Controller-integrated rotating electric machine

This application is based on and claims the benefit of priority from earlier Japanese Patent Application No. 2016-4272 filed Jan. 13, 2016, the description of which is incorporated herein by reference.

The present disclosure relates to a controller-integrated rotating electric machine.

Conventionally, a controller-integrated rotating electric machine that has a rotating electric machine and a controller is used as a rotating electric machine for a vehicle.

Such a controller-integrated rotating electric machine is disclosed in Japanese Patent No. 5774207, for example.

JP No. 5774207 discloses a controller having a power module structure in which cooling fins (heat sink) are fixed to a power module via an insulating member.

Note that the cooling fins are integrally formed with the heat sink in JP No. 5774207.

The cooling fins of the controller do not have a potential as they are fixed via the insulating member. For this reason, there is no concern of electrolytic corrosion of the cooling fins.

However, the conventional controller has a configuration that the power module and the cooling fins are bonded and the resin is filled around the power module.

In this configuration, the cooling fins are going to have a potential in a case where minute conductive foreign matter enters into a bonding portion to form a conductive path route, or in a case where a void is generated in the bonding portion and water vapor enters to form a leak path.

Then, a housing of the rotating electric machine is normally connected to a battery, and the cooling fins are going to have a potential different from that of the housing. That is, even with the conventional controller, there was a possibility of electrolytic corrosion in the cooling fins.

An embodiment provides a controller-integrated rotating electric machine equipped with a controller in which reliability is suppressed from deteriorating due to electrolytic corrosion.

A controller-integrated rotating electric machine according to a first aspect includes a rotating electric machine having a rotor in which a magnetic pole is formed by energizing a rotor winding, a stator disposed so as to face the rotor, and a housing holding the rotor and the stator.

The controller-integrated rotating electric machine further includes a controller having a plurality of switching element modules, each of which includes a switching element, an inverter circuit for supplying alternating current to the rotating electric machine, and a rectification circuit for rectifying alternating current supplied from the rotating electric machine.

Cooling fins, each of which has an insulating coating on a surface thereof facing the switching element module, are bonded to the switching element module.

In the controller-integrated rotating electric machine of the present disclosure, the controller is provided with the cooling fins. Then, the cooling fins have the insulating coatings on the surfaces facing the switching element module.

According to the present configuration, the cooling fins are electrically insulated. That is, there is no potential difference between the cooling fins and the switching element module, and electrolytic corrosion is suppressed from occurring.

In the accompanying drawings:

FIG. 1 shows an axial cross-sectional view of a controller-integrated rotating electric machine of an embodiment;

FIG. 2 shows a front view of the controller-integrated rotating electric machine of the embodiment as viewed from a controller side;

FIG. 3 is a front view showing a configuration of a power terminal-integrated power assembly;

FIG. 4 shows a circuit diagram of the controller-integrated rotating electric machine according to the embodiment;

FIG. 5 is a perspective view showing a configuration of a power module and cooling fins;

FIG. 6 is a configuration diagram showing a configuration of the power terminal-integrated power assembly;

FIG. 7 shows a view describing a mounting structure of the cooling fins;

FIG. 8 is a sectional view schematically showing a connection structure between the power module and a bus bar assembly of the power assembly;

FIG. 9 is a front view showing a configuration of another power assembly;

FIG. 10 is a front view showing a configuration of yet another power assembly; and

FIG. 11 is a sectional view schematically showing a connection structure between a power module and a bus bar assembly of a modified power assembly.

[Embodiment]

Hereinafter, the present disclosure will be described in more detail by using an embodiment.

In the present embodiment, a controller-integrated rotating electric machine of the present disclosure will be described applying it to a rotating electric machine for a vehicle mounted on a vehicle.

A configuration of a controller-integrated rotating electric machine of the present embodiment will be described with reference to FIGS. 1 to 10 .

FIG. 1 is a sectional view showing a configuration of a controller-integrated rotating electric machine 1 of the present embodiment.

The controller-integrated rotating electric machine 1 of the present embodiment is a device mounted on a vehicle and generating a driving force for driving a vehicle by being supplied with electric power from a battery.

It is also a device that generates electric power for charging the battery by being supplied with a driving force from an engine of the vehicle.

The controller-integrated rotating electric machine 1 includes a rotating electric machine 10 and a controller 11 .

[Rotating Electric Machine]

The rotating electric machine 10 is a machine that generates a driving force for driving the vehicle by being supplied with the electric power.

The rotating electric machine 10 is also a machine that generates electric power for charging the battery by being supplied with the driving force from the engine.

The rotating electric machine 10 includes a housing 100 , a stator 101 , a rotor 102 , slip rings 103 , and brushes 104 .

The housing 100 is a member that accommodates the stator 101 and the rotor 102 in a state in which they are opposed to each other, and is a member that rotatably supports the rotor 102 .

Further, the housing 100 is also a member to which the controller 11 is fixed. The housing 100 is composed of a front housing 100 A and a rear housing 100 B.

The stator 101 constitutes a part of a magnetic path, and is a member that generates a rotating magnetic field by a current being applied.

