WO2023145419A1 - Dynamo-electric machine unit - Google Patents

Abstract

A dynamo-electric machine unit according to the present disclosure comprises: a dynamo-electric machine having a stator, and a rotor for rotating about the axis thereof relative to the stator; and an electric power conversion device located side-by-side with the dynamo-electric machine in the axial direction along the axis of the rotor. The electric power conversion device has a capacitor unit located in a central portion of the electric power conversion device, and a plurality of power modules arranged in the circumferential direction around the axis of the rotor so as to surround the capacitor unit. The capacitor unit has a capacitor body portion, a positive pole conductor, and a negative pole conductor. Each of the plurality of power modules has a power module body portion, a positive pole terminal connected to the positive pole conductor, and a negative terminal connected to the negative pole conductor. The positive pole terminals and the negative pole terminals are arranged so as to face the capacitor unit, and first connection portions of the positive pole conductor and the positive pole terminals, and second connection portions of the negative pole conductor and the negative pole terminals, are positioned between the capacitor body portion and the power module body portions.

Description

Rotating electric machine unit

The present disclosure relates to rotating electric machine units.
This application claims priority based on Japanese Patent Application No. 2022-009936 filed in Japan on January 26, 2022, the contents of which are incorporated herein.

　Conventionally, a rotary electric machine unit in which a rotary electric machine and a power conversion device are integrated is known. In Patent Literature 1, the power conversion device has a capacitor unit and a plurality of power modules. A positive electrode conductor and a negative electrode conductor of the capacitor unit are formed in a ring shape or an arc shape, and are arranged on the inner peripheral side of the power module. A positive conductor and a negative conductor of the capacitor unit are connected to each of the plurality of power modules via wires.

Japanese Patent No. 4708951

A surge voltage is generated when switching the ON state/OFF state of the switching element of the power module. When the surge voltage generated in the power module increases, it becomes difficult to input a large amount of current to the power module, making it difficult to increase the output of the rotary electric machine unit.

The present disclosure has been made in view of the circumstances described above, and aims to provide a rotating electric machine unit capable of suppressing the surge voltage generated in the power module and increasing the output.

One aspect of a rotating electrical machine unit according to the present disclosure includes a rotating electrical machine having a stator, a rotor rotating about an axis with respect to the stator, and an axial direction along the axis of the rotor. a power conversion device arranged in parallel with the rotating electrical machine, the power conversion device comprising: a capacitor unit arranged in a central portion of the power conversion device; a plurality of power modules arranged in a circumferential direction around the axis of the child, wherein the capacitor unit has a capacitor main body, a positive electrode conductor, and a negative electrode conductor, and the plurality of power modules are Each has a power module main body, a positive terminal connected to the positive conductor, and a negative terminal connected to the negative conductor, and the positive terminal and the negative terminal face the capacitor unit. A first connecting portion between the positive electrode conductor and the positive electrode terminal and a second connecting portion between the negative electrode conductor and the negative electrode terminal are positioned between the capacitor main body and the power module main body. are doing.

According to the present disclosure, it is possible to provide a rotating electric machine unit capable of suppressing the surge voltage generated in the power module and increasing the output.

1 is a circuit diagram of a rotating electric machine unit according to Embodiment 1. FIG. 1 is a perspective view of a rotating electric machine unit according to Embodiment 1; FIG. FIG. 2 is a perspective view of the rotary electric machine unit according to Embodiment 1, showing a state in which a terminal block cover is removed; 1 is a perspective view of the rotating electric machine unit according to Embodiment 1, showing a state in which a case and a terminal block are removed; FIG. 1 is a plan view of the rotary electric machine unit according to Embodiment 1, showing a state in which a case and a terminal block are removed; FIG. FIG. 6 is a cross-sectional view taken along line AA of FIG. 5; 1 is a perspective view of the rotating electric machine unit according to Embodiment 1, showing a state in which a case, a terminal block, and a control board are removed; FIG. 1 is a plan view of the rotating electric machine unit according to Embodiment 1, showing a state where a case, a terminal block, and a control board are removed; FIG. FIG. 9 is a cross-sectional view taken along line BB of FIG. 8; FIG. 9 is a cross-sectional view taken along line CC of FIG. 8; 1 is a perspective view of a capacitor unit according to Embodiment 1; FIG. 1 is a perspective view of a busbar according to Embodiment 1; FIG. 1 is a perspective view of a rotating electrical machine according to Embodiment 1; FIG. 4 is a perspective view of a second plate according to Embodiment 1; FIG. 4 is a perspective view of a first plate according to Embodiment 1; FIG. 3 is a perspective view of a base according to Embodiment 1; FIG. 4 is a perspective view of an inner tubular portion according to Embodiment 1. FIG. 4 is a perspective view of an inner tubular portion according to Embodiment 1. FIG. FIG. 10 is a perspective view of the rotary electric machine unit according to Embodiment 2, showing a state in which the case, the terminal block, and the control board are removed;

Embodiment 1.
A rotating electric machine unit 1 according to Embodiment 1 will be described below with reference to the drawings.
FIG. 1 is a circuit diagram of a rotating electric machine unit 1. As shown in FIG. FIG. 2 is a perspective view of the rotary electric machine unit 1. FIG. As shown in FIG. 2, the rotating electrical machine unit 1 includes a rotating electrical machine 2, a power conversion device 3, and a cooler 4 (first cooling section). The rotating electric machine 2, the power conversion device 3, and the cooler 4 are integrated. As a result, the size of the rotary electric machine unit 1 can be reduced.
In this specification, the direction along the axis of the rotor 22 of the rotary electric machine 2 is called "axial direction". Also, when viewed from the axial direction, the direction intersecting with the axis of the rotor 22 is called the "radial direction", and the direction around the axis of the rotor 22 is called the "circumferential direction".

First, the circuit configuration (electrical configuration) of the rotary electric machine unit 1 will be described with reference to FIG. In this embodiment, as the rotary electric machine unit 1, a six-phase drive type rotary electric machine unit will be described as an example. The rotating electric machine unit 1 is mounted on a vehicle, for example.

The rotating electric machine 2 includes six coils 25U1, 25V1, 25W1, 25U2, 25V2, and 25W2 corresponding to six phases (U1 phase, V1 phase, W1 phase, U2 phase, V2 phase, W2 phase). Note that the coils 25U1, 25V1, 25W1, 25U2, 25V2, and 25W2 are also simply referred to as coils 25 in this specification.

The power conversion device 3 includes a capacitor unit 34 and six power modules 35U1, 35V1, 35W1, 35U2, and 35V2 respectively corresponding to six phases (U1 phase, V1 phase, W1 phase, U2 phase, V2 phase, W2 phase). , 35W2. Note that the power modules 35U1, 35V1, 35W1, 35U2, 35V2, and 35W2 are also simply referred to as power modules 35 in this specification.

DC power is input to the power converter 3 from a DC power supply E such as a battery. The power conversion device 3 converts the DC power output from the DC power supply E into AC power and supplies the AC power to the rotary electric machine 2 .

The capacitor unit 34 is connected between the positive terminal and the negative terminal of the DC power supply E. The capacitor unit 34 has a plurality of capacitor elements 34a connected in parallel. Note that the capacitor unit 34 may have only one capacitor element 34a. The capacitor unit 34 is a smoothing capacitor that stabilizes the voltage against fluctuations in the power of the DC power supply E or power fluctuations on the power module 35 side so that the voltage does not fluctuate greatly.

Each power module 35 is connected between the positive terminal and the negative terminal of the DC power supply E. As shown in FIG. Each power module 35 includes a switching element SW1 and a diode D1 on the upper arm side, and a switching element SW2 and a diode D2 on the lower arm side. The switching elements SW1 and SW2 are, for example, IGBTs (Insulated Gate Bipolar Transistors). The switching elements SW1 and SW2 are connected in series.
A connection point between the switching element SW1 and the switching element SW2 is connected to the coil 25 of the corresponding phase. The diode D1 is connected in parallel in the opposite direction to the switching element SW1. The diode D2 is connected in parallel in the opposite direction to the switching element SW2.

Next, the structure of the rotating electric machine unit 1 will be described.
The power conversion device 3 has a case 31 and a terminal block 32 having a cover 32c. FIG. 3 is a perspective view of the rotary electric machine unit 1, showing a state in which the cover 32c of the terminal block 32 is removed. FIG. 4 is a perspective view of the rotary electric machine unit 1, showing a state in which the case 31 and the terminal block 32 are removed. FIG. 5 is a plan view of the rotary electric machine unit 1, showing a state in which the case 31 and the terminal block 32 are removed. FIG. 6 is a cross-sectional view along line AA in FIG. FIG. 7 is a perspective view of the rotary electric machine unit 1, showing a state in which the case 31, the terminal block 32, and the control board 36 are removed. FIG. 8 is a plan view of the rotating electric machine unit 1, showing a state in which the case 31, the terminal block 32, and the control board 36 are removed. 9 is a cross-sectional view taken along line BB of FIG. 8. FIG. 10 is a cross-sectional view taken along line CC of FIG. 8. FIG.

