旋转轴14的轴向另一端侧,在所述壳体13的上壁上设有使所述第三收纳室49与所述第一收纳室21之间连通的第四开口部50,形成为平板带状的所述动力线45、46、47和与所述旋变器41相连的信号线51贯通所述第四开口部50而被导入所述收纳箱17的所述第一收纳室21内。
在所述箱体主部18a的底部安装有覆盖所述箱体侧开口部50的一部分的端子保持部件52,贯通所述第四开口部50的所述动力线45~47进一步贯通所述端子保持部件52,并固定在所述端子保持部件52上。
一并参照图4,所述第一冷却套30和所述第二冷却套32构成对所述电动发电机11A、所述动力驱动单元28和所述电压转换器29进行冷却的液体冷却系统55A的一部分,该液体冷却系统55A包括散热器56、从该散热器56吸入不冻液等冷却液的冷却液泵57、被导入来自该冷却液泵57的冷却液的所述第二冷却套32、被从第二冷却套32输送冷却液的所述第一冷却套30、设置在所述电动发电机11A的壳体13内的电动机冷却部(未图示)、和与该电动机冷却部相连且设于所述壳体13内的油冷却器58的一部分58a。
在所述箱体18的所述箱体主部18a中的所述旋转轴14的轴向另一端侧的壁面上,设有用于接受来自所述冷却液泵57的冷却液并向所述第二冷却套32供给的冷却液导入管59,在所述箱体主部18a的底部及所述箱体剩余部18b上,呈中空状地一体成型有从所述第二冷却套32向所述第一冷却套30引导冷却液的通路60和为了向所述壳体13内的所述电动机冷却部引导冷却液而设置在所述壳体13的上部的导管61,所述通路60及所述导管61液密地连接于所述第一冷却套30的所述冷却液流通部30a。另外,在相对于所述旋转轴14的轴线与所述箱体剩余部18b相反的一侧,在所述壳体13的侧壁上设有冷却液导出管62(参照图3),该冷却液导出管62用于从所述电动机冷却部导出冷却液并将冷却液导入所述散热器56侧。
在所述电动发电机11A所具有的所述壳体13内与所述电动机冷却部相连配设的所述油冷却器58包括所述液体冷却系统55A所包含的所述一部分58a、和使与所述液体冷却系统55A的冷却液实现热交换的油流通的另一部分58b。该油冷却器58的所述另一部分58b包含在通过油喷雾等来冷却所述变速器12的油冷却系统64A中,所述油冷却系统64A包括:油泵65,其浸渍于在所述变速器12的变速箱16内贮存的油中而被收纳在该变速箱16内;所述油冷却器58的所述另一部分58b,其被供给由该油泵65汲取的油;以及变速器12的油喷雾部(未图示),其被供给在该另一部分58b中与冷却液进行了热交换的油,通过油喷雾部散布而积存在所述变速器12的变速箱16内的油被所述油泵65汲取。
接着,对该第一实施方式的作用进行说明,控制电动发电机11A的动作的动力驱动单元28和电压转换器29收纳于单一的收纳箱17,所述收纳箱17包括:箱体18,其包括配置在所述电动发电机11A的壳体13的上方且向上方开放的箱体主部18a、以及向侧方开放且与所述箱体主部18a的侧壁一体相连且垂下到所述壳体13的侧方的箱体剩余部18b;上方盖部件19,其在与所述箱体主部18a之间形成收纳所述动力驱动单元28的第一收纳室21,并安装在所述箱体主部18a的上方开放端部;以及侧方盖部件20,其在与所述箱体剩余部18b之间形成收纳所述电压转换器29的第二收纳室22,并安装在该箱体剩余部18b的侧方开放端部,因此,所述动力驱动单元28及所述电压转换器29分散配置于所述电动发电机11A的上方和所述电动发电机11A的侧方,在搭载于所述电动发电机11A的壳体13的状态下,可将包括所述电动发电机11A的整个高度抑制得极小,而且,由于所述动力驱动单元28和所述电压转换器29被收纳在单一的收纳箱17内,所以还能够抑制部件数量的增加。
另外,由分隔所述第二收纳室22的一部分并安装在所述箱体剩余部18b上的散热用盖体31和所述箱体剩余部18b构成第二冷却套32,所述电压转换器29与所述散热用盖体31接触并收纳在所述第二收纳室22内,因此,所述动力驱动单元28、所述电压转换器29以及所述第二冷却套32能够在不增大电力转换装置的整体高度的情况下高效地收纳在单一的收纳箱17内,并且能够高效地冷却所述电压转换器29。
另外,所述箱体18通过与所述壳体13的压铸一体成型而形成,由此,所述壳体13的上壁兼作收纳所述动力驱动单元28的所述第一收纳室21的底部,省略了紧固螺钉、气密部件等,抑制了部件数量的增加,并且,能够实现包括所述电动发电机11A的电力转换装置的轻量化。
另外,在所述箱体主部18a的侧壁中的位于所述第二冷却套32的上方且将所述第一收纳室21与所述第二收纳室22之间隔开的部分,设有使所述第一收纳室21与所述第二收纳室22之间连通的第一、第二及第三开口部33、34、35,在这些开口部33~35中,贯插有向电压转换器29供给电力的电力供给用母线36、连结所述电容器模块27与所述电压转换器29之间的一对高电压用母线37、38、以及连结所述电压转换器29与所述ECU26之间的导线39等通电部件,因此,这些通电部件不会暴露在所述收纳箱17的外部,通过减少防水连接器等,可以实现低成本化。