In addition, while the stator 101 constitutes a part of the magnetic path, the stator 101 is also a member that generates alternating current by interlinking with a later-described magnetic flux generated by the rotor 102 .

The stator 101 includes a stator core 101 A and stator windings 101 B.

The rotor 102 constitutes a part of the magnetic path, and is a member that forms a magnetic pole by a current being applied. The rotor 102 includes a rotating shaft 102 A, a rotor core 102 B, and a rotor winding 102 C.

The slip rings 103 and the brush 104 s are members for supplying direct current to the rotor winding 102 C. The slip rings 103 are fixed onto an outer peripheral surface of the rotating shaft 102 A via insulating members.

The brushes 104 are pressed against the rotary shaft 102 A by springs 104 A, and are held by a brush holder in a state where end faces thereof are in contact with outer peripheral surfaces of the slip rings 103 .

[Controller]

The controller 11 is a device that controls the electric power supplied from the battery to the rotating electric machine 10 so as to generate the driving force to the rotating electric machine 10 .

Further, the controller 11 is also a device that converts electric power generated by the rotating electric machine 10 and supplies it to the battery in order to charge the battery.

The controller 11 is a device that includes an inverter circuit that supplies alternating current to the rotating electric machine 10 , and a rectification circuit that rectifies alternating current supplied from the rotating electric machine 10 .

As shown in FIG. 2 , the controller 11 includes a power terminal-integrated power assembly 110 , power assemblies 111 and 112 , a regulator 113 , and a cover (not shown).

The controller 11 corresponds to a control section, and the power assemblies 110 , 111 , 112 correspond to switching element modules.

[Power Terminal-integrated Power Assembly]

The power terminal-integrated power assembly 110 is an aggregate of components constituting the inverter circuit and the rectification circuit.

As shown in FIG. 3 , the power terminal-integrated power assembly 110 includes a power module 110 A, cooling fins 110 B, and a power terminal-integrated bus bar assembly 110 C.

As shown in FIG. 4 , the power module 110 A is a switching element module having four switching elements (MOSFETs 110 D to 110 G) constituting the inverter circuit and the rectification circuit.

The power module 110 A includes an IC 110 H as a control section for controlling each of the MOSFETs 110 D to 110 G.

The MOSFETs 110 D and 110 E, and the MOSFETs 110 F and 110 G are connected in series, respectively.

Sources of the MOSFETs 110 D and 110 F are connected to drains of the MOSFETs 110 E and 110 G, respectively.

Among the two MOSFETs 110 D and 110 E connected in series, the MOSFET 110 D connected to a positive electrode side of a battery B 1 corresponds to a high potential side switching element, and the MOSFET 110 E corresponds to a low potential side switching element.

As shown in FIG. 4 , the MOSFETs 110 D to 110 G of the power module 110 A and the MOSFETs 111 D to 111 E of a power module 111 A are connected to each phase of a set of three-phase electric windings 101 C.

That is, the two power modules 110 A and 111 A control the three-phase electric windings 101 C.

The series-connected MOSFETs 110 D to 110 E of the power module 110 A are connected to one phase of the three-phase electric windings 101 C.

The MOSFETs 110 F to 110 G are connected to another phase of the three-phase electric windings 101 C.

The series-connected MOSFETs 111 D to 111 E of the power module 111 A are connected to the remaining phase of the three-phase electric windings 101 C.

That is, the power module 110 A is connected to two phases of the three-phase electric windings 101 C, and the power module 111 A is connected to the remaining phase of the three-phase electric windings 101 C.

As shown in FIGS. 4 to 5 , the power module 110 A is provided with the MOSFETs 110 D and 110 F on the same substrate portion 110 I, the MOSFET 110 E on the substrate portion 110 J, and the MOSFET 110 G on the substrate portion 110 L, respectively.

The power module 110 A includes a substrate portion 110 K provided with the IC 110 H and connected to the MOSFETs 110 E and 110 G, and a terminal section 110 M through which a control signal of the IC 110 H flows.

The MOSFETs 110 D to 110 G and the IC 110 H are resin-molded by the power module 110 A.

The substrate portions 110 I to 110 M installed by the MOSFETs 110 D to 110 G are made of conductive metal plates.

FIG. 5 is a perspective view of the power module 110 A to which the cooling fins 110 B are attached as seen from a surface 110 Aa side of the power module 110 A.

FIG. 6 is a configuration diagram showing a mounting configuration of each element of the power module 110 A, and a broken line shows a resin mold.

In FIG. 6 , each of the substrate portions 110 I to 110 M is shown developed in plain view.

The substrate portions 110 I to 110 M in FIG. 6 are bent in a direction perpendicular to a surface of the drawing (toward the front side of the drawing) at one-dotted broken lines outside the resin mold in the drawing.

As shown in FIG. 6 , the substrate portions 110 I to 110 M also function as terminals for connecting the power module 110 A and external circuits.

The substrate portion 110 I corresponds to a battery side terminal connected to the positive electrode of the battery B 1 , the substrate portions 110 J, 110 L correspond to a motor side terminal connected to the rotating electric machine 10 , and the substrate portion 110 K corresponds to a low potential side terminal connected to the negative electrode of the battery B 1 , respectively.

