JP4229947B2 - Control device-integrated rotating electrical machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a controller-integrated rotating electrical machine in which a rotating electrical machine and a control device for controlling the output are integrated, and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, this type of controller-integrated rotating electrical machine has a configuration in which a heat sink on which a switching element is soldered and mounted is fixed to a rear housing of a generator motor by fastening. The rear cover is placed on the heat sink from the counter load side direction of the generator motor toward the rotor shaft direction, and is fixed to the heat sink and the rear housing, and a ground potential is applied to the heat sink. It is comprised so that it may fix on the insulating sheet provided in the base surface of the heat sink via (for example, refer patent document 1).

JP 2004-282905 A (paragraphs 0020, 0023, FIGS. 1 and 2)

  In the above conventional technique, when the heat sink on which the soldered switching element is mounted is fixed to the rear housing by fastening, the fastening direction is configured to be parallel to the soldering surface of the switching element. Yes. For this reason, the stress due to the fastening force between the heat sink and the rear housing acts in a shearing direction on the soldering surface of the switching element, which may damage the solder.

  Further, the switching element has a lead terminal having a polarity different from that of the electrode parallel to the base surface of the heat sink. This lead terminal is joined to a terminal portion insulated from a portion to which the electrode parallel to the base surface is soldered, and joined to a conductive pattern provided on the heat sink via an insulating layer, or It is joined to a terminal member provided separately. In any case, since the electrodes parallel to the base surface of the switching element are stressed at the time of fastening as in the case of the soldering portion, it has been desired to have a structure that does not cause damage at that time.

  The present invention has been made to solve the above-described problems, and provides a controller-integrated rotating electrical machine that is highly reliable and that can improve productivity, and a method for manufacturing the same.

In order to achieve the above object, a controller-integrated dynamoelectric machine according to the