MECHANICALLY AND ELECTRICALLY INTEGRATED ROTARY ELECTRIC MACHINE

• US 20160285335A1
• Filed: 06/09/2014
• Published: 09/29/2016
• Est. Priority Date: 12/13/2013
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Electric Corporation
• Inventors: WATANABE, Norihiro, MIYAMA, Yoshihiro, ARITA, Hideaki, DAIKOKU, Akihiro
• Granted Patent: US 10,003,233 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 15/0068 Connecting winding sections; Forming leads; Connecting leads to terminals
• CPC Class Codes: H02K 2203/09 Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: H02K 5/203 specially adapted for liquids, e.g. cooling jackets

Abstract

In a mechanically and electrically integrated rotary electric machine, a motor portion and an inverter portion are inserted inside a cylindrical frame. The motor portion has a plurality of coils. The inverter portion has a plurality of switching elements. The coils and the switching elements are electrically connected by a connector. The connector has: an end portion connector that distributes sinusoidal electric currents from the switching elements to the respective coils; and a plurality of axial connectors that direct the sinusoidal electric currents from the switching elements to the end portion connector. The end portion connector is disposed on an end portion of the motor portion near an output shaft. The axial connectors are disposed parallel to an axial direction of the frame so as to pass from the switching elements through a mounted region of the motor portion.

Claims

1. A mechanically and electrically integrated rotary electric machine comprising:

a cylindrical frame;

a motor portion comprising;

a cylindrical stator core;

a plurality of coils that are disposed around an inner circumference of the stator core; and

a rotor that is rotatably disposed inside the stator core,

the motor portion being inserted inside the frame;

an inverter portion comprising a plurality of switching elements, the inverter portion being fixed to an inner circumferential surface of the frame; and

a connector that electrically connects the coils and the switching elements,

wherein the connector comprises;

an end portion connector that is disposed on an end portion of the motor portion near an output shaft, and that distributes sinusoidal electric currents from the switching elements to each of the coils; and

a plurality of axial connectors that are disposed so as to pass from the switching elements through a mounted region of the motor portion parallel to an axial direction of the frame, the axial connectors directing the sinusoidal electric currents from the switching elements to the end portion connector.

2. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein:

a plurality of tooth portions that protrude radially inward are disposed around the inner circumference of the stator core;

a plurality of stator grooves are disposed parallel to an axial direction of the stator core around an outer circumference of the stator core;

the stator grooves are disposed at identical positions to the tooth portions in a circumferential direction of the stator core; and

the axial connectors are inserted into the stator grooves.

3. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein:

a plurality of frame grooves are disposed parallel to the axial direction of the frame around an inner circumference of the frame; and

the axial connectors are inserted into the frame grooves.

4. The mechanically and electrically integrated rotary electric machine according to claim 3, wherein:

a coolant flow channel is disposed inside a wall portion of the frame; and

the frame grooves are disposed so as to be adjacent to the coolant flow channel.

5. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein:

a plurality of tooth portions that protrude radially inward are disposed around the inner circumference of the stator core;

slot portions are respectively formed between adjacent tooth portions; and

the axial connectors pass through the slot portions.

6. The mechanically and electrically integrated rotary electric machine according to claim 5, wherein:

the slot portions include;

a plurality of normal slot portions; and

a widened slot portion that has a larger width dimension than the normal slot portions; and

the axial connectors pass through the widened slot portion.

7. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein two or more of the axial connectors are gathered together in a mounted region of the inverter portion, and are disposed at an identical position in a circumferential direction of the motor portion.

8. The mechanically and electrically integrated rotary electric machine according to claim 7, wherein the axial connectors are gathered together in groups of three phases and are twisted together with each other.

9. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein the axial connector has a shape that has a cross section that is constituted by at least two arms.

10. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein:

the axial connectors comprise;

an alternating-current output terminal that is connected to the switching elements;

an electroconductive buffering member; and

an axial connecting member; and

the axial connecting member is connected to the alternating-current output terminal such that the buffering member is interposed.

11. The mechanically and electrically integrated rotary electric machine according to claim 1, wherein:

a plurality of tooth portions that protrude radially inward are disposed around the inner circumference of the stator core;

a plurality of stator grooves are disposed parallel to an axial direction of the stator core around an outer circumference of the stator core;

the stator grooves are disposed at similar or identical positions to the tooth portions in a circumferential direction of the stator core;

the axial connectors are inserted into the stator grooves; and

conduit members that are made of an insulating material are interposed between the axial connectors and inner wall surfaces of the stator grooves.

12. The mechanically and electrically integrated rotary electric machine according to claim 2, wherein a surface at a tip end portion of the axial connector on which a first aperture portion is formed and a surface of the end portion connector on which a second aperture portion is formed are stacked and fastened by a screw.

13. A manufacturing method for a mechanically and electrically integrated rotary electric machine comprising:

a cylindrical frame;

a motor portion comprising;

a cylindrical stator core;

a plurality of coils that are disposed around an inner circumference of the stator core; and

a rotor that is rotatably disposed inside the stator core,

the motor portion being inserted inside the frame;

an inverter portion comprising a plurality of switching elements, the inverter portion being fixed to an inner circumferential surface of the frame; and

a connector that electrically connects the coils and the switching elements,

wherein the connector comprises;

an end portion connector that is disposed on an end portion of the motor portion near an output shaft, and that distributes sinusoidal electric currents from the switching elements to each of the coils; and

a plurality of axial connectors that comprise alternating-current output terminals that are connected to the switching elements, the axial connectors directing the sinusoidal electric currents from the switching elements to the end portion connector,

the manufacturing method comprising;

a first step in which the stator core is fixed to the frame;

a second step, after the first step, in which the alternating-current output terminals are inserted into a plurality of stator grooves that are disposed parallel to an axial direction of the stator core around an outer circumference of the stator core; and

a third step, after the second step, in which the switching elements are affixed to an inner circumferential surface of the frame.

14. The manufacturing method according to claim 13, further comprising a fourth step, after the third step, in which a surface at a tip end portion of the axial connector on which a first aperture portion is formed and a surface of the end portion connector on which a second aperture portion is formed are stacked and fastened by a screw.