Drains of the MOSFETs 110 D and 110 F are connected to the substrate portion 110 I.

As shown in FIG. 5 , the substrate portion 110 I has a substantially X-shaped configuration protruding from a portion where the drains of the MOSFETs 110 D and 110 F are connected to an outside of the resin mold at one location and branching into two branches outside the resin mold.

The substrate portion 110 I has a pair of connecting portions 110 Ia, 110 Ia, which are connected to a bus bar 110 N, which is one of the external circuits, of the power terminal-integrated bus bar assembly 110 C, at a tip portion thereof branched into two branches.

The pair of connecting portions 110 Ia, 110 Ia are formed so as to have the same shapes.

The substrate portion 110 J is connected to the drain of the MOSFET 110 E.

In addition, the substrate portion 110 J is connected to the source of the MOSFET 110 D by a bridge.

The substrate portion 110 J forms a series connecting portion between the MOSFET 110 D and the MOSFET 110 E.

The substrate portion 110 J projects outward from the resin mold at one location, and has a connecting portion 110 Ja, which is connected to the bus bar 110 P of the bus bar assembly 110 C, at a tip portion thereof.

The connecting portion 110 Ja is formed so as to have the same shape as the pair of connecting portions 110 Ia, 110 Ia.

The substrate portion 110 L is connected to the drain of the MOSFET 110 G.

In addition, the substrate portion 110 L is connected to the source of the MOSFET 110 F by a bridge.

The substrate portion 110 L forms a series connecting portion between the MOSFET 110 F and the MOSFET 110 G.

The substrate portion 110 L projects outward from the resin mold at one location, and has a connecting part 110 La, which is connected to the bus bar 110 Q of the bus bar assembly 110 C, at a tip portion thereof.

The connecting portion 110 La is formed so as to have the same shape as the connecting portions 110 Ia, 110 Ia, 110 Ja.

As shown in FIGS. 5 and 6 , the respective connecting portions 110 Ia, 110 Ia, 110 Ja and 110 La of the substrate portions 110 I, 110 J and 110 L protrude from a one side of a rectangular resin mold.

The substrate portion 110 K is provided with the IC 110 H. The substrate portion 110 K is connected to the sources of the MOSFETs 110 E, 110 G via bridges.

As shown in FIG. 6 , the substrate portion 110 K has a substantially H-shaped configuration protruding at two positions to the outside of the resin mold, and has a pair of connecting portions 110 Ka, 110 Ka connected to the bus bar of the bus bar assembly 110 O at tip portions of the protrusions.

The pair of connecting portions 110 Ka, 110 Ka are formed so as to have the same shapes as the connecting portions 110 Ia, 110 Ia, 110 Ja, 110 La.

As shown in FIGS. 5 and 6 , the pair of connecting portions 110 Ka, 110 Ka of the substrate portion 110 K protrude from another side of the rectangular resin mold.

The pair of connecting portions 110 Ka and 110 Ka protrude so as to be opposed from the one side of the rectangular resin mold.

A control signal of the IC 110 H flows through the terminal sections 110 M, 110 M.

The terminal sections 110 M, 110 M are connected to the IC 110 H by a conductive path route (not shown).

As shown in FIGS. 5 and 6 , the pair of terminal sections 110 M, 110 M protrude from the other side of the rectangular resin mold like the pair of connecting portions 110 Ka, 110 Ka.

In the power module 110 A, a back surface 110 Ab thereof to which the cooling fins 110 B are connected is formed by a heat sink made of metal for dissipating the heat generated by the power module 110 A.

The back surface 110 Ab of the power module 110 A corresponds to a surface on which the drain connected to the positive electrode of the battery B 1 of the MOSFET 110 shown in FIGS. 5 and 6 is positioned.

The cooling fins 110 B shown in FIGS. 2 and 3 are members made of metal for dissipating the heat generated by the power module 110 A.

The metal forming the cooling fins 110 B is not limited as long as it is a material capable of dissipating the heat generated by the power module 110 A.

As such a metal, a metal having excellent thermal conductivity can be used, and specific examples of the metal include aluminum, copper, gold and silver.

Note that a metal having a thermal conductivity comparable to that of these metals can be used in an operating temperature range of the controller-integrated rotating electric machine of the present embodiment.

That is, other metals and alloys can be used.

The cooling fins 110 B are made of aluminum, having insulating coatings formed on their surfaces.

The insulating coatings on the surface of the cooling fins 110 B are not limited as long as they can demonstrate insulation properties.

As the insulating coating, a coating such as an anodized coating or a resin coating can be mentioned.

Although the anodized coating may be coated on the cooling fins 110 B in a state where the cooling fins 110 B are being formed into a predetermined shape, the anodized coating may be coated on a long shaped body extending along a direction perpendicular to the surface of FIG. 2 and cut into a predetermined length afterwards.

In the present embodiment, the anodized coating is coated on a long shaped body and the body is cut into a predetermined length to form the cooling fins 110 B.