<Power converter>
As shown in FIGS. 2, 4, 7, etc., the power converter 3 includes a case 31, a terminal block 32, a signal connector 33, a capacitor unit 34, a control board 36, and a plurality of power modules 35. (in the present embodiment, six power modules 35U1, 35V1, 35W1, 35U2, 35V2, 35W2), a plurality of (six in the present embodiment) bus bars 37, and a plurality of (six in the present embodiment) ) current sensor 38 .

The case 31 covers electronic components such as the capacitor unit 34, the power module 35, and the control board 36 from above. This ensures insulation between these electronic components and components mounted around the rotary electric machine unit 1 , and prevents foreign matter from entering the rotary electric machine unit 1 from outside.

As shown in FIGS. 2 and 3, the terminal block 32 is provided on the upper surface of the case 31. As shown in FIGS. The terminal block 32 connects the DC power supply E and the capacitor unit 34 . The terminal block 32 has a positive electrode side connection terminal 32a, a negative electrode side connection terminal 32b, and a cover 32c.

The positive side connection terminal 32a is connected to the positive terminal of the DC power supply E and the positive conductor 342 of the capacitor unit 34, which will be described later. The negative connection terminal 32b is connected to the negative terminal of the DC power supply E and the negative conductor 343 of the capacitor unit 34, which will be described later. The cover 32 c covers the positive electrode side connection terminal 32 a and the negative electrode side connection terminal 32 b from above and prevents foreign matter from entering the inside of the power converter 3 .

The signal connector 33 is provided on the side surface of the case 31 . Further, as shown in FIG. 4, the signal connector 33 is connected to the control board 36 via a signal connector harness 33a. The signal connector 33 is used to exchange various signals between an external control device mounted on a vehicle or the like and the power conversion device 3 .
When viewed in the axial direction, the side on which the signal connector 33 is arranged with respect to the axial center of the rotor 22 is called the front side, and the opposite side is called the rear side. The terminal block 32 and the signal connector 33 are arranged on the front side of the rotary electric machine unit 1 .

11 is a perspective view of the capacitor unit 34. FIG. As shown in FIG. 11 , the capacitor unit 34 has a body portion 341 (capacitor body portion), a positive electrode conductor 342 and a negative electrode conductor 343 . As shown in FIG. 5 , the capacitor unit 34 is arranged in the central portion of the power conversion device 3 . The capacitor unit 34 is fixed to a first plate 41 of the cooler 4, which will be described later.

The body part 341 has a cylindrical shape. The body portion 341 includes a plurality of capacitor elements 34a (see FIG. 1). A harness fixing portion 341 a is formed on the outer peripheral surface of the main body portion 341 . A through-hole extending in the axial direction is formed in the harness fixing portion 341a, and a resolver harness 27c (harness) of the rotary electric machine 2, which will be described later, is inserted through the through-hole. A plurality of attachment portions 341 b for attaching the capacitor unit 34 to the first plate 41 are formed in the lower portion of the body portion 341 . The attachment portion 341b is a protrusion that protrudes radially outward from the outer peripheral surface of the main body portion 341 . A bolt hole 341c through which a bolt 41f2 (see FIGS. 7 and 8) is inserted is formed in the mounting portion 341b.

The positive electrode conductor 342 and the negative electrode conductor 343 are plate-like members. The positive conductor 342 is connected to the positive connection terminal 32a of the terminal block 32 and the positive terminal 35b of the power module 35, which will be described later. The negative conductor 343 is connected to the negative connection terminal 32b of the terminal block 32 and the negative terminal 35c of the power module 35, which will be described later.

For example, oxygen-free copper is used as the material of the positive electrode conductor 342 and the negative electrode conductor 343 . Tough pitch copper may be used as the material of the positive electrode conductor 342 and the negative electrode conductor 343 in order to reduce material costs, improve availability, and the like. The plate thickness of the positive electrode conductor 342 and the negative electrode conductor 343 is, for example, 0.5 to 2.5 mm.

The positive conductor 342 has a positive first end 342 a connected to the positive connection terminal 32 a of the terminal block 32 and a second positive end 342 b connected to the positive terminal 35 b of the power module 35 .

The positive electrode side first end portion 342 a is pulled out from the lower end of the main body portion 341 and extends axially toward the positive electrode side connection terminal 32 a of the terminal block 32 . As shown in FIG. 4 , the positive electrode side first end 342 a is inserted through an opening 36 b formed in the central portion of the control board 36 . The positive electrode side first end portion 342 a extends so as not to pass through the axial center of the rotor 22 . That is, the positive electrode side first end portion 342a is arranged so as not to overlap the axial center of the rotor 22 when viewed in the axial direction. The tip of the positive electrode-side first end portion 342a is bent and comes into contact with the positive electrode-side connection terminal 32a from above. A bolt hole 342c through which a bolt 344 (see FIG. 3) is inserted is formed at the tip of the positive electrode side first end 342a. A tip portion of the positive electrode side first end portion 342a is fixed to the positive electrode side connection terminal 32a by a bolt 344 .

The positive electrode side second end portion 342b is provided corresponding to the power module 35 of each phase. That is, six positive electrode side second ends 342b are provided. The positive electrode side second end portion 342 b is pulled out from the lower end of the main body portion 341 and extends toward the positive electrode terminal 35 b of the power module 35 . The positive electrode side second end portion 342 b extends so as not to pass through the axial center of the rotor 22 . That is, the positive electrode side second end 342b is arranged so as not to overlap the axial center of the rotor 22 when viewed in the axial direction. The tip of the positive electrode side second end 342b is bent so as to extend in the axial direction. The six positive electrode side second ends 342b are arranged at regular intervals (60° intervals) in the circumferential direction. The six positive electrode side second ends 342b have the same shape.

The negative conductor 343 has a negative first end 343 a connected to the negative connection terminal 32 b of the terminal block 32 and a second negative end 343 b connected to the negative terminal 35 c of the power module 35 .

The negative electrode side first end portion 343 a is pulled out from the lower end of the main body portion 341 and extends axially toward the negative electrode side connection terminal 32 b of the terminal block 32 . As shown in FIG. 4 , the negative first end 343 a is inserted through the opening 36 b of the control board 36 . The negative electrode side first end portion 343 a extends so as not to pass through the axial center of the rotor 22 . That is, the negative electrode side first end portion 343a is arranged so as not to overlap the axial center of the rotor 22 when viewed in the axial direction. The tip of the negative electrode first end portion 343a is bent and contacts the negative electrode connection terminal 32b from above. A bolt hole 343c through which a bolt 344 (see FIG. 3) is inserted is formed at the tip of the negative electrode-side first end 343a. A tip portion of the negative electrode first end portion 343a is fixed to the negative electrode connection terminal 32b by a bolt 344. As shown in FIG.

The negative electrode side second end portion 343b is provided corresponding to the power module 35 of each phase. That is, six negative electrode side second ends 343b are provided. The negative electrode side second end portion 343 b is pulled out from the lower end of the main body portion 341 and extends toward the negative electrode terminal 35 c of the power module 35 . The negative electrode side second end portion 343 b extends so as not to pass through the axial center of the rotor 22 . That is, the negative electrode side second end portion 343b is arranged so as not to overlap the axial center of the rotor 22 when viewed in the axial direction. A tip portion of the negative electrode side second end portion 343b is bent so as to extend in the axial direction. The six negative electrode side second ends 343b are arranged at equal intervals (60° intervals) in the circumferential direction. The six negative electrode side second end portions 343b have the same shape.

As shown in FIGS. 7 and 8, the six power modules 35 are arranged so as to surround the capacitor unit 34. The six power modules 35 are arranged at regular intervals (60° intervals) in the circumferential direction. Power modules 35U1, 35V1, 35W1, 35U2, 35V2, and 35W2 are arranged in this order in the circumferential direction. Therefore, the power modules 35 of the same phase (for example, power modules 35U1 and 35U2 of U1 phase and U2 phase) are arranged so as to face each other in the radial direction with the capacitor unit 34 interposed therebetween.

Each power module 35 includes a main body portion 35a (power module main body portion), a positive terminal 35b, a negative terminal 35c, an output terminal 35d, a signal terminal 35e on the upper arm side, and a signal terminal 35f on the lower arm side. have.

