Patent Application
20090179510
1. Field of the Invention
The present invention relates in general to rotating electrical machines and more particularly to a rotating electrical machine suitably used as a machine serving as both a generator and an engine starter operating as the generator while a vehicle is running (an engine is running) and a starter while the engine is stationary.
2. Description of the Related Art
In recent years, efforts are being made toward reduction in CO2 emissions from vehicles for prevention of global warming. As part of measures for achieving the goal of the reduced CO2 emissions, bringing the engine to a stop when the vehicle is stationary (idling stop) is being studied. Various arrangements have been devised as idling stop mechanisms. Among them, a technique that starts the engine using a conventional vehicle generator has been proposed. An inverter unit is required for driving the vehicle generator as a motor. A known arrangement integrates the inverter unit with the vehicle generator to provide a compact and lightweight machine that serves as both the vehicle generator and the engine starter (see, for example, Japanese Patent No. 3598586).
The inverter unit is more susceptible to heat than other components. If a compact machine is built by integrating the inverter unit with the vehicle generator, the inverter unit temperature runs high, so that an operating temperature limit thereof could be exceeded. Arrangements are therefore known, in which an air from a fan attached to a rotating electrical machine is blown properly against a switching semiconductor device (see, for example, JP-A-2004-274992 and JP-A-2006-504386).
Another known arrangement includes an inverter unit mounted with a gap relative to the vehicle generator (see, for example, JP-A-2006-33986).
The arrangements disclosed in JP-A-2004-274992 and JP-A-2006-504386, however, use the air generation through rotation of the fan for cooling the inverter unit. Consequently, when the vehicle remains stationary and the vehicle generator stops rotating, the fan also remains stationary, which poses a problem of increased temperature of the inverter unit.
In the arrangement disclosed in JP-A-2006-33986, the gap, specifically, an air layer interposed between the vehicle generator and the inverter unit helps reduce the effect of thermal radiation from the vehicle generator while the vehicle generator is not rotating more than in the arrangements of JP-A-2004-274992 and JP-A-2006-504386. A problem remains unsolved, however, in that the effect of heat transfer from a mounting spacer cannot be ignored. Furthermore, a radiation fin is disposed on the side of the vehicle generator, which makes the radiation fin susceptible to the thermal radiation from the vehicle generator.
It is an object of the present invention to provide a rotating electrical machine capable of reducing the temperature of an inverter unit even without air for cooling from a fan.
(1) To achieve the foregoing object, provided according to one aspect of the present invention is a rotating electrical machine comprising:
a rotating electrical machine main body, the rotating electrical machine main body having:
an inverter unit, the inverter unit having:
the rotating electrical machine main body and the inverter unit are coupled with each other by the case being connected with the housing;
the rotating electrical machine main body and the inverter unit are in communication with each other such that the cooling air circulated by rotation of the fan cools the inverter unit and then flows into the housing; and
the rotating electrical machine further includes a suppression means disposed between the rotating electrical machine main body and the switching semiconductor devices, the suppression means preventing thermal radiation radiated (or irradiated) from the rotating electrical machine main body from reaching the switching semiconductor devices.
The foregoing configuration allows the temperature of the inverter unit to be reduced even without the cooling air from the fan.
(2) In the above-referenced (1), preferably, the rotating electrical machine further includes a radiation means disposed opposite the suppression means with respect to the switching semiconductor devices, the radiation means radiating heat of the switching semiconductor devices.
(3) In the above-referenced (1), preferably, the suppression means forms part of the case formed of a resin and the switching semiconductor devices are molded in the resin case.
(4) In the above-referenced (1), preferably, the switching semiconductor devices are disposed on a substrate fixed to the case and the suppression means includes a gel or a resin packed in a recess formed between the case and the substrate on the side on which the switching semiconductor devices are disposed.
(5) In the above-referenced (1), preferably, the rotating electrical machine further includes a reflection means disposed on the front side of the suppression means and on the side of the rotating electrical machine main body, the reflection means reflecting the thermal radiation from the rotating electrical machine main body.
(6) In the above-referenced (1), preferably, the switching semiconductor devices are disposed at hidden positions when the inverter unit is viewed from the position of the rotating electrical machine main body.
(7) In the above-referenced (1), preferably, the rotating electrical machine further includes a resin material covering the fan on the side of the rotating electrical machine main body.
(8) In the above-referenced (1), preferably, the switching semiconductor devices inside the inverter unit generate heat more in a driving mode than in a power generation mode.
(9) In the above-referenced (1), preferably, the case includes a hole through which the cooling air from the fan of the rotating electrical machine main body passes and the case includes an edge formed in a protruding condition on the periphery of the hole on the side of the hole opposite the rotating electrical machine main body.