The cooling fins 110 B are bonded to the back surface 110 Ab of the power module 110 A with an insulating adhesive.

The adhesive having insulating property is an adhesive that demonstrates electrical insulation in the operating temperature range of the controller-integrated rotating electric machine of the present embodiment.

As the insulating adhesive, it is preferable to use an adhesive having excellent thermal conductivity. A resin adhesive can be mentioned as such an adhesive. Specifically, silicone-based adhesives can be mentioned.

The insulating adhesive may contain filler. Like the adhesive, the filler preferably has not only insulation but also thermal conductivity, and inorganic filler can be mentioned. More specifically, glass fillers and ceramic fillers can be mentioned.

The power terminal-integrated bus bar assembly 110 C is an aggregate of components for wiring the power module 110 A.

More specifically, as shown in FIG. 3 , the power terminal-integrated bus bar assembly 110 C is a member that fixes the bus bars 110 N to 110 Q described later for wiring the power module 110 A with a resin, and a power terminal 11 OR described later is connected with a predetermined bus bar 110 N.

As shown in FIG. 3 , the bus bar assembly 110 C includes the bus bars 110 N to 110 Q and the power terminal 110 R.

As shown in FIG. 3 , the bus bar 110 N is a member made of a plate-like metal for wiring the drains of the MOSFETs 110 D and 110 F to the positive electrode of the battery B 1 .

The bus bar 110 N is connected to the pair of connecting portions 110 Ia, 110 Ia of the substrate portion 110 I.

Connection between the bus bar 110 N and the pair of connecting portions 110 Ia, 110 Ia is performed by welding (for example, TIG welding).

The bus bar 110 O is a member made of a plate-like metal for wiring to the grounded negative electrode of the battery B 1 by wiring the sources of the MOSFETs 110 E, 110 G to the grounded housing 100 of the rotating electric machine 10 .

The bus bar 110 P is a member made of a plate-like metal for wiring the series connecting portion between the MOSFETs 110 D and 110 E to a first windings 101 C constituting the stator windings 101 B.

The bus bar 110 Q is a member made of a plate-like metal for wiring the series connecting portion between the MOSFETs 110 F and 110 G to the first windings 101 C constituting the stator windings 101 B.

As shown in FIG. 3 , the bus bars 110 N to 110 Q are integrally fixed with resin with a predetermined space therebetween.

As shown in FIGS. 3 and 4 , the power terminal 110 R is a member made of a metal for connecting the wiring from the positive electrode of the battery B 1 .

The power terminal 110 R is integrally fixed with resin together with the bus bars 110 N to 110 Q in a state of being connected to the bus bar 110 N.

As shown in FIGS. 2 and 3 , the power module 110 A is fixed to the bus bar assembly 110 C in a state of being connected to the bus bars 110 N to 110 Q.

The cooling fins 110 B are fixed to the power module 110 A and the bus bar assembly 110 C.

As described above, the cooling fins 110 B are bonded to the power module 110 A with the insulating adhesive. Further, as shown in FIG. 7 , the cooling fins 110 B are fixed to the bus bar assembly 110 C by thermal crimping.

FIG. 7 is a diagram of a vicinity of the cooling fins 110 B of the power module 110 A as seen from the cooling fins 110 B side (that is, the back surface 110 Ab side of the power module 110 A).

As shown in FIG. 7 , a total of four notches 110 S are formed on two opposing sides of the cooling fins 110 B, the sides oppose along a circumferential direction of the rotary shaft 102 A when assembled with the rotating electric machine 10 .

Two notches 110 S are formed per side. The notches 110 S are disposed at symmetrical positions in the circumferential direction of the cooling fins 110 B.

That is, when the cooling fins 110 B are rotated 180 degrees in the circumferential direction in the state shown in FIG. 7 , the notches 110 S before and after the rotation are formed to coincide.

Protrusions 110 T to be inserted into the notches 110 S are formed on the bus bar assembly 110 C.

When the power assembly 110 is formed, the protrusions 110 T are formed at positions where they are inserted into the notches 110 S with heights such that their tips protrude through the cooling fins 110 B.

The protrusions 110 T are provided so as to be insertable into each of the two sides on which the notch 110 S is formed.

The two protrusions 110 T are disposed at symmetrical positions in the circumferential direction of the cooling fins 110 B.

One of the protrusions 110 T is disposed in a notch 110 S that is apart from the pair of power terminals 110 R among the two notches 110 S disposed on one side.

A tip of the protrusion 110 T expands radially more than the size of the notch 110 S by thermal crimping in a state where the protrusion 110 T is inserted in the notch 110 S, and the protrusion 110 T fixes the cooling fins 110 B in a state where it is in close contact with the bus bar assembly 110 C.

As shown in FIG. 2 , the power assembly 110 is disposed such that one side of the rectangular resin mold (specifically, a side from which the terminal sections 110 Ia, 110 Ia, 110 Ja, 110 La protrude) is positioned in an axial direction of the rotary shaft 102 A and in a direction away from the housing 100 (specifically, the rear housing 100 B).

In the power assembly 110 , the connection between the power module 110 A and the bus bar assembly 110 C is not limited.