The body portion 35a has a substantially rectangular shape when viewed from the axial direction. The body portion 35a includes a switching element SW1 and a diode D1 on the upper arm side, and a switching element SW2 and a diode D2 on the lower arm side.

The positive terminal 35b, the negative terminal 35c, the output terminal 35d, the signal terminal 35e on the upper arm side, and the signal terminal 35f on the lower arm side are plate members.
As a material of the positive terminal 35b, the negative terminal 35c, the output terminal 35d, the signal terminal 35e on the upper arm side, and the signal terminal 35f on the lower arm side, for example, oxygen-free copper is used. Tough pitch copper is used as the material for the positive terminal 35b, the negative terminal 35c, the output terminal 35d, the signal terminal 35e on the upper arm side, and the signal terminal 35f on the lower arm side in order to reduce material costs and improve availability. may be The plate thickness of the positive terminal 35b, the negative terminal 35c, the output terminal 35d, the signal terminal 35e on the upper arm side, and the signal terminal 35f on the lower arm side is, for example, 0.5 to 1.5 mm.

The positive electrode terminal 35b is arranged to face the positive electrode side second end portion 342b of the positive electrode conductor 342 . Specifically, the positive terminal 35b extends in the axial direction. The positive electrode terminal 35b and the tip portion of the positive electrode-side second end portion 342b face each other in a direction perpendicular to the axial direction (in the present embodiment, substantially in the radial direction) and are in contact with each other. The positive electrode terminal 35b is directly connected to the positive electrode side second end 342b. The direct connection means that the positive electrode terminal 35b and the positive electrode side second end portion 342b are connected in contact with each other without using a wire or the like. Resistance welding, ultrasonic bonding, TIG welding, or laser welding, for example, is used to connect the positive electrode terminal 35b and the positive electrode side second end portion 342b. As shown in FIG. 8, when viewed from the axial direction, the first connection portion C1 between the positive electrode side second end portion 342b and the positive electrode terminal 35b is connected to the main body portion 341 of the capacitor unit 34 and the main body portion 35a of the power module 35. is located between

The negative electrode terminal 35c is arranged to face the negative electrode side second end 343b of the negative electrode conductor 343 . Specifically, the negative terminal 35c extends in the axial direction. The negative electrode terminal 35c and the tip portion of the negative electrode-side second end portion 343b are opposed to each other in a direction perpendicular to the axial direction (in the present embodiment, substantially radial direction) and are in contact with each other. The negative terminal 35c is directly connected to the negative second end 343b. The direct connection means that the negative electrode terminal 35c and the negative electrode side second end portion 343b are connected in contact with each other without using a wire or the like. Resistance welding, ultrasonic bonding, TIG welding, or laser welding, for example, is used to connect the negative electrode terminal 35c and the negative electrode-side second end portion 343b. As shown in FIG. 8, when viewed from the axial direction, the second connection portion C2 between the negative electrode side second end portion 343b and the negative electrode terminal 35c is connected to the main body portion 341 of the capacitor unit 34 and the main body portion 35a of the power module 35. is located between

In the present embodiment, the length of the path from the positive conductor 342 of the capacitor unit 34 to the negative conductor 343 of the capacitor unit 34 via the positive terminal 35b and the negative terminal 35c of the power module 35 is A capacitor unit 34 and a power module 35 are provided so as to be substantially the same. That is, the lengths of the connection paths between the capacitor units 34 and the power modules 35 are substantially the same for all the power modules 35 . Here, the fact that the lengths of the paths are substantially the same means that the total length of the path from the positive electrode conductor 342 to the negative electrode conductor 343 via the positive electrode terminal 35b and the negative electrode terminal 35c is is within ±5%. Thereby, the surge voltage generated in each power module 35 can be equalized. Therefore, it becomes possible to input a large amount of current to the power module 35, and it becomes possible to increase the output of the rotary electric machine unit 1. FIG.
In addition, in the present disclosure, the length of the connection path between the capacitor unit 34 and the power module 35 should be approximately the same for at least two power modules 35 . Even in this case, the surge voltages generated in these two power modules 35 can be equalized. Therefore, it becomes possible to input a large amount of current to the power module 35, and it becomes possible to increase the output of the rotary electric machine unit 1. FIG.

Also, in all the power modules 35, the wiring resistance of the connection paths from the positive conductor 342 to the coil terminal 25a and from the negative conductor 343 to the coil terminal 25a is uniform. Therefore, it is possible to prevent currents flowing through the power modules 35 from being biased among the plurality of power modules 35 .

Also, the capacitor unit 34 and the power module 35 are connected by the shortest route. As a result, the inductance of the connection path between the capacitor unit 34 and the power module 35 can be reduced, and the surge voltage generated in the power module 35 can be suppressed. Therefore, it becomes possible to input a large amount of current by the power module 35, and it becomes possible to further increase the output of the rotary electric machine unit 1. FIG.

The output terminal 35d is connected to the coil terminal 25a of the coil 25 via the busbar 37. The signal terminal 35e on the upper arm side is connected to the switching element SW1 and the diode D1 on the upper arm side. The signal terminal 35f on the lower arm side is connected to the switching element SW2 and the diode D2 on the lower arm side. The signal terminal 35 e on the upper arm side and the signal terminal 35 f on the lower arm side are connected to the control board 36 . As shown in FIGS. 4 and 5, the signal terminal 35 e on the upper arm side and the signal terminal 35 f on the lower arm side are directly attached to the control board 36 .

Each bus bar 37 connects the power module 35 and the coil 25 of the corresponding phase. 12 is a perspective view of the busbar 37. FIG. As shown in FIG. 12, the bus bar 37 is a substantially L-shaped plate member. Bus bar 37 has a first plate portion 371 and a second plate portion 372 .
Oxygen-free copper, for example, is used as the material of the bus bar 37 . As a material of the bus bar 37, tough pitch copper may be used for cost reduction and availability improvement of the material. The plate thickness of the bus bar 37 is, for example, 0.5 to 2.5 mm.

As shown in FIG. 8, the busbars 37 are arranged between the power modules 35 adjacent in the circumferential direction. The first plate portion 371 extends in the circumferential direction while the busbar 37 is fixed to the first plate 41 . The second plate portion 372 extends radially while the bus bar 37 is fixed to the first plate 41 .

A first terminal 371a connected to the output terminal 35d is formed at the end of the first plate portion 371 . The first terminal 371a is arranged to face the output terminal 35d. The first terminal 371a is directly connected to the output terminal 35d. In addition, being directly connected means that the first terminal 371a and the output terminal 35d are connected in contact with each other without using a wire or the like.
Resistance welding, ultrasonic bonding, TIG welding, or laser welding, for example, is used to connect the first terminal 371a and the output terminal 35d. As shown in FIG. 8, the third connection portion C3 between the first terminal 371a and the output terminal 35d is located radially outside the main body portion 35a of the power module 35 when viewed in the axial direction.

A second terminal 372a is formed at the end of the second plate portion 372 to be connected to the coil terminal 25a. The second terminal 372a is arranged to face the coil terminal 25a. The second terminal 372a is directly connected to the coil terminal 25a. The direct connection means that the second terminal 372a and the coil terminal 25a are connected by being in contact with each other without using a wire or the like. Resistance welding, ultrasonic bonding, TIG welding, or laser welding, for example, is used to connect the second terminal 372a and the coil end 25a. As shown in FIG. 8, the fourth connection portion C4 between the second terminal 372a and the coil terminal 25a is located radially inside the main body portion 35a of the power module 35 when viewed in the axial direction.

The second plate portion 372 has a mounting portion 373 to which the current sensor 38 is mounted. The attachment portion 373 is provided so as to protrude toward the control board 36 from the second terminal 372a in the axial direction.

A current sensor 38 is provided on each bus bar 37 . Current sensor 38 detects the current flowing through bus bar 37 . The current sensor 38 is arranged below the control board 36 . That is, the current sensor 38 is arranged closer to the stator 21 of the rotating electrical machine 2 than the control board 36 is. The current sensor 38 has a signal terminal 38 a connected to the control board 36 . As shown in FIG. 4, the signal terminals 38a are attached directly to the control board 36. As shown in FIG. As a result, the noise resistance is improved, and the detection accuracy of the current value of the bus bar 37 by the current sensor 38 is improved.

As shown in FIGS. 7 and 8, the busbar 37 and current sensor 38 are covered with a resin member 39. As shown in FIG. As a material of the resin member 39, for example, polyphenylene sulfide (PPS) is used. The signal terminal 38 a is exposed from the resin member 39 .
The resin member 39 is fixed to the first plate 41 by bolts 41f3 and supports 41e. The busbar 37 and the current sensor 38 are thereby fixed to the first plate 41 . As shown in FIG. 7, the resin member 39 is formed with a bolt hole 39a through which the bolt 41f3 is inserted and a through hole 39b through which the strut 41e is inserted.