(10) In the above-referenced (1), preferably, the switching semiconductor devices of the inverter unit are MOS-FET transistors performing synchronous rectification during the power generation mode of the rotating electrical machine main body.
(11) To achieve the foregoing object, provided according to another aspect of the present invention is a rotating electrical machine comprising:
a rotating electrical machine main body, the rotating electrical machine main body having:
an inverter unit, the inverter unit having:
the rotating electrical machine main body and the inverter unit are coupled with each other by the case being connected with the housing;
the rotating electrical machine main body and the inverter unit are in communication with each other such that the cooling air circulated by rotation of the fan cools the inverter unit and then flows into the housing; and
a path along which the thermal radiation radiated (or irradiated) from the rotating electrical machine main body reaches the switching semiconductor devices when the fan is stopped operating as a result of a stop of the engine includes a suppression means provided thereon, the suppression means preventing the thermal radiation from reaching the switching semiconductor devices.
The foregoing arrangements allow the temperature of the inverter unit to be reduced even without the cooling air from the fan.
In accordance with the aspects of the present invention, the temperature of the inverter unit can be reduced even without the cooling air from the fan.
The present invention will be described hereinafter with reference to the accompanying drawings.
The configuration of a rotating electrical machine according to an embodiment of the present invention will be described below with reference to
The overall configuration of the rotating electrical machine according to the embodiment of the present invention will be first described with reference to
The rotating electrical machine according to the embodiment of the present invention includes a rotating electrical machine main body 40 and an inverter unit 30. The rotating electrical machine main body 40 used in the rotating electrical machine according to the embodiment of the present invention is a three-phase synchronous rotating electrical machine having a claw pole-type rotor. The rotating electrical machine main body 40 serves as both a generator and an engine starter. The inverter unit 30 converting the DC power of, for example, a battery to three-phase AC power is integrally formed on a side face of the rotating electrical machine main body 40.
In the rotating electrical machine main body 40, a rotor 4 is rotated by the rotative power of an engine when the engine is operating, so that a stator 1 generates electric power; for starting the engine, the rotor 4 is rotated through a magnetic action with the stator 1, which gives the engine the rotative power. The inverter unit 30 controls the operation and output power of the rotating electrical machine main body 40. The rotating electrical machine main body 40 and the inverter unit 30 are coupled with each other by a case 14 of the inverter unit 30 being connected to a housing 3 of the rotating electrical machine main body 40.
The configuration of the rotating electrical machine according to the embodiment of the present invention is described below in detail.
The stator 1 of the rotating electrical machine main body 40 includes stator coils 13 for three phases wave-wound around a slot in a stator core. The stator 1 of the rotating electrical machine main body 40 is sandwiched between a front housing 2 and a rear housing 3. The stator 1 has its outer periphery covered in the front housing 2. To improve heat conduction between the outer periphery of the stator 1 and the front housing 2, a resin or a similar material having a high coefficient of thermal conductivity may be inserted.
The front housing 2 includes a plurality of holes 2a, 2b formed therein for introducing a cooling air from the outside. The hole 2a is disposed on an end face of the front housing 2 and used for introducing the cooling air into the rotating electrical machine main body 40. The hole 2b is disposed on an outer peripheral surface of the front housing 2 and used for drawing air out of the rotating electrical machine main body 40. In addition, the rear housing 3 includes a plurality of holes 3a, 3b formed therein for introducing the cooling air from the outside. The hole 3a is disposed on an end face of the rear housing 3 and used for introducing the cooling air drawn through holes 16a in a cover 16 into the inside of the rotating electrical machine main body 40. The hole 3b is disposed on an outer peripheral surface of the rear housing 3 and used for drawing air out of the inside of the rotating electrical machine main body 40.
The rotor 4 is disposed on an inner peripheral side of the stator 1 so as to oppose the stator 1 via an air gap. The rotor 4 includes a Lundell-type rotor core 5 composed of a first claw pole 5A and a second claw pole 5B. The rotor core 5 is fixed to a shaft 9. A magnetic field coil 8 is wound on an inner periphery of the rotor core 5. A field current is supplied to the magnetic field coil 8 via a brush 6 and a slip ring 7. The field current supplied to the magnetic field coil 8 generates field magnetic flux required for generating electricity and driving. A magnet may be inserted between the first claw pole 5A and the second claw pole 5B to improve an output of the field magnetic flux.
The rotor core 5 is rotatably supported by bearings 10 mounted in the front housing 2 and the rear housing 3. A pulley 11 is fixed to one end of the shaft 9. The pulley 11 is run by a belt put around an engine crankshaft pulley, which allows the rotating electrical machine to operate as the generator. When the rotating electrical machine operates as the starter, the driving force generated in the shaft 9 is transmitted to the engine via the pulley 11 and used for starting the engine.