For example, the configuration shown in FIG. 8 can be adopted.

FIG. 8 is a sectional view schematically showing a connection structure between the power module 110 A (substrate portions 110 I, 110 K) of the power assembly 110 and the bus bar assembly 110 C (bus bars 110 N, 110 O).

Note that FIG. 8 is the sectional view of a valley portion of the cooling fins 110 B, and although not shown, an adhesive layer formed from the above adhesive is formed between the power module 110 A and the cooling fins 110 B.

As shown in FIG. 8 , the substrate portion 110 J and the substrate portion 110 K protruding from the power module 110 A (the resin mold thereof) are bent in a direction towards the surface 110 Aa of the power module 110 A (or in a direction away from the back surface 110 Ab, or a direction substantially perpendicular to a spreading direction of the surface 110 Aa).

In the bus bar assembly 110 C, tips of the bus bars 110 P, 110 O protrude and are bent similarly to the substrate portions 110 J, 110 K of the power module 110 A.

The bus bar assembly 110 C is assembled onto the surface 110 Aa side of the power module 110 A.

Then, the terminal sections 110 Ja, 110 Ka of the substrate portions 110 J, 110 K come in contact with the tips of the bus bars 110 P, 110 O.

Then, the contact portions (the terminal sections 110 Ja, 110 Ka) are joined by welding.

As described above, the power module 110 A and the bus bar assembly 110 C can be connected.

In FIG. 8 , in order not to expose the substrate portions 110 J, 110 K and the bus bars 110 P and 110 O, the peripheries thereof are surrounded by caps 114 A, and insulating resins 114 B are filled therein.

Note that the cap 114 A is a member for holding the resin 114 B therein, and a hole for injecting the resin 114 B before solidification may be formed.

In addition, as shown in FIG. 8 , a silicon resin layer 114 C filled with thermally conductive silicone resin is formed between the resin 114 B and the cooling fins 110 B.

[Other Power Assemblies]

The power assembly 111 shown in FIG. 2 is an aggregate of components constituting an inverter circuit and a rectification circuit.

The power assembly 111 has a configuration substantially similar to that of the power assembly 110 .

Unspecified configurations of the power assembly 111 are similar to those of the power assembly 110 , and are given the same reference numerals in the drawing.

As shown in FIG. 9 , the power assembly 111 includes a power module 111 A, cooling fins 111 B, and a bus bar assembly 111 C.

The power module 111 A is a switching element module having four switching elements constituting the inverter circuit and the rectification circuit, and MOSFETs 111 D to 111 G.

The MOSFETs 111 D and 111 E, and the MOSFETs 111 F and 111 G are connected in series, respectively.

Sources of the MOSFETs 111 D and 111 F are connected to drains of the MOSFETs 111 E and 111 G, respectively.

The cooling fins 111 B shown in FIG. 9 are members made of metal for dissipating the heat generated by the power module 111 A.

The bus bar assembly 111 C is an aggregate of components for wiring the power module 111 A.

More specifically, the bus bar assembly 111 C is a member that fixes the bus bars 111 N to 111 Q for wiring the power module 111 A with resin.

The power module 111 A is fixed to the bus bar assembly 111 C in a state of being connected to the bus bars 111 N to 111 Q.

The cooling fins 111 B are fixed to the power module 111 A and the bus bar assembly 111 C.

The power assembly 112 shown in FIG. 2 is an aggregate of components constituting an inverter circuit and a rectification circuit.

The power assembly 112 has a configuration substantially similar to those of the power assemblies 110 , 111 .

Unspecified configurations of the power assembly 112 are similar to those of the power assemblies 110 , 111 , and are given the same reference numerals in the drawing.

As shown in FIGS. 2 and 10 , the power assembly 112 includes a power module 112 A, cooling fins 112 B, and a bus bar assembly 112 C.

The power module 112 A is a switching element module having four switching elements constituting the inverter circuit and the rectification circuit, and MOSFETs 112 D to 112 G.

The MOSFETs 112 D and 112 E, and the MOSFETs 112 F and 112 G are connected in series, respectively.

Sources of the MOSFETs 112 D and 112 F are connected to drains of the MOSFETs 112 E and 112 G, respectively.

The cooling fins 112 B shown in FIGS. 2 and 10 are members made of metal for dissipating the heat generated by the power module 112 A.

The bus bar assembly 112 C is an aggregate of components for wiring the power module 112 A.

More specifically, the bus bar assembly 112 C is a member that fixes the bus bars 112 N to 112 Q for wiring the power module 112 A with resin.

The power module 112 A is fixed to the bus bar assembly 112 C in a state of being connected to the bus bars 112 N to 112 Q.

The cooling fins 112 B are fixed to the power module 112 A and the bus bar assembly 112 C.

[Other Structures]

In the present embodiment, as shown in FIG. 4 , the MOSFETs 111 F to 111 G of the power module 111 A and the MOSFETs 112 D to 112 G of the power module 112 A are connected to each phase of a set of three-phase electric windings 101 D.

That is, the two power modules 111 A and 112 A control the set of three-phase electric windings 101 D.