As shown in FIGS. 4 and 5, the control board 36 has a disk shape. An opening 36 b is formed in the central portion of the control board 36 . A capacitor unit 34 is arranged in the opening 36 b of the control board 36 . That is, the capacitor unit 34 is inserted through the opening 36b. As shown in FIG. 6, the control board 36 is fixed to the first plate 41 by bolts 41f1 and posts 41e. The control board 36 is formed with a bolt hole 36a through which the bolt 41f1 is inserted.

The signal terminal 35e on the upper arm side, the signal terminal 35f on the lower arm side, and the signal terminal 38a are directly connected to the control board 36. A signal connector 33 is connected to the control board 36 via a signal connector harness 33a. A resolver 27 of the rotary electric machine 2, which will be described later, is connected to the control board 36 via a resolver harness 27c. The resolver harness 27c is inserted through the opening 36b. The control board 36 controls the power module 35 based on control commands input from an external control device mounted on a vehicle or the like.

<Rotating electric machine>
The rotary electric machine 2 will be described with reference to FIGS. 9, 13, and the like. 13 is a perspective view of the rotating electric machine 2. FIG.
As shown in FIG. 9, the rotary electric machine 2 includes a stator 21, a rotor 22, a shaft 23, a housing 24, and a plurality of coils 25 (six coils 25U1, 25V1, 25W1 in the present embodiment). , 25U2, 25V2, 25W2), first and second bearings 26a and 26b, and a resolver 27.

The stator 21 is annular. The stator 21 is provided so as to surround the outer circumference of the rotor 22 . The stator 21 is fixed to the housing 24 .

The rotor 22 is provided inside the stator 21. The rotor 22 is rotatable around the axis with respect to the stator 21 .

A shaft 23 is arranged at the center of the rotor 22 . One end of the shaft 23 in the axial direction (lower side in FIG. 9) is an output end that transmits the rotation of the rotor 22 to a vehicle or the like.

The coil 25 is wound around the stator 21. The coil 25 is distributed around the stator 21, for example. As the coil 25, for example, a rectangular wire having a square cross section with a side of 0.5 to 6.0 mm is used. A coil terminal 25 a of the coil 25 of each phase is connected to the power module 35 of the corresponding phase via a bus bar 37 . As shown in FIG. 13, the six coil terminals 25a are arranged at regular intervals (at intervals of 60°) in the circumferential direction. The coil terminal 25a extends linearly in the axial direction toward the busbar 37 and is directly connected to the busbar 37 . As a result, the coil terminal 25a can be connected to the busbar 37 by the shortest path, and the amount of rectangular wire used for the coil 25 can be reduced. Moreover, since the molding process of the coil terminal 25a is unnecessary, the manufacturing cost can be reduced.

The resolver 27 detects the rotation angle of the shaft 23. The resolver 27 includes a resolver stator 27a and a resolver rotor 27b. The resolver stator 27 a is fixed to the housing 24 . The resolver rotor 27b is attached to the upper end of the shaft 23 (end on the non-output side).

The resolver 27 is connected to the control board 36 via a resolver harness 27c. The resolver harness 27 c is pulled out from the resolver stator 27 a and extends toward the control board 36 . The resolver harness 27c extends to avoid the portion where the power module 35 is arranged. As a result, noise caused by the power module 35 can be prevented from being transmitted to the resolver harness 27c, and the detection accuracy of the rotation angle of the shaft 23 can be improved.

The housing 24 accommodates the stator 21, rotor 22, and shaft 23. The housing 24 includes a lid portion 241 , an inner cylinder portion 242 , an outer cylinder portion 243 and a bottom portion 244 .

The lid portion 241 is a circular plate-like member. The lid portion 241 is fixed to the upper end of the inner cylindrical portion 242 . The lid portion 241 covers the stator 21 and the rotor 22 from above. As shown in FIG. 13, the lid portion 241 is formed with a coil through-hole 241a through which the coil end 25a is inserted. The six coil through holes 241a are arranged at equal intervals (at intervals of 60°) in the circumferential direction.

The inner cylindrical portion 242 has a cylindrical shape. The inner cylindrical portion 242 covers the stator 21 from the radial outside. The stator 21 is fixed to the inner cylindrical portion 242 by, for example, shrink fitting or press fitting.
The outer tube portion 243 has a cylindrical shape. The outer tubular portion 243 covers the inner tubular portion 242 from the radial outside. The outer tubular portion 243 is fixed to the inner tubular portion 242 by, for example, shrink fitting or press fitting.
The inner cylindrical portion 242 and the outer cylindrical portion 243 constitute a second cooling portion 6 (see FIG. 9) that cools the rotary electric machine 2 . Details of the second cooling unit 6 will be described later.

The bottom part 244 is a circular plate-like member. The bottom portion 244 is fixed to the lower end of the outer cylindrical portion 243 . The bottom portion 244 covers the stator 21 and the rotor 22 from below. The bottom portion 244 is provided with a mounting portion 244a for mounting the rotary electric machine unit 1 to the vehicle.

A first bearing 26a is provided at the upper end of the shaft 23 (end on the non-output side). The first bearing 26 a is fixed to the lid portion 241 . A second bearing 26b is provided at the lower end (end on the output side) of the shaft 23 . A second bearing 26 b is fixed to the bottom 244 . The first bearing 26a and the second bearing 26b rotatably support the shaft 23 .

<Cooler>
The cooler 4 will be described with reference to FIGS. 6, 9, 10, 14 to 16, and the like. Cooler 4 is provided between rotating electric machine 2 and power converter 3 . The cooler 4 has a first plate 41 , a plurality of (six in this embodiment) second plates 42 , and a base 43 .

14 is a perspective view of the second plate 42. FIG. As shown in FIG. 14, the second plate 42 is a substantially rectangular plate member. A second plate 42 is provided for each power module 35 . As shown in FIG. 10 , the power module 35 is attached to the first surface of the second plate 42 . The power module 35 is fixed to the first surface of the second plate 42 by soldering, for example. The second surface of the second plate 42 is provided with radiation fins 42a (first radiation fins). As shown in FIG. 7, the second plate 42 is fixed to the first plate 41 by supports 41e. The power module 35 is thereby fixed to the first plate 41 . The second plate 42 is formed with a through hole 42b through which the column 41e is inserted.

15 is a perspective view of the first plate 41. FIG. As shown in FIG. 15, the first plate 41 is a circular plate-like member. The first plate 41 is formed with a harness through-hole 41a through which the resolver harness 27c is inserted. A coil through-hole 41b through which the coil end 25a is inserted is formed in the first plate 41 . The six coil through-holes 41b are arranged at equal intervals (at intervals of 60°) in the circumferential direction. A plurality of (six in the present embodiment) openings 41 c are formed in the first plate 41 . As shown in FIG. 10, in a state where the second plate 42 is fixed to the first plate 41, the radiation fins 42a are arranged inside the opening 41c. The six openings 41c are arranged at equal intervals (at intervals of 60°) in the circumferential direction.

The first surface of the first plate 41 is provided with a bottomed first attachment hole 41d1 to which a bolt 41f2 is attached. The first surface of the first plate 41 is provided with a bottomed second attachment hole 41d2 to which the support 41e is attached. The first surface of the first plate 41 is provided with a bottomed third attachment hole 41d3 to which a bolt 41f3 is attached. A second surface of the first plate 41 is fixed to the base 43 .

The first mounting hole 41d1 is provided at a position overlapping the bolt hole 341c formed in the capacitor unit 34 when viewed from the axial direction. The capacitor unit 34 is attached to the first plate 41 by inserting the bolt 41f2 through the bolt hole 341c and fastening it to the first attachment hole 41d1. Further, as shown in FIG. 6, a heat radiating member 44 is provided between the first plate 41 and the capacitor unit 34. As shown in FIG.

The second mounting hole 41d2 is provided at a position overlapping the through hole 42b formed in the second plate 42 when viewed from the axial direction. The support 41e attached to the second attachment hole 41d2 is inserted through the through hole 42b formed in the second plate 42. As shown in FIG. Thereby, the second plate 42 is fixed to the first plate 41 .

As shown in FIG. 6, the upper end of the support 41e contacts the control board 36. As shown in FIG. A bottomed attachment hole 41e1 to which a bolt 41f1 is attached is provided at the upper end of the support 41e. The mounting hole 41e1 is provided at a position overlapping the bolt hole 36a formed in the control board 36 when viewed in the axial direction. The control board 36 is fixed to the first plate 41 by inserting the bolt 41f1 through the bolt hole 36a and fastening it to the mounting hole 41e1 while the control board 36 is in contact with the upper end of the post 41e. .