另外,在所述壳体13的端壁13a,设置有所述电动发电机11A的定子用端子台40,并且安装有检测所述旋转轴14的旋转状态的旋变器41,所述壳体13的在所述旋转轴14的轴向上靠近所述端壁13a的上壁上设置有与所述第一收纳室21连通的第四开口部50,与三相引出线42、43、44一起安装在所述定子用端子台40上的动力线45、46、47和与所述旋变器41相连的信号线51贯通所述第四开口部50而被导入所述第一收纳室21内,因此高压的动力线45~47不会暴露在外部,难以发生在电动汽车遭遇碰撞事故的状况下的意外的漏电事故,能够提高安全性,另外,由于不需要防水连接器等,所以能够实现低成本化。
进而,与所述电动发电机11A所具备的旋转轴14联动且连结的变速器12的至少一部分以该变速器12所具备的输出轴15的轴线与所述电动发电机11A的旋转轴线平行的方式并列配置于所述壳体13的侧方,所述箱体剩余部18b及所述侧方盖部件20在俯视时配置在所述变速器12中的配置在所述壳体13的侧方的部分和所述壳体13之间,因此,尽管所述电压转换器29配置在所述电动发电机11A的侧方,也能够实现机电一体型驱动装置的紧凑化。
接着,参照图5对本发明的第二实施方式进行说明,对于与上述第一实施方式对应的部分仅标注相同的参照标号进行图示,省略详细的说明。
第一冷却套30和第二冷却套32构成对所述动力驱动单元28和所述电压转换器29进行冷却的液体冷却系统55B的一部分,该液体冷却系统55B包括散热器56、从该散热器56吸入不冻液等冷却液的冷却液泵57、被导入来自该冷却液泵57的冷却液的所述第二冷却套32、被从第二冷却套32输送冷却液的所述第一冷却套30、以及被从该第一冷却套30输送冷却液并且使冷却液返回所述散热器56的油冷却器58的一部分58a。
所述油冷却器58包括所述液体冷却系统55B所包含的所述一部分58a和使与所述液体冷却系统55B的冷却液实现热交换的油流通的另一部分58b。所述油冷却器58的所述另一部分58b包含在通过油喷雾等来冷却电动发电机11B及变速器12的油冷却系统64B中,所述油冷却系统64B包括:油泵65,其浸渍于在所述变速器12的变速箱16内贮存的油中而被收纳在该变速箱16内;所述油冷却器58的所述另一部分58b,其被供给由该油泵65汲取的油;以及电动发电机11B的油冷却部(未图示)和变速器12的油喷雾部(未图示),它们被供给在该另一部分58b中与冷却液进行了热交换的油,通过所述油冷却部(未图示)及所述油喷雾部而积存在所述变速器12的所述变速箱16内的油被所述油泵65汲取,向所述油冷却器58的所述另一部分58b供给。
根据该第二实施方式,也能够起到与上述第一实施方式相同的效果。
以上,对本发明的实施方式进行了说明,但本发明并不限定于上述实施方式,在不脱离权利要求书所记载的本发明的情况下,能够进行各种设计变更。
Claims (4)
1.一种机电一体型电力转换装置,其中,控制电动机(11A、11B)的动作的动力驱动单元(28)和电压转换器(29)收纳在单一的收纳箱(17)的内部并被模块化,其特征在于,
所述收纳箱(17)包括:
箱体(18),其包括箱体主部(18a)和箱体剩余部(18b),所述箱体主部(18a)配置在所述电动机(11A、11B)的壳体(13)的上方且向上方开放,所述箱体剩余部(18b)向侧方开放,并与所述箱体主部(18a)的侧壁一体相连且垂下到所述壳体(13)的侧方;
上方盖部件(19),其在与所述箱体主部(18a)之间形成收纳所述动力驱动单元(28)的第一收纳室(21),并安装在所述箱体主部(18a)的上方开放端部;以及
侧方盖部件(20),其在与所述箱体剩余部(18b)之间形成收纳所述电压转换器(29)的第二收纳室(22),并安装在该箱体剩余部(18b)的侧方开放端部,
由分隔所述第二收纳室(22)的一部分并安装在所述箱体剩余部(18b)上的散热用盖体(31)和所述箱体剩余部(18b)构成冷却套(32),所述电压转换器(29)与所述散热用盖体(31)接触并被收纳在所述第二收纳室(22)内。
2.根据权利要求1所述的机电一体型电力转换装置,其特征在于,
所述箱体主部(18a)及所述箱体剩余部(18b)与所述壳体(13)通过压铸一体成型而形成。
3.根据权利要求2所述的机电一体型电力转换装置,其特征在于,
在所述电动机(11A、11B)所具有的旋转轴(14)的轴向的任意一端侧的所述壳体(13)的端壁(13a)上,设置有所述电动机(11A、11B)的定子用端子台(40),并且安装有检测所述旋转轴(14)的旋转状态的旋转角度检测单元(41),
所述壳体(13)的在所述旋转轴(14)的轴向上靠近所述端壁(13a)的上壁上,设有与所述第一收纳室(21)连通的开口部(50),
与三相引出线(42、43、44)一起安装在所述定子用端子台(40)上的动力线(45、46、47)和与所述旋转角度检测单元(41)相连的信号线(51)贯通所述开口部(50)而被导入所述第一收纳室(21)内。
4.一种电动汽车用驱动装置,其具备权利要求1~3中的任意一项所述的机电一体型电力转换装置的所述电动机(11A、11B)作为驱动源,其特征在于,
与所述电动机(11A、11B)所具有的旋转轴(14)联动且连结的变速器(12)的至少一部分以该变速器(12)所具有的输出轴(15)的轴线与所述电动机(11A、11B)的旋转轴线平行的方式并列配置在所述壳体(13)的侧方,
所述箱体剩余部(18b)及所述侧方盖部件(20)在俯视时配置在所述变速器(12)中的配置于所述壳体(13)的侧方的部分与所述壳体(13)之间。
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