The regulator 113 includes a circuit that causes a field current to flow to the rotor 102 .

The cover (not shown) is a member made of resin for covering the power terminal-integrated power assembly 110 and the power assemblies 111 , 112 .

The cover is fixed to the housing 100 (more specifically, the rear housing 100 B) so as to cover the power terminal-integrated power assembly 110 and the power assemblies 111 , 112 in a state that one end portion of the power terminal 110 R is exposed to the outside.

Note that a method of fixing the power assemblies 110 , 111 , 112 and the like of the controller 11 to the housing 100 (more specifically, the rear housing 100 B) is not limited.

In the present embodiment, bolts penetrating the respective power assemblies 110 , 111 , 112 are used to fix to the housing 100 .

[Operation of Controller-Integrated Rotating Electric Machine]

Next, operation of the controller-integrated rotating electric machine 1 will be described with reference to FIGS. 1 and 4 .

First, operation when generating the driving force for driving the vehicle will be described.

When the ignition switch is turned on in the vehicle, direct current is supplied to the rotor winding 102 C via the brushes 104 and the slip rings 103 shown in FIG. 1 by the regulator 113 .

When the direct current is supplied to the rotor winding 102 C, magnetic poles are formed on an outer circumferential surface of the rotor 102 .

When the vehicle is in a state of receiving a signal from a vehicle-side ECU (not shown), the direct current is supplied from the battery B 1 to the power modules 110 A, 111 A, 112 A, as shown in FIG. 4 .

The MOSFETs 110 D to 110 G, 111 D and 111 E constituting the inverter circuit switch at a predetermined timing so as to convert the direct current supplied from the battery B 1 into three-phase alternating current.

In addition, the MOSFETs 111 F, 111 G, and 112 D to 112 G constituting the inverter circuit switch at a predetermined timing so as to convert the direct current supplied from the battery B 1 into three-phase alternating current.

As a result, three-phase alternating current is supplied to the first windings 101 C and second windings 101 D.

Thereby, the rotating electric machine 10 generates the driving force for driving the vehicle.

Next, generating electric power for charging the battery will be described.

In a state where the direct current is supplied to the rotor winding 102 C shown in FIG. 1 via the regulator 113 and the magnetic poles are formed on the outer circumferential surface of the rotor 102 , when the driving force is supplied from the engine, each of the first windings 101 C and the second windings 101 D generate the three-phase alternating current.

The MOSFETs 110 D to 110 G, 111 D and 111 E constituting the rectification circuit switch at a predetermined timing so as to rectify the three-phase alternating current generated by the first windings 101 C.

In addition, the MOSFETs 111 F, 111 G, and 112 D to 112 G constituting the rectification circuit switch at a predetermined timing so as to rectify the three-phase alternating current generated by the second windings 101 D.

As a result, the three-phase alternating currents generated by the first windings 101 C and the second windings 101 D are converted into direct current and supplied to the battery B 1 .

Thus, the battery B 1 is charged by electric power generated by the rotating electric machine 10 .

[Effects of Controller-Integrated Rotating Electric Machine]

Next, effects of the controller-integrated rotating electric machine 1 of the present embodiment will be described.

[First Effect]

In the controller-integrated rotating electric machine 1 of the present embodiment, the cooling fins 110 B (including 111 B, 112 B) are joined to the power module 110 A (including 111 A, 112 A).

In addition, the anodized coating as an insulating coating is formed on the cooling fins 110 B.

Since the cooling fins 110 B have the anodized coating thereon, no potential difference is generated between the power module 110 A and the cooling fins 110 B.

As a result, migration and tracking between the two can be suppressed from occurring, and deterioration of the performance of the controller-integrated rotating electric machine 1 due to insulation failure between them can be prevented from occurring.

In addition, since the cooling fins 110 B have the insulating coatings, the insulation between the power module 110 A and the cooling fins 110 B can be inspected by applying a potential (giving a potential difference) between them.

Furthermore, by adjusting a magnitude of the applied potential difference, it becomes possible to check the breakdown voltage of an insulation part. That is, insulation reliability is improved.

Furthermore, since the cooling fins 110 B have the insulation coatings, no potential difference is generated between the cooling fins 110 B and the power module 110 A even if an abnormality occurs in the cooling fins 110 B, so that high insulation reliability can be obtained.

Incidentally, as an abnormality of the cooling fins 110 B, for example, it may be mentioned that a terminal having another potential comes in contact with the cooling fins 110 B, or the cooling fins 110 B have an electric conduction path of electric potential due to water such as salt water.

[Second Effect]

In the present embodiment, the cooling fins 110 B (including 111 B, 112 B) are joined to the power module 110 A (including 111 A, 112 A) by the insulating adhesive.

According to this configuration, the cooling fins 110 B and the power module 110 A can be fixed while securing electrical insulation between them.

Furthermore, since the insulating adhesive has a high thermal conductivity, the adhesive has functions of fixing both of them and radiating heat.

That is, the number of parts can be reduced, and the cost required for the rotating electric machine 1 can be reduced.