The third mounting hole 41d3 is provided at a position overlapping the bolt hole 39a formed in the resin member 39 when viewed from the axial direction. The resin member 39 is attached to the first plate 41 by inserting the bolt 41f3 through the bolt hole 39a and fastening it to the third attachment hole 41d3. Further, the resin member 39 is formed with a through hole 39b through which the support 41e is inserted. The resin member 39 is more reliably fixed to the first plate 41 by inserting the support 41e into the through hole 39b.

16 is a perspective view of the base 43. FIG. As shown in FIGS. 6, 9, 16, etc., the base 43 has a substantially cylindrical shape. A first plate 41 is fixed to the first surface (upper surface) of the base 43 . A lid portion 241 of the housing 24 is fixed to the second surface (lower surface) of the base 43 .
As shown in FIG. 16, the base 43 is formed with a harness through-hole 43a through which the resolver harness 27c is inserted. The base 43 is formed with a coil through hole 43b through which the coil end 25a is inserted. Six coil through holes 43b are formed at equal intervals (at 60° intervals) in the circumferential direction. Further, as shown in FIG. 6, a hollow portion 43c in which the resolver 27 is arranged is formed in the lower portion of the base 43. As shown in FIG.

Here, the cooler 4 is formed with a first cooling channel through which the coolant flows. As the coolant, for example, water (cooling water) is used. As shown in FIG. 16, the first cooling channel has an inlet channel 51, a first channel 52, a second channel 53, a third channel 54, and an outlet channel 55. . Refrigerant is supplied to the inlet channel 51 . A first channel 52 , a second channel 53 , and a third channel 54 branch from the inlet channel 51 . The first flow path 52 is formed at a position overlapping half of the six power modules 35 (specifically, the power modules 35U1, 35V1, 35W1) when viewed from the axial direction. The first flow path 52 extends from the inlet flow path 51 to one side in the circumferential direction. The second flow path 53 is formed at a position overlapping half of the six power modules 35 (specifically, the power modules 35U2, 35V2, and 35W2) when viewed from the axial direction. The second flow path 53 extends from the inlet flow path 51 to the other side in the circumferential direction. The third flow path 54 is formed at a position overlapping the capacitor unit 34 when viewed in the axial direction. The refrigerant from the first flow path 52 , the second flow path 53 , and the third flow path 54 merge in the outlet flow path 55 . The outlet channel 55 communicates with a second cooling channel formed inside the second cooling section 6 .

A coolant supply port 45 , a groove portion 46 and a coolant discharge port 47 are provided on the base 43 .

The coolant supply port 45 is a hole penetrating the peripheral wall of the base 43 in the radial direction. The inside of the coolant supply port 45 is used as the inlet channel 51 . One end of the coolant supply port 45 is connected to a first joint 48 to which coolant is supplied from the outside. Note that the first joint 48 is arranged on the front side of the rotary electric machine unit 1 . The other end of the coolant supply port 45 is connected to the groove portion 46 . The coolant supply port 45 communicates between the first joint 48 and the groove portion 46 .

The coolant discharge port 47 is a hole axially penetrating the base 43 . The inside of the coolant outlet 47 is used as an outlet channel 55 . The coolant discharge port 47 is arranged on the opposite side of the coolant supply port 45 in the circumferential direction. One end of the coolant discharge port 47 is connected to the groove portion 46 . The other end of the coolant discharge port 47 is connected to an opening 242c (see FIG. 9) of the inner cylindrical portion 242, which will be described later.

The groove 46 is formed on the upper surface of the base 43 . The groove portion 46 includes an annular groove portion 461 , a circular groove portion 462 , an upstream communication groove portion 463 and a downstream communication groove portion 464 .

The annular groove portion 461 extends in the circumferential direction and has an annular shape when viewed from the axial direction. The coolant supply port 45 opens to the radially outer side surface of the annular groove portion 461 . The coolant discharge port 47 opens to the bottom surface of the annular groove portion 461 .

The annular groove portion 461 is a first annular groove portion 461a which is one side portion sandwiched between the refrigerant supply port 45 and the refrigerant discharge port 47, and the other side portion sandwiched between the refrigerant supply port 45 and the refrigerant discharge port 47. and a second annular groove portion 461b. The first annular groove portion 461a is provided in the lower portion of half of the six power modules 35 (specifically, the power modules 35U1, 35V1, and 35W1). The second annular groove portion 461b is provided in the lower portion of the other half of the six power modules 35 (specifically, the power modules 35U2, 35V2, and 35W2).
The first flow path 52 is formed by the first annular groove portion 461a, the second surface of the first plate 41, and the second surface of the second plate . A second flow path 53 is formed by the second annular groove portion 461 b , the second surface of the first plate 41 , and the second surface of the second plate 42 . As shown in FIG. 10 , the heat radiating fins 42 a provided on the second surface of the second plate 42 are arranged in the first channel 52 or the second channel 53 .

As shown in FIGS. 10 and 16, on the bottom surface of the annular groove 461, a protrusion 461c is formed at a portion axially facing the power module 35 (second plate 42). The heat radiation fins 42a of the second plate 42 are arranged on the convex portion 461c. A concave portion 461d is formed between the convex portions 461c. By alternately providing the convex portions 461c and the concave portions 461d in the circumferential direction in this manner, the cross-sectional area of the coolant flowing toward the heat radiation fins 42a is increased, and the coolant flow in the first flow path 52 and the second flow path 53 is increased. Pressure loss can be reduced.

The circular groove 462 is arranged inside the annular groove 461 . A circular groove portion 462 is provided in the lower portion of the capacitor unit 34 . Further, as shown in FIG. 9, the heat radiating member 44 is arranged between the circular groove 462 and the capacitor unit 34 .
The upstream communication groove portion 463 is provided between the annular groove portion 461 and the circular groove portion 462 . When viewed from the axial direction, the upstream communication groove portion 463 is provided so as to radially face the coolant supply port 45 . The upstream communication groove portion 463 communicates between the annular groove portion 461 and the circular groove portion 462 .
The downstream communication groove portion 464 is provided between the annular groove portion 461 and the circular groove portion 462 . When viewed from the axial direction, the downstream communication groove portion 464 is provided so as to radially face the coolant discharge port 47 . The downstream communication groove portion 464 communicates between the annular groove portion 461 and the circular groove portion 462 .
The circular groove portion 462 , the upstream communication groove portion 463 , the downstream communication groove portion 464 , and the second surface of the first plate 41 form the third flow path 54 .

The upstream communication groove portion 463 and the downstream communication groove portion 464 are formed avoiding the harness through hole 43a and the coil through hole 43b. In the illustrated example, each of the upstream communication groove portion 463 and the downstream communication groove portion 464 is composed of a pair of groove portions provided with the coil through hole 43b interposed therebetween.

The coolant supplied from the first joint 48 passes through the inlet channel 51 and branches into the first channel 52 , the second channel 53 and the third channel 54 . Heat generated in the power modules 35U1, 35V1, and 35W1 is heat-exchanged with the coolant flowing through the first flow path 52 via the second plate 42. As shown in FIG. This cools the power modules 35U1, 35V1, and 35W1. Heat generated in the power modules 35U2, 35V2, and 35W2 is heat-exchanged with the coolant flowing through the second flow path 53 via the second plate 42. This cools the power modules 35U2, 35V2, and 35W2. By providing the heat radiation fins 42 a on the second plate 42 , the contact area between the coolant and the second plate 42 can be increased, and the cooling effect of the power module 35 can be enhanced. Heat generated in the capacitor unit 34 (capacitor element 34 a ) is heat-exchanged with the refrigerant flowing through the third flow path 54 via the heat radiating member 44 and the first plate 41 . This cools the capacitor unit 34 (capacitor element 34a). After that, the coolant from the first flow path 52 , the second flow path 53 , and the third flow path 54 joins at the outlet flow path 55 and is discharged toward the second cooling section 6 .

<Second cooling unit>
As shown in FIG. 9 , the inner cylinder portion 242 and the outer cylinder portion 243 constitute the second cooling portion 6 . A second cooling channel through which a coolant flows is formed in the second cooling portion 6 . The second cooling flow path is formed between the outer peripheral surface of the inner tubular portion 242 and the inner peripheral surface of the outer tubular portion 243 .

17A and 17B are perspective views of the inner tubular portion 242. FIG. As shown in FIGS. 17A and 17B, the inner cylinder portion 242 has a cylindrical main body portion 242a and a flange portion 242b protruding radially outward from the upper end of the main body portion 242a. An opening 242c that communicates with the coolant discharge port 47 of the cooler 4 is formed in the flange portion 242b. As shown in FIG. 9, the coolant discharge port 47 and the opening 242c are connected by a third joint 65. As shown in FIG.

