Liquid-cooled rotary electric machine integrated with an inverter

• US 20030173839A1
• Filed: 03/12/2003
• Published: 09/18/2003
• Est. Priority Date: 03/15/2002
• Status: Active Grant

• Current Assignee: DENSO Corporation, Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: DENSO Corporation
• Inventors: Tatematsu, Kazutaka, Nakamura, Seiji, Torii, Koshi
• Granted Patent: US 6,992,409 B2
• Time in Patent Office: Days
• US Class Current: 310/52
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 5/18 with ribs or fins for improving heat transfer
• CPC Class Codes: H02K 5/203 specially adapted for liquids, e.g. cooling jackets

Abstract

A rotary electric machine includes a rotor for rotation around a rotational axis, a stator core that has a cylindrical shape and includes a slot therein, a cooling unit having a coolant passage, and a casing that accommodates the rotor and the stator core. A stator coil is inserted in the slot of the stator core and has a coil end protruded from a side face of the stator core. An electric part is mounted on the cooling unit and controls a current of the stator core. The rotor is rotatably supported inside of the stator core. The cooling unit cools both the stator core and the electric part. The cooling portion is accommodated in spacing defined by the side face of the stator core and an outer circumference wall of the coil end.

Claims

1. A rotary electric machine, comprising:

a stator core, which has a cylindrical shape and includes a slot therein;

a rotor, which is rotatably supported inside of the stator core;

a casing, which accommodates the rotor and the stator core;

a stator coil, which is inserted in the slot of the stator core, and includes a coil end protruded from a side face of the stator core;

a cooling unit, which includes a coolant passage; and

an electric part, which is mounted on the cooling unit, and controls the stator coil,

Wherein the cooling unit is accommodated in spacing defined by a side face of the stator core and an outer circumference wall of the coil end, and contacts the side face of the stator core.

2. A rotary electric machine according to claim 1, wherein the coolant passage of the cooling unit is annular.

3. A rotary electric machine according to claim 1, further comprising:

a through bolt for bolting the cooling unit and the stator core in an axial direction of the rotor.

4. A rotary electric machine according to claim 2, wherein

the cooling unit includes a plate and a body,

the coolant passage is disposed in the body and has an opening,

the opening is opened in the axial direction of the rotor, and

the plate has a ring plate shape and adheres to the body of the cooling unit so that the plate seals the opening of the coolant passage.

5. A rotary electric machine according to claim 4, further comprising:

a through bolt for bolting the body and the plate of the cooling unit and the stator core in the axial direction of the rotor.

6. A rotary electric machine according to claim 4, wherein

the coolant passage has a helical passage, and

the plate includes a coolant inlet and a coolant outlet that are connected to two ends of the coolant passage, respectively.

7. A rotary electric machine according to claim 1, wherein

the body of the cooling unit includes a housing,

the housing has a cylindrical shape, covers the stator core, and contacts an outer circumference wall of the stator core.

8. A rotary electric machine according to claim 4, wherein the electric part is mounted on the plate of the cooling unit.

9. A rotary electric machine according to claim 8, further comprising:

a cover, which is mounted on the plate of the cooling unit so that the cover protects the electric part.

10. A rotary electric machine according to claim 9, further comprising an electric terminal, wherein

the electric terminal is mounted on the plate of the cooling unit, is protruded from the cover, and connects to an external power supply so that the external power supply supplies an electric power to the electric part through the electric terminal.

11. A rotary electric machine according to claim 1, wherein the rotor includes a centrifugal fan, which is disposed more inside than the coil end in a radial direction of the rotor.

12. A rotary electric machine according to claim 11, wherein the cooling unit includes a cooling fin, which is protruded from the cooling unit so that a blow caused by the centrifugal fan is cooled with the cooling fin.

13. A rotary electric machine according to claim 4, further comprising a bearing, wherein

the rotor is rotatably supported with the plate of the cooling unit through the bearing.

14. A rotary electric machine according to claim 1, wherein the electric part includes a semiconductor switching device.

15. A rotary electric machine according to claim 1, further comprising:

a resin material, which is filled in spacing among the cooling unit, the stator core, and the coil end of the stator coil.

16. A rotary electric machine according to claim 8, wherein the electric part is mounted on one side of the plate of the cooling unit, and the other side of the plate faces the stator core.

17. A rotary electric machine according to claim 6, wherein an axial direction of the helical passage is parallel to the axial direction of the rotor.

18. A rotary electric machine according to claim 1, wherein the electric part is mounted on one side of the cooling unit, and the stator core contacts the other side of the cooling unit.

19. A rotary electric machine according to claim 1, wherein

the cooling unit is integrated with the casing,

the casing includes a ring-shape groove and a coolant pipe as the cooling unit, and

the coolant pipe is disposed in the ring-shape groove.