[Third Effect]

In the present embodiment, the cooling fins 110 B (including 111 B and 112 B) are made of aluminum having the anodized coating as an insulation coating.

According to this configuration, an electrically insulating coating can be applied to the cooling fins 110 B having excellent thermal conductivity.

Furthermore, since the anodized coating is formed by processing aluminum, it is a coating (insulation coating) that does not cause peeling.

This also ensures electrical insulation between the cooling fins 110 B (including 111 B and 112 B) and the power module 110 A (including 111 A and 112 A).

[Fourth Effect]

In the present embodiment, each of the cooling fins 110 B (including 111 B and 112 B) has the same sectional shape in the direction perpendicular to the rotating shaft 102 A of the rotor 102 , and the anodized coatings are formed on the outer peripheral surfaces other than both axial end surfaces.

The cooling fins 110 B having such a structure can be manufactured by molding a long shaped aluminum molded body, and cutting it to a predetermined length after forming the anodized coatings thereon.

The pure aluminum molded body before forming the anodized coating has low hardness (that is, plastic deformation is likely to occur), and burrs are generated on cut surfaces when a long shaped molded body is cut.

However, when the anodized coating is formed, the hardness becomes high (that is, plastic deformation hardly occurs), and occurrence of burrs can be suppressed from being generated even if similar cutting processing is performed.

That is, it becomes possible to manufacture by the manufacturing method mentioned above, and the cooling fins 110 B can be manufactured without performing a process of removing burrs.

It should be noted that it is preferable to apply a treatment for forming the anodized coating on the cut surface of the cut molded body (molded body having the coatings) in this manufacturing method.

[Fifth Effect]

In the present embodiment, the controller 11 is divided into three power modules (a plurality of module portions) 110 , 111 , and 112 .

According to this configuration, the respective power modules 110 to 112 can be densely arranged along the circumferential direction of the rotating shaft 102 A of the rotor 102 .

This can suppress the size of the controller 11 from increasing.

In addition, the degree of freedom of the assembling positions of the respective power modules 110 to 112 is improved, and thus the cooling performance can be enhanced.

Furthermore, by having the three power modules 110 to 112 , even if any abnormality occurs in any one of the power modules 110 to 112 , it can be coped with by only replacing the concerned power module.

This can reduce the cost required for maintaining the rotating electric machine 1 .

[Sixth Effect]

In the present embodiment, the stator 101 includes two sets of three-phase electric windings 101 C and 101 D.

Further, each of the three-phase electric windings 101 C and 101 D is controlled by two different power modules 110 , 111 , and 111 , 112 .

With this configuration of the power modules 110 to 112 , the fifth effect described above can be demonstrated more reliably.

[Seventh Effect]

In the present embodiment, each of the power modules 110 to 112 has ICs 110 H to 112 H for controlling respective MOSFETs (switching elements).

Since each power module has an IC, a signal line connecting the MOSFET and the IC is also arranged in the power module.

This can improve environmental resistance and vibration resistance of the power modules 110 to 112 .

Furthermore, since the length of the signal line is shortened, EMC resistance is also improved.

[Eighth Effect]

In the present embodiment, each of the power modules 110 to 112 is arranged along the circumferential direction of the rotating shaft 102 A of the rotor 102 .

According to this configuration, the regulator 113 and the three power modules 110 to 112 can be arranged along the circumferential direction of the rotating shaft 102 A over the entire circumference.

In other words, the size of the controller 11 can be suppressed from increasing.

[Ninth Effect]

In the present embodiment, the high potential side MOSFETs 110 D and 110 F are connected to the battery (B 1 ) via a single substrate portion 110 I.

The substrate portion 110 I includes two connecting portions 110 Ia, 110 Ia (a plurality of connecting portions) that are the connecting portions of the bus bar 110 N of the bus bar assembly 110 C.

According to this configuration, damage to the power module 110 ( 111 , 112 ) can be suppressed from occurring.

Further, it is possible to set a joining condition (welding condition) between the substrate portion 110 I and the bus bar 110 N to the same condition as the other joining part (welding part).

That is, it is possible to suppress cost required for manufacturing the power module 110 ( 111 , 112 ) from increasing.

Specifically, in the present embodiment, the drain sides of the high potential side MOSFETs 110 D and 110 F are connected to the single substrate portion 110 I.

Then, the bus bar 110 N is connected to the positive electrode of the battery B 1 .

According to this configuration, two high-potential currents (large currents) of the MOSFET 110 D and the MOSFET 110 F flow through the substrate portion 110 I.

When there is only one connecting portion, a large current concentrates at this connecting portion, and problems such as heat generation are likely to occur.

On the other hand, concentration of a large current can be suppressed from occurring by providing two (a plurality of) connecting portions.

In other words, damage to the power module 110 ( 111 , 112 ) can be suppressed from occurring.

Further, the connection portion between the substrate portion 110 I and the bus bar 110 N is welded.

Since the number of the connecting portions 110 Ia, 110 Ia serving as the welding portions is plural, it is possible to lower respective welding conditions.

That is, in order to weld at a single place, it is necessary to increase the size of the connecting portion 110 Ia because of the above-mentioned large current problem.