The second cooling channel has a communication channel 61 , a fourth channel 62 , a fifth channel 63 and a discharge channel 64 . The communication channel 61 communicates with the outlet channel 55 . The fourth channel 62 and the fifth channel 63 branch from the communication channel 61 . The fourth flow path 62 extends from the communication flow path 61 to one side in the circumferential direction. The fifth flow path 63 extends from the communication flow path 61 to the other side in the circumferential direction. The coolant from the fourth flow path 62 and the fifth flow path 63 merge in the discharge flow path 64 . The coolant is discharged to the outside through the discharge channel 64 .

A first groove portion 71, a second groove portion 72, a third groove portion 73, and a fourth groove portion 74 are formed on the outer peripheral surface of the body portion 242a.

The first groove portion 71 is formed below the opening portion 242c. The first groove portion 71 extends in the axial direction. The upper end of the first groove portion 71 communicates with the opening portion 242c. The lower end of the first groove portion 71 is closed. A communication passage 61 is formed by the first groove portion 71 and the inner peripheral surface of the outer cylindrical portion 243 .

The second groove portion 72 is formed on the opposite side of the first groove portion 71 in the circumferential direction. The second groove portion 72 extends in the axial direction. The upper and lower ends of the second groove portion 72 are closed. A discharge passage 64 is formed by the second groove portion 72 and the inner peripheral surface of the outer cylindrical portion 243 .

The third groove portion 73 is connected to the first groove portion 71 and the second groove portion 72 . The third groove portion 73 extends to one side in the circumferential direction from the first groove portion 71 to the second groove portion 72 . A plurality of third grooves 73 are formed at intervals in the axial direction. A fourth flow path 62 is formed by the third groove portion 73 and the inner peripheral surface of the outer cylindrical portion 243 .

The fourth groove portion 74 is connected to the first groove portion 71 and the second groove portion 72 . The fourth groove portion 74 extends from the first groove portion 71 to the second groove portion 72 to the other side in the circumferential direction. A plurality of fourth grooves 74 are formed at intervals in the axial direction. A fifth flow path 63 is formed by the fourth groove portion 74 and the inner peripheral surface of the outer cylindrical portion 243 .

As shown in FIG. 9, an opening 243a is formed at the lower end of the outer cylindrical portion 243 so as to penetrate the peripheral wall of the outer cylindrical portion 243 in the radial direction. The opening portion 243a is provided so as to face the second groove portion 72 of the inner cylinder portion 242 in the radial direction. The opening 243 a is connected to the second groove 72 . The opening 243a is connected to a second joint 66 that discharges the coolant to the outside. The opening 243 a communicates the second groove 72 and the second joint 66 . The second joint 66 is arranged on the front side of the rotary electric machine unit 1 .

The coolant discharged from the coolant discharge port 47 of the cooler 4 flows into the communication channel 61 through the opening 242c. The coolant flows downward through the communication channel 61 and branches into the fourth channel 62 and the fifth channel 63 . The coolant flowing through the fourth flow path 62 cools one half of the rotating electric machine 2 in the circumferential direction. The coolant flowing through the fifth flow path 63 cools the other half of the rotating electric machine 2 in the circumferential direction. Since the plurality of fourth flow passages 62 and fifth flow passages 63 are provided at intervals in the axial direction, cooling efficiency of the rotating electric machine 2 by the second cooling section 6 is improved. After that, the refrigerant from the fourth flow path 62 and the fifth flow path 63 joins in the discharge flow path 64, flows downward through the discharge flow path 64, and is discharged to the outside through the opening 243a and the second joint 66. be done.

In the present embodiment, in the rotating electric machine unit 1, the power conversion device 3 includes a capacitor unit 34 arranged in the central portion of the power conversion device 3, and a plurality of capacitor units 34 arranged in the circumferential direction so as to surround the capacitor unit 34. and a power module 35 . The capacitor unit 34 has a body portion 341 , a positive conductor 342 and a negative conductor 343 . Each of the plurality of power modules 35 has a body portion 35 a , a positive terminal 35 b connected to the positive conductor 342 , and a negative terminal 35 c connected to the negative conductor 343 . The positive terminal 35 b and the negative terminal 35 c are arranged to face the capacitor unit 34 . A first connection portion C1 between the positive electrode conductor 342 and the positive electrode terminal 35b and a second connection portion C2 between the negative electrode conductor 343 and the negative electrode terminal 35c are located between the body portion 341 and the body portion 35a.
As a result, the connection path between the capacitor unit 34 and the power module 35 can be shortened, so the inductance in this connection path can be suppressed, and the surge voltage generated in the power module 35 can be suppressed. Therefore, it becomes possible to input a large amount of current to the power module 35, and it becomes possible to increase the output of the rotary electric machine unit 1. FIG.

Further, the length of the first path from the positive electrode conductor 342 to the negative electrode conductor 343 via the positive electrode terminal 35b and the negative electrode terminal 35c of the first power module 35 among the plurality of power modules 35 is The length of the second path to the negative conductor 343 via the positive terminal 35b and the negative terminal 35c of the second power module 35 among the plurality of power modules 35 is substantially the same. Note that the length of the first path is substantially the same as the length of the second path means that the difference between the length of the first path and the length of the second path is ±5% with respect to the total length of the first path. means within the range of
Thereby, the surge voltages generated in the first power module 35 and the second power module 35 can be equalized. Therefore, it becomes possible to input a large amount of current by the power module 35, and it becomes possible to further increase the output of the rotary electric machine unit 1. FIG.

Further, in all of the plurality of power modules 35, the path length from the positive electrode conductor 342 to the negative electrode conductor 343 via the positive electrode terminal 35b and the negative electrode terminal 35c is substantially the same.
As a result, the surge voltage generated in each power module 35 can be equalized for all the power modules 35 . Therefore, it becomes possible to input a large amount of current by the power module 35, and it becomes possible to further increase the output of the rotary electric machine unit 1. FIG.

The positive conductor 342 and the positive terminal 35b are directly connected, and the negative conductor 343 and the negative terminal 35c are directly connected.
Accordingly, since the capacitor unit 34 and the power module 35 can be connected without using wires or the like, the cost of the rotating electric machine unit 1 can be suppressed. Moreover, since the connection path between the capacitor unit 34 and the power module 35 can be shortened, the inductance in this connection path can be suppressed, and the surge voltage generated in the power module 35 can be suppressed. Therefore, it becomes possible to input a large amount of current by the power module 35, and it becomes possible to further increase the output of the rotary electric machine unit 1. FIG.

Moreover, the power conversion device 3 further includes a plurality of bus bars 37 that connect the plurality of power modules 35 and the plurality of coils 25, respectively.
Thereby, the power module 35 and the coil 25 can be easily connected using the bus bar 37 .

The power conversion device 3 further includes a control board 36 that controls the plurality of power modules 35 and a plurality of current sensors 38 that respectively detect currents flowing through the plurality of busbars 37 . Each of the multiple current sensors 38 is directly connected to the control board 36 .
As a result, the connection path between the signal terminal 38a of the current sensor 38 and the control board 36 can be shortened, so that noise resistance can be improved. Further, since the current sensor 38 and the control board 36 are connected without using a harness or the like, the cost and weight of the rotary electric machine unit 1 can be reduced.

Moreover, each of the plurality of bus bars 37 has a first terminal 371 a connected to the corresponding power module 35 among the plurality of power modules 35 and a second terminal 372 a connected to the corresponding coil 25 among the plurality of coils 25 . , have The first terminals 371a are positioned radially outward of the main body portion 35a of the corresponding power module 35 .
Thereby, the power module 35 and the coil 25 can be more easily connected using the bus bar 37 .

Moreover, each of the plurality of bus bars 37 further has an attachment portion 373 to which the current sensor 38 is attached. The attachment portion 373 is provided so as to protrude toward the control board 36 from the second terminal 372a in the axial direction.
Thereby, the signal terminal 38 a of the current sensor 38 can be easily connected to the control board 36 .

Also, the plurality of bus bars 37 and the plurality of power modules 35 are alternately arranged in the circumferential direction.
As a result, the mounting density of the power conversion device 3 can be improved, and the size of the rotating electric machine unit 1 can be reduced.
Further, when the current sensor 38 is provided on the bus bar 37, the signal terminal 38a of the current sensor 38 can be directly connected to the control board 36 without using a harness or the like. Therefore, the noise resistance is improved, and the detection accuracy of the current value of the bus bar 37 by the current sensor 38 is improved.