20. A rotary electric machine according to claim 1, wherein

the stator core, the stator coil, and the rotor provide an alternating current dynamotor, and

the electric part provides an inverter circuit for controlling an electric power delivery between an direct current power supply and the alternating current dynamotor.

21. A rotary electric machine according to claim 20, wherein

the cooling unit has first and second surfaces,

the first surface of the cooling unit faces the alternating current dynamotor,

the second surface of the cooling unit is opposite to the first surface,

the electric part includes a semiconductor switching device and a smoothing capacitor,

the semiconductor switching device is disposed between the direct current power supply and the stator coil, provides the inverter circuit for converting direct current to alternating current or alternating current to direct current, and is mounted on the second surface of the cooling unit so that the semiconductor switching device is cooled by the cooling unit, and

the smoothing capacitor connects to a direct current terminal of the inverter circuit, and is mounted on the first surface of the cooling unit so that the smoothing capacitor is cooled by the cooling unit.

22. A rotary electric machine, comprising:

an alternating current motor with a stator coil; and

an inverter, which is disposed on an axial side of the motor, and controls an electric power delivery between a direct current power supply and the stator coil of the motor, wherein

the inverter includes a semiconductor switching device, a smoothing capacitor, and a cooling unit,

the cooling unit has first and second surfaces,

the first surface faces the motor,

the second surface is opposite to the first surface,

the semiconductor switching device is disposed between the direct current power supply and the stator coil, provides an inverter circuit for converting direct current to alternating current or alternating current to direct current, and is mounted on the second surface of the cooling unit to be cooled by the cooling unit, and

the smoothing capacitor connects to a direct current terminal of the inverter circuit, and is mounted on the first surface of the cooling unit to be cooled by the cooling unit.

23. A rotary electric machine according to claim 22, further comprising:

a conductive layer; and

an insulating sheet, wherein

the conductive layer is disposed on the second surface of the cooling unit so that the semiconductor switching device is mounted on the conductive layer, and

the insulating sheet is disposed between the conductive layer and the second surface of the cooling unit.

24. A rotary electric machine according to claim 23, wherein the conductive layer provides a higher potential electrode of the direct current power supply.

25. A rotary electric machine according to claim 22, further comprising:

a first conductive layer with an insulating sheet, which is disposed on the second surface of the cooling unit; and

a second conductive layer, which is disposed directly on the second surface of the cooling unit, wherein

the semiconductor switching device includes first and second semiconductor elements,

the first semiconductor element is mounted on the first conductive layer,

the insulating sheet is disposed between the first conductive layer and the second surface of the cooling unit, and

the second semiconductor element is mounted on the second conductive layer.

26. A rotary electric machine according to claim 25, wherein the second conductive layer provides an alternating current line of the inverter circuit for connecting to the stator coil.

27. A rotary electric machine according to claim 22, wherein the inverter includes a microcomputer, which outputs information about the inverter circuit to an external system.

28. A rotary electric machine according to claim 22, wherein

the cooling unit includes a coolant passage having an opening on the first surface of the cooling unit, and

the smoothing capacitor is fixed to the first surface of the cooling unit so that the opening of the coolant passage is sealed by the smoothing capacitor.

30. A rotary electric machine according to claim 28, wherein

the cooling unit has a concave, and

the concave is disposed on the first surface of the cooling unit so that the smoothing capacitor is inserted and fitted into the concave of the cooling unit and the opening of the cooling passage is sealed by the smoothing capacitor.

31. A rotary electric machine according to claim 25, wherein the first and second conductive layers are made of copper.

32. A rotary electric machine according to claim 22, wherein each of the smoothing capacitor and the semiconductor switching device has a resin casing, respectively.

29. A rotary electric machine, comprising:

a cooling unit having first and second surfaces, which are parallel to each other;

a capacitor mounted on the first surface of the cooling unit; and

an electric part mounted on the second surface of the cooling unit, wherein

the cooling unit includes a coolant passage with an opening on the first surface of the cooling unit, and

the capacitor is fixed to the first surface of the cooling unit so that the opening of the coolant passage is sealed by the capacitor.

33. A rotary electric machine, comprising:

a cooling unit having a surface;

an insulation sheet;

a first busbar mounted on the surface of the cooling unit through the insulation sheet;

a first electric part mounted on the first busbar;

a second busbar, which includes a body mounted on the surface of the cooling unit through the insulation sheet and a leg protruded from the body;

a second electric part mounted on the body of the second busbar; and

a third busbar mounted on the surface of the cooling unit, wherein

the leg of the second busbar has a bottom face connected to a top face of the first electric part,

the second busbar has a predetermined step between the body and the leg of the second busbar, and

the third busbar has a bottom face connected to a top face of the second electric part.

35. A rotary electric machine according to claim 33, wherein

the top face of the first electric part provides an alternating current output electrode and a bottom face of the first electric part provides a higher potential direct current electrode, and

the top face of the second electric part provides a lower potential direct current electrode and a bottom face of the second electric part provides an alternating current output electrode.