In this case, it is necessary to make the welding condition higher in output.

Then, the welding condition of the connecting portion 110 Ia becomes different from those of the other connecting portions 110 Ja, 110 La, and in manufacturing the power module 110 ( 111 , 112 ), it is necessary to adjust the manufacturing equipment to the welding condition with high output, and it is necessary to change the conditions.

This leads to an increase in manufacturing cost.

On the other hand, as in the present embodiment, by providing the plurality of connecting portions 110 Ia (provided at two positions), it is possible to make the connecting portion 110 Ia have the same shape as the other connecting portions 110 Ja, 110 La, and to make the welding conditions the same.

In other words, it is not necessary to change the welding conditions, and the power module 110 can be obtained at lower cost.

[Tenth Effect]

In the present embodiment, the substrate portion 110 I ( 111 I, 112 I) connected to the positive electrode of the battery B 1 , the substrate portion 110 L ( 111 L, 112 L) and the substrate portion 110 J ( 111 J, 112 J), and the substrate portion 110 K ( 111 K, 112 K) of the power assembly 110 ( 111 , 112 ) are assembled in a state of being away from the back side of the resin mold.

According to this configuration, creepage distances between the substrate portions 110 I ( 111 I, 112 I) and the substrate portions 110 K ( 111 K, 112 K) can be obtained, and a short circuit failure due to a foreign matter or electric corrosion caused by leakage with the GND can be reduced, and reliability and environmental resistance are improved.

[Eleventh Effect]

In the present embodiment, the substrate portions 110 I ( 111 I, 112 I) of the power assembly 110 ( 111 , 112 ) connected to the positive electrode of the battery B 1 and the motor side terminals 110 J, 110 L of the power assembly 110 ( 111 , 112 ) connected to the rotating electric machine 10 are assembled in the direction away from the housing (specifically, the rear housing 100 B).

Further, the power assembly 110 is assembled in a state parallel to the axial direction of the rotating shaft 102 A.

According to this configuration, the substrate portions 110 I ( 111 I, 112 I) of the power assemblies 110 ( 111 , 112 ) and the motor side terminals 110 J, 110 L are positioned farthest from the housing 100 .

In other words, creepage distances between the substrate portion 110 I and the housing 100 can be obtained, and the above-described effects are demonstrated.

[Twelfth Effect]

In the present embodiment, the power assemblies 110 ( 111 , 112 ) fix the bus bars 110 N to 110 Q ( 111 N to 111 Q, 112 N to 112 Q) with resin.

Then, parts of the cooling fins 110 B ( 111 B, 112 B) are fixed in a state of being embedded in the resin.

According to this configuration, the resin for fixing the bus bars 110 N to 110 Q by the power assembly 110 is used for fixing the cooling fins 110 B.

That is, it is possible to fix the cooling fins 110 B without increasing the number of parts.

Further, since the cooling fins 110 B ( 111 B, 112 B) are fixed with the insulating resin, it is possible to float the cooling fins 110 B ( 111 B, 112 B) in potential.

Note that the state in which the parts of the cooling fins 110 B ( 111 B, 112 B) are embedded in the resin means a state in which the resin is molded so that the cooling fins 110 B are integrated with the bus bars 110 N to 110 Q, or a state in which the cooling fins 110 B are fixed to the resin by thermal crimping.

In the thermal crimping, the cooling fins 110 B and the resin are pressed in a heated state, and the resin covers the parts of the cooling fins 110 B (sandwiching parts of edge portions).

According to the thermal crimping as described above, the parts of the radiation fins 110 B are embedded in the resin.

[Thirteenth Effect]

In the present embodiment, the cooling fins 110 B have the plurality of notches 110 S, and the bus bar assembly 110 C has the protrusions 110 T with the tips having enlarged diameters in a state of penetrating at least two notches 110 S.

According to this configuration, the assembling ability of assembling the cooling fins 110 B to the bus bar assembly 110 C is improved.

In particular, by disposing the notches 110 S at symmetrical positions of the cooling fins 110 B, it is possible to adjust the orientation of the cooling fins 110 B for each of the power modules 110 to 112 .

In addition, the bus bar assemblies 110 C to 112 C have different shapes.

In this case, if there is the protrusion 110 T at the same position, interference of a processing jig may occur.

However, if a plurality of (preferably four or more) notches 110 S are provided, it is possible to dispose the protrusion 110 T on the notch 110 S where interference is unlikely to occur, and the assembling ability is improved also.

[Modification of Embodiment]

In the above embodiment, the connection structure between the power module 110 A and the bus bar assembly 110 C has been described with two substrate portions 110 I, 110 K protruding from the back side of the resin mold.

In this case, as shown in FIG. 11 , the low potential side substrate portion 110 K may be exposed.

Note that since the low potential side substrate portion 110 K has the same potential as the housing 100 in the present modified embodiment, a potential difference is not generated and no problem occurs even if the substrate portion 110 K is short-circuited with the housing 100 .

With this configuration, the number of the caps 114 A and the resin 114 B can be reduced, and the power assembly 110 can be obtained at a lower cost.