The rotary electric machine unit 1 also includes a cooler 4 that cools the power conversion device 3 in which a first cooling passage through which a coolant flows is formed. The first cooling channel includes an inlet channel 51 to which a coolant is supplied, and branches from the inlet channel 51. When viewed from the axial direction, the power modules 35U1 of the first group among the plurality of power modules 35, A first flow path 52 formed at a position overlapping with 35V1 and 35W1, and a second group branching from the inlet flow path 51 and different from the first group among the plurality of power modules 35 when viewed from the axial direction. A second flow path 53 formed at a position overlapping the power modules 35U2, 35V2, and 35W2, and a third flow path 53 branched from the inlet flow path 51 and formed at a position overlapping the capacitor unit 34 when viewed in the axial direction. It has a flow path 54 and an outlet flow path 55 through which the refrigerant from the first flow path 52 , the second flow path 53 , and the third flow path 54 merge and the refrigerant is discharged from the cooler 4 . The outlet passage 55 communicates with a second cooling passage formed inside the second cooling portion 6 that cools the rotating electric machine 2 . The second cooling flow path includes a communication flow path 61 that communicates with the outlet flow path 55, a fourth flow path 62 that branches from the communication flow path 61 and extends to one side in the circumferential direction from the communication flow path 61, and a communication flow path. While branching from the passage 61 and extending to the other side in the circumferential direction from the communication passage 61 , the coolant from the fourth passage 62 and the fifth passage 63 merge, and the second cooling portion 6 and a discharge channel 64 through which the coolant is discharged.

The coolant is branched to flow through the first channel 52 and the second channel 53 . Therefore, compared with the case where a plurality of power modules 35 are arranged on one system of cooling flow path, it is possible to suppress unevenness in temperature of the coolant between the upstream side and the downstream side of the cooling flow path. Therefore, the plurality of power modules 35 can be uniformly cooled, and the cooling performance of the rotating electric machine unit 1 can be improved. Further, as a result, it is possible to improve the density of the current input to the power module 35, and it is possible to increase the output of the rotary electric machine unit 1. FIG.
Moreover, since the condenser unit 34 can be cooled by the refrigerant flowing through the third flow path 54, the cooling performance of the rotating electric machine unit 1 is further improved. As a result, it is possible to improve the density of the current input to the capacitor unit 34, and the output of the rotary electric machine unit 1 can be increased.
Furthermore, since the first cooling flow path of the cooler 4 and the second cooling flow path of the second cooling section 6 communicate within the rotating electrical machine unit 1, the rotating electrical machine unit 1 can be made smaller.
Furthermore, the coolant flowing through the fourth flow path 62 cools half of the rotating electrical machine 2 on one side in the circumferential direction, and the coolant flowing through the fifth flow path 63 cools the other half of the rotating electrical machine 2 in the circumferential direction. can be cooled, the cooling efficiency of the rotating electric machine 2 by the second cooling unit 6 is improved.

Also, the terminal block 32 , the signal connector 33 , the first joint 48 , and the second joint 66 are arranged on the front side of the rotary electric machine unit 1 .
As a result, the terminal block 32, the signal connector 33, the first joint 48, and the second joint 66 can be integrated in one of the circumferential directions of the rotary electric machine unit 1, so that the rotary electric machine unit 1 can be easily mounted on a vehicle or the like. Improve maintainability.

In addition, when viewed from the axial direction, of the positive electrode conductor 342 and the negative electrode conductor 343, the portions extending from the main body portion 341 (that is, the positive electrode side first end portion 342a, the positive electrode side second end portion 342b, the negative electrode side first end portion 343a) , and the negative electrode side second end portion 343b) are arranged so as not to overlap with the axial center.
Thereby, the body portion 341 of the capacitor unit 34 can be arranged on the axis of the rotor 22 . Therefore, the length of the first path of the negative electrode conductor 343 from the positive electrode conductor 342 via the positive electrode terminal 35b and the negative electrode terminal 35c of the first power module 35 among the plurality of power modules 35 is set to a plurality of lengths from the positive electrode conductor 342 The length of the second path to the negative electrode conductor 343 via the positive electrode terminal 35b and the negative electrode terminal 35c of the second power module 35 of the power modules 35 can be substantially the same. Therefore, since the surge voltages generated in the first power module 35 and the second power module 35 can be made uniform, a large amount of current can be input to the power module 35, and the output of the rotary electric machine unit 1 can be increased. becomes possible.

An opening 36b through which the capacitor unit 34 is inserted is formed in the central portion of the control board 36. As shown in FIG. A plurality of current sensors 38 are arranged closer to the stator 21 than the control board 36 is.
Thereby, the control board 36 can be arranged close to the plurality of power modules 35 while avoiding contact between the control board 36 and the capacitor unit 34 . As a result, the signal terminal 38a of the current sensor 38 and the control board 36 can be easily and directly connected, so that the noise resistance is improved and the detection accuracy of the current value of the bus bar 37 by the current sensor 38 is improved.

In addition, of the positive electrode conductor 342 and the negative electrode conductor 343, the portions extending from the body portion 341 and connected to the DC power source E (that is, the positive electrode side first end portion 342a and the negative electrode side first end portion 343a) are provided with the opening portion 36b. is inserted into the A resolver harness 27c that connects the resolver 27 to the control board 36 is inserted through the opening 36b.
As a result, the path length of the resolver harness 27c can be shortened, so the noise resistance is improved, and the detection accuracy of the rotation angle of the shaft 23 by the resolver 27 is improved. Moreover, since the path length of the resolver harness 27c can be shortened, the manufacturing cost of the resolver harness 27c can be reduced.

Embodiment 2.
Next, the rotary electric machine unit 1 according to Embodiment 2 will be described. Since the basic configuration of the rotary electric machine unit according to the present embodiment is the same as that of the rotary electric machine unit 1 of the first embodiment, different points will be mainly described. FIG. 18 is a perspective view of the rotary electric machine unit 1, showing a state in which the case 31, the terminal block 32, and the control board 36 are removed.

As shown in FIG. 18, in the power module 35 of the present embodiment, the positive electrode terminal 35b and the negative electrode terminal 35c extend from the body portion 35a in a direction orthogonal to the axial direction (in the present embodiment, substantially radial direction). extends to In the capacitor unit 34, the tip portion of the positive electrode side second end portion 342b of the positive electrode conductor 342 and the tip portion of the negative electrode side second end portion 343b of the negative electrode conductor 343 are arranged in a direction perpendicular to the axial direction (in the present embodiment, approximately radial direction).

The positive electrode terminal 35b is arranged so as to axially overlap the tip of the positive electrode side second end 342b. The positive electrode terminal 35b abuts the tip of the positive electrode side second end 342b from above. That is, the upper surface of the positive electrode terminal 35b (that is, the surface of the positive electrode terminal 35b opposite to the stator 21 side) and the lower surface of the tip of the positive electrode-side second end 342b (that is, the positive electrode-side second end 342b) The surface on the side of the stator 21 at the tip portion faces in the axial direction and contacts each other. In addition, the thickness of the positive electrode terminal 35b (that is, the size of the positive electrode terminal 35b in the axial direction) is the thickness of the tip of the positive electrode-side second end 342b (that is, the thickness of the tip of the positive electrode-side second end 342b). axial dimension).

The positive electrode terminal 35b is directly connected to the positive electrode side second end 342b. The direct connection means that the positive electrode terminal 35b and the positive electrode side second end portion 342b are connected in contact with each other without using a wire or the like. For example, laser welding is used to connect the positive electrode terminal 35b and the positive electrode side second end portion 342b. In this case, laser welding is performed from the positive electrode terminal 35b side. A laser-welded portion between the positive terminal 35b and the positive electrode-side second end portion 342b is a first connection portion C1 between the positive electrode-side second end portion 342b and the positive electrode terminal 35b. A first connecting portion C1 between the positive electrode side second end portion 342b and the positive electrode terminal 35b is positioned between the main body portion 341 of the capacitor unit 34 and the main body portion 35a of the power module 35 when viewed from the axial direction.

The negative electrode terminal 35c is arranged so as to axially overlap the tip of the negative electrode-side second end 343b. The negative electrode terminal 35c abuts the tip of the negative electrode-side second end 343b from above. That is, the upper surface of the negative electrode terminal 35c (that is, the surface of the negative electrode terminal 35c opposite to the stator 21 side) and the lower surface of the tip of the negative electrode-side second end portion 343b (that is, the negative electrode-side second end portion 343b) The surface on the side of the stator 21 at the tip portion faces in the axial direction and contacts each other. Further, the plate thickness of the negative electrode terminal 35c (that is, the size of the negative electrode terminal 35c in the axial direction) is the thickness of the tip portion of the negative electrode-side second end portion 343b (that is, the thickness of the tip portion of the negative electrode-side second end portion 343b). axial dimension).