Fans 12a, 12b are mounted on both end faces of the rotor core 5 of the rotor 4.
The case 14 made of resin (hereinafter referred to as “resin case 14”) is mounted on an end face of the rotating electrical machine main body 40 opposite the pulley 11. The resin case 14 holds the inverter unit 30 in place. A plurality of switching semiconductor devices 15 are mounted on the resin case 14. MOS-FET is used as the switching semiconductor devices 15. At least six switching semiconductor devices 15 are used to convert DC power to AC power. A first switching semiconductor device 15 and a second switching semiconductor device 15 are connected in series with each other to form a U-phase vertical arm. A third switching semiconductor device 15 and a fourth switching semiconductor device 15 are connected in series with each other to form a V-phase vertical arm. A fifth switching semiconductor device 15 and a sixth switching semiconductor device 15 are connected in series with each other to form a W-phase vertical arm. The U-phase vertical arm, the V-phase vertical arm, and the W-phase vertical arm are connected in parallel with each other.
When the rotating electrical machine operates as the starter, the DC power from an external DC power source, such as the battery, is converted to three-phase AC power by the inverter unit 30 and supplied to each coil of the stator coils 13 for three phases as a stator current. When the rotating electrical machine operates as the generator, the stator current generated in the stator coil 13 is synchronously rectified by the inverter unit 30 and the generated DC power is stored in the external battery or the like.
The inverter unit 30 mounted on the resin case 14 is mounted with a semiconductor switching device for field current control (not shown). The brush 6 is housed in a brush holder. The brush holder is attached to the resin case 14. The field current that has undergone duty control by the field current control semiconductor switching device is supplied to the magnetic field coil 8 via the brush 6 and the slip ring 7.
Further, the inverter unit 30 has a heatsink 17 as a means of dissipating heat generated from the switching semiconductor devices 15. Being disposed on a side opposite the rotating electrical machine main body 40 relative to the switching semiconductor devices 15, the heatsink 17 is less susceptible to the thermal radiation from the rotating electrical machine main body 40, thus effectively dissipating heat.
The inverter unit 30 is the resin case 14 having a control device and the switching semiconductor devices 15 molded thereinside. Detailed arrangements near the inverter unit 30 will be described later with reference to
The cover 16 formed of a resin for protecting the brush 6 and the heatsink 17 is attached to the rear side of the resin case 14 of the inverter unit 30.
The resin case 14 includes holes 14a formed therein. The holes 14a function to allow the cooling air to flow, as will be described later with reference to
The arrangement near the inverter unit 30 used in the rotating electrical machine according to the embodiment of the present invention will be described below with reference to
The mounting structure for the inverter unit 30 will be described in details with reference to
A metal foil 25 as a means of reflecting the thermal radiation (infrared rays) from the rotating electrical machine main body 40 is attached on the side of the resin case 14 adjacent to the rotating electrical machine main body 40. Note that painting or plating that reflects the thermal radiation from the rotating electrical machine main body 40 may be used in place of the metal foil 25. For painting, a paint containing a pigment having a high reflectivity is used. The pigment having the high reflectivity reflects infrared radiation as the thermal radiation. For plating, electroless plating of a metal material is used.
Types of heat other than the thermal radiation are transmitted to the inverter unit 30 through, for example, air convection. The switching semiconductor device 15 is covered with the resin having a low thermal conductivity, and an increase in temperature of the switching semiconductor device 15 can be reduced.
Flow of cooling air in the rotating electrical machine according to the embodiment of the present invention will be described below with reference to
As described earlier with reference to
Referring to
As shown in
The thermal radiation in the rotating electrical machine according to the embodiment of the present invention will be described below with reference to
When the rotating electrical machine is used as the starter, a large current of, for example, 300 A is passed through the stator coil 13. When the rotating electrical machine is used as the generator, a large current of, for example, 100 A is passed through the stator coil 13. Consequently, an amount of heat generated by the switching semiconductor device 15 is greater during driving than during generating. The current flowing through the magnetic field coil 8 is, on the other hand, small ranging, for example, from 5 to 10 A. The stator coil 13 therefore generates the greatest amount of heat.
The heat of the stator coil 13 is conducted to the stator core. When the temperature of the stator 1 increases, that of the rotor 4 also increases. It should be noted that the stator 1 is structured to be in contact with the outside via the housing, so that heat of the stator 1 can be relatively easily dissipated. The rotor 4 is, on the other hand, accommodated inside the stator 1 and heat of the rotor 4 is therefore hard to dissipate. As a result, the rotor 4 serves as a major source of the thermal radiation.
Referring to
The thermal radiation 23 therefore in the third place moves through the holes 14a for introducing the cooling air in the inverter unit 30 from the end face of the rear housing 3 as shown in
Referring now to
Referring to
Note that the amount of heat conducted from the rotating electrical machine can be reduced by using a resin or other material having a low thermal conductivity for the fans 12a, 12b.
Temperature increase in the rotating electrical machine according to the embodiment of the present invention will be described below with reference to
In
In
When a stationary engine is started in the start mode (START), a driving current more than a generated current flows through the switching semiconductor device 15 and, as a result, the temperature Tinv of the inverter unit 30 increases rapidly. The start mode (START), however, lasts for only about several seconds and the power generation mode (GEN) is set soon after the engine has been started, so that the temperature Tinv of the inverter unit 30 decreases rapidly.
A large current flows though the stator coil 13 and the temperature of the rotating electrical machine main body 40 increases gradually.
When in the power generation mode (GEN), the temperature Tinv of the inverter unit 30 becomes substantially constant. This is because of the following reason. Specifically, in accordance with the embodiment of the present invention, a synchronous rectification system using the MOS-FET as the switching semiconductor device 15 is employed for rectifying the generated current. The synchronous rectification system generates a reduced amount of heat than a commonly found diode rectification system does. In addition, during the power generation mode (GEN), the temperature of the rotating electrical machine remains constant, since the rotating electrical machine is cooled by the cooling air blown by the fan 12a attached to the rotor core 5 of the rotating electrical machine.
In the stop mode (STOP) (during idling stop), the engine also remains stationary, so that no cooling air is available from the rotating electrical machine.
In the rotating electrical machine according to the prior art arrangement, therefore, the temperature Tinv-pr of the inverter unit 30 increases regardless of the timing at which the vehicle is stationary, since the inverter unit 30 is heated by the thermal radiation from the rotating electrical machine that has been generating heat during the power generation mode (GEN). If the vehicle is set into the start mode (START) for restarting the engine in the above-referenced condition, the temperature Tinv-pr of the inverter unit 30 exceeds an allowable temperature limit Tlmt of the switching semiconductor device 15 and there is a danger of breakdown.
The rotating electrical machine according to the embodiment of the present invention, on the other hand, is structured such that the switching semiconductor device 15 and the heatsinks 17 are not subject to the effect of the thermal radiation. The temperature Tinv of the inverter unit 30 therefore remains low. Given this condition, the temperature of the switching semiconductor device 15 can be kept to a level equivalent to, or lower than, the allowable temperature limit Tlmt even with repeated engine starting operations.
Arrangements of a rotating electrical machine according to another embodiment of the present invention will be described below with reference to
An aluminum plate 19 of an inverter unit 30 is molded inside a resin case 14A. The rotating electrical machine according to the second embodiment of the present invention, however, differs from the rotating electrical machine according to the first embodiment of the present invention shown in
A heatsink 17 made of aluminum is fixed to the aluminum plate 19 with an adhesive 18. An insulating resin 20 and a copper-plate wiring pattern 21 are formed, in sequence, on the aluminum plate 19. The switching semiconductor device 15 is mounted on the copper-plate wiring pattern 21.
The recess in the resin case 14A formed on the side on which the switching semiconductor device 15 is mounted is packed with a gel 31, such as a silicon gel. Specifically, the switching semiconductor device 15 is covered in the gel 31. The switching semiconductor device 15 is therefore structured not to be affected by dust deposits. Wire bonding is employed for connecting the switching semiconductor device 15 with the wiring pattern 21. A bonding wire used is held in place by the gel 31, so that the connection is free from any mechanical effect, such as vibration. A hardened resin, instead of the gel 31, may be used.
A metal foil 25 as a means of reflecting the thermal radiation from a rotating electrical machine main body 40 is attached on a surface of the gel 31 on a side of the resin case 14 adjacent to the rotating electrical machine main body 40. Note that painting or plating that reflects the thermal radiation from the rotating electrical machine main body 40 may be used in place of the metal foil 25. For painting, a paint containing a pigment having a high reflectivity is used. The pigment having the high reflectivity reflects infrared radiation as the thermal radiation. For plating, electroless plating of a metal material is used.
Types of heat other than the thermal radiation are transmitted to the inverter unit 30 through, for example, air convection. The switching semiconductor device 15 is covered in the gel 31 having a low thermal conductivity and an increase in temperature of the switching semiconductor device 15 can be reduced.
The embodiments of the present invention are a method applicable to the rotating electrical machine for idling stop. The embodiments of the present invention are also applicable to means of reducing engine vibration and of assisting in engine torque during acceleration of the vehicle.
As described heretofore, according to the embodiments of the present invention, the increase in temperature of the switching semiconductor device 15 can be reduced even if the inverter unit 30 is heated by the thermal radiation from the rotating electrical machine immediately after the vehicle is stopped, so that a driving current that can start the engine can be supplied to the rotating electrical machine.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-316398 | Dec 2007 | JP | national |