36. A rotary electric machine according to claim 35, wherein

the second electric part includes a control electrode,

the control electrode is mounted on the top face of the second electric part and is adjacent to the lower potential direct current electrode.

37. A rotary electric machine according to claim 33, wherein

the third busbar includes a body mounted on the surface of the cooling unit and a leg protruded from the body,

the leg of the third busbar has a bottom face connected to a top face of the second electric part, and

the third busbar has a predetermined step between the body and the leg of the third busbar.

38. A rotary electric machine according to claim 33, further comprising a motor, wherein

the motor has a rotational shaft,

the cooling unit is mounted on the motor,

the first busbar has a ring plate shape concentric with the rotational shaft of the motor, and

the first and second electric parts are aligned in a radial direction of the rotational shaft and are adjacent each other.

39. A rotary electric machine according to claim 38, wherein

a plurality of pairs of the first and second electric parts provide a multi-phase inverter circuit, and

each pair of the first and second electric parts has a rotational symmetry around the rotational shaft of the motor.

40. A rotary electric machine according to claim 38, further comprising:

a smoothing capacitor mounted on the surface of the cooling unit, wherein

the smoothing capacitor has a pair of terminal for connecting the first and third busbars, respectively,

three pairs of the first and second electric parts provide a three-phase inverter circuit,

the smoothing capacitor and one pair of the first and second electric parts are disposed on a first diametric line of the motor, and

the other two pairs of the first and second electric parts are disposed on a second diametric line of the motor so that the second diametric line is perpendicular to the first diametric line.

41. A rotary electric machine according to claim 38, wherein

the leg of the second busbar extends from the body of the second busbar to an outside of the radial direction of the rotational shaft of the motor, and has a tongue-like shape.

42. A rotary electric machine according to claim 38, wherein

the third busbar includes a body having a ring plate shape concentric with the rotational shaft of the motor and a leg protruded from the body of the third busbar, and

the leg of the third busbar has a bottom face connected to a top face of the second electric part.

43. A rotary electric machine according to claim 38, wherein the cooling unit is integrated with the motor.

44. A rotary electric machine according to claim 39, further comprising:

a smoothing capacitor mounted on the surface of the cooling unit, wherein

the smoothing capacitor having a pair of terminal for connecting the first and third busbars, respectively,

a plurality of pairs of the first and second electric parts provides a multi-phase inverter circuit,

the plurality of pairs of the first and second electric parts and the smoothing capacitor are disposed in rotational symmetry around the rotational shaft of the motor.

45. A rotary electric machine according to claim 33, wherein the first and second electric parts include a flywheel diode and an insulated gate bipolar transistor, respectively.

46. A rotary electric machine according to claim 33, wherein the first and second electric parts include a flywheel diode and a metal-oxide semiconductor transistor, respectively.

47. A rotary electric machine according to claim 33, wherein the first and second electric parts provide card type power semiconductor modules, respectively.

48. A rotary electric machine according to claim 36, wherein the first electric part forms a collector follower, and the second electric part forms an emitter follower.

34. A rotary electric machine, comprising:

a cooling unit having a surface;

an insulation sheet;

a first busbar mounted on the surface of the cooling unit through the insulation sheet;

a first electric part mounted on the first busbar;

a second busbar, which includes a body mounted on the surface of the cooling unit through the insulation sheet and a leg protruded from the body;

a second electric part mounted on the body of the second busbar; and

a third busbar mounted on the surface of the cooling unit, wherein

the leg of the second busbar has a bottom face connected to a top face of the first electric part,

the third busbar is connected to a top face of the second electric part, and

the surface of the cooling unit has a predetermined step so that the body and the leg of the second busbar are flat.

49. A rotary electric machine, comprising:

a cooling unit having a surface for mounting parts;

an insulation sheet;

a first busbar mounted on the surface of the cooling unit through the insulation sheet;

a first electric part mounted on the first busbar;

a second busbar, which includes a body mounted on the surface of the cooling unit through the insulation sheet and a leg protruded from the body;

a second electric part mounted on the body of the second busbar; and

a third busbar , which includes a body mounted on the surface of the cooling unit and a leg protruded from the body, wherein

the leg of the second busbar has a bottom face connected to a top face of the first electric part,

the leg of the third busbar has a bottom face connected to a top face of the second electric part, and

the surface of the cooling unit has first and second predetermined steps so that each body and leg of the second and third busbars is flat, respectively.

50. A rotary electric machine according to claim 49, further comprising a motor, wherein

the motor includes a rotational shaft,

the cooling unit is mounted on the motor,

the first busbar has a ring plate shape concentric with the rotational shaft of the motor,

the body of the third busbar has a ring plate shape concentric with the rotational shaft of the motor, and

the first and second electric parts are aligned in a radial direction of the rotational shaft and are adjacent each other.