The negative terminal 35c is directly connected to the negative second end 343b. The direct connection means that the negative electrode terminal 35c and the negative electrode side second end portion 343b are connected in contact with each other without using a wire or the like. Laser welding, for example, is used to connect the negative electrode terminal 35c and the negative electrode-side second end portion 343b. In this case, laser welding is performed from the negative electrode terminal 35c side. The laser-welded portion between the negative electrode terminal 35c and the negative electrode-side second end portion 343b is the second connection portion C2 between the negative electrode-side second end portion 343b and the negative electrode terminal 35c. A second connection portion C2 between the negative electrode-side second end portion 343b and the negative electrode terminal 35c is positioned between the main body portion 341 of the capacitor unit 34 and the main body portion 35a of the power module 35 when viewed from the axial direction.

As described above, in the present embodiment, the positive electrode side second end portion 342b of the positive electrode conductor 342 and the positive electrode terminal 35b are axially opposed to each other and are in contact with each other. The end portion 343b and the negative terminal 35c are axially opposed to each other and are in contact with each other.
As a result, the amount of material used for the positive electrode conductor 342, the negative electrode conductor 343, the positive electrode terminal 35b, and the negative electrode terminal 35c can be reduced. Weight reduction is possible.

When the plate thickness of the tip of the positive electrode side second end portion 342b is smaller than the plate thickness of the positive electrode terminal 35b, the tip portion of the positive electrode side second end portion 342b is arranged above the positive electrode terminal 35b. and laser welding may be performed from the tip side of the positive electrode side second end portion 342b. Further, when the plate thickness of the tip of the negative electrode side second end portion 343b is smaller than the plate thickness of the negative electrode terminal 35c, the tip portion of the negative electrode side second end portion 343b is arranged above the negative electrode terminal 35c. and laser welding may be performed from the tip side of the negative electrode side second end portion 343b. That is, laser welding is performed from the tip portion of the positive electrode side second end portion 342b and the positive electrode terminal 35b, whichever is thinner, and the tip portion of the negative electrode side second end portion 343b and the negative electrode terminal 35c are welded. , laser welding from the thinner side. As a result, it is possible to reduce the penetration depth of the weld required for laser welding, so that the output of the laser welder can be reduced and the equipment cost can be reduced. Furthermore, since the time required for laser welding can be shortened, productivity can be improved.

It should be noted that the technical scope of the present disclosure is not limited to the above embodiments, and various modifications can be made without departing from the gist of the present disclosure.

1 Rotating electric machine unit 2 Rotating electric machine 3 Power conversion device 4 Cooler (first cooling unit)
6 second cooling unit 21 stator 22 rotor 25 coil 27 resolver 27c harness for resolver (harness)
32 terminal block 33 signal connector 34 capacitor unit 35 power module 35a main body (power module main body)
35b Positive electrode terminal 35c Negative electrode terminal 36 Control board 36b Opening 37 Bus bar 38 Current sensor 48 First joint 51 Inlet channel 52 First channel 53 Second channel 54 Third channel 55 Outlet channel 61 Communication channel 62 4th flow path 63 5th flow path 64 discharge flow path 66 second joint 341 main body (condenser main body)
342 Positive electrode conductor 343 Negative electrode conductor 371a First terminal 372a Second terminal 373 Mounting portion C1 First connection portion C2 Second connection portion

Claims (15)

a rotating electric machine having a stator and a rotor rotating about an axis with respect to the stator;
a power conversion device arranged side by side with the rotating electric machine in an axial direction along the axis of the rotor;
with
The power conversion device includes a capacitor unit arranged in a central portion of the power conversion device, and a plurality of power modules arranged in a circumferential direction around the axis of the rotor so as to surround the capacitor unit. have
The capacitor unit has a capacitor body, a positive electrode conductor, and a negative electrode conductor,
each of the plurality of power modules has a power module main body, a positive electrode terminal connected to the positive electrode conductor, and a negative electrode terminal connected to the negative electrode conductor;
The positive terminal and the negative terminal are arranged to face the capacitor unit,
A first connecting portion between the positive electrode conductor and the positive electrode terminal and a second connecting portion between the negative electrode conductor and the negative electrode terminal are positioned between the capacitor body and the power module body. electrical unit. The length of a first path from the positive electrode conductor to the negative electrode conductor via the positive electrode terminal and the negative electrode terminal of a first power module among the plurality of power modules is equal to the length of the first path from the positive electrode conductor to the plurality of power modules. 2. The rotary electric machine unit according to claim 1, wherein the length of the second path to the negative conductor via the positive terminal and the negative terminal of a second power module of the power modules is substantially the same as that of the second path. 3. The electric rotating machine unit according to claim 2, wherein in all of said plurality of power modules, paths from said positive electrode conductor to said negative electrode conductor via said positive electrode terminal and said negative electrode terminal have substantially the same length. The rotating electric machine unit according to any one of claims 1 to 3, wherein the positive conductor and the positive terminal are directly connected, and the negative conductor and the negative terminal are directly connected. The rotating electric machine further has a plurality of coils wound around the stator,
The rotating electric machine unit according to any one of claims 1 to 4, wherein said power conversion device further comprises a plurality of busbars connecting said plurality of power modules and said plurality of coils, respectively. The power conversion device further includes a control board that controls the plurality of power modules, and a plurality of current sensors that respectively detect currents flowing through the plurality of bus bars,
6. The rotating electric machine unit according to claim 5, wherein each of said plurality of current sensors is directly connected to said control board. each of the plurality of bus bars has a first terminal connected to a corresponding power module out of the plurality of power modules and a second terminal connected to a corresponding coil out of the plurality of coils;
7. The rotating electric machine unit according to claim 6, wherein said first terminal is located radially outside of said power module body portion of said corresponding power module. each of the plurality of bus bars further has a mounting portion to which the current sensor is mounted;
8. The rotating electric machine unit according to claim 7, wherein said mounting portion is provided so as to protrude further toward said control board than said second terminal in said axial direction. The electric rotating machine unit according to any one of claims 5 to 8, wherein the plurality of bus bars and the plurality of power modules are alternately arranged in the circumferential direction. a first cooling unit that cools the power conversion device by forming a first cooling flow path through which a coolant flows;
further comprising
The first cooling channel is
an inlet channel to which the coolant is supplied;
a first flow path branched from the inlet flow path and formed at a position overlapping a first group of power modules among the plurality of power modules when viewed in the axial direction;
a second flow path branched from the inlet flow path and formed at a position overlapping with a second group of power modules different from the first group among the plurality of power modules when viewed in the axial direction;
a third flow path branched from the inlet flow path and formed at a position overlapping with the capacitor unit when viewed in the axial direction;
an outlet flow path through which the refrigerant from the first flow path, the second flow path, and the third flow path merges and the refrigerant is discharged from the first cooling section;
The outlet flow path communicates with a second cooling flow path formed inside a second cooling section that cools the rotating electric machine,
the second cooling channel,
a communication channel that communicates with the outlet channel;
a fourth flow path branched from the communication flow path and extending from the communication flow path to one side in the circumferential direction;
a fifth flow path branched from the communication flow path and extending from the communication flow path to the other side in the circumferential direction;
and a discharge channel through which the coolant from the fourth channel and the fifth channel joins and the coolant is discharged from the second cooling unit. The rotary electric machine unit described in . The power conversion device further includes a terminal block that connects the DC power supply and the capacitor unit, and a signal connector that is connected to an external device,
A first joint that supplies the coolant from the outside is connected to the inlet channel,
A second joint for discharging the refrigerant to the outside is connected to the discharge channel,
When viewed from the axial direction, the side on which the signal connector is arranged with respect to the axial center of the rotor is called the front side, and the opposite side is called the rear side,
11. The rotary electric machine unit according to claim 10, wherein said terminal block, said signal connector, said first joint, and said second joint are arranged on a front side of said rotary electric machine unit. The positive electrode conductor and the negative electrode conductor according to any one of claims 1 to 11, wherein portions of the positive electrode conductor and the negative electrode conductor extending from the capacitor main body are arranged so as not to overlap the axial center when viewed from the axial direction. rotating electrical unit. An opening through which the capacitor unit is inserted is formed in the central portion of the control board,
7. The rotating electric machine unit according to claim 6, wherein said plurality of current sensors are arranged closer to said stator than said control board. The rotating electric machine further includes a resolver that detects a rotation angle of a shaft provided in the rotor,
A portion of the positive conductor and the negative conductor that extends from the capacitor main body and is connected to a DC power supply, and a harness that connects the resolver to the control board are inserted through the opening.
The rotary electric machine unit according to claim 13. The positive conductor and the positive terminal are opposed in the axial direction and are in contact with each other, and the negative conductor and the negative terminal are opposed in the axial direction and are in contact with each other. 15. The rotating electric machine unit according to any one of 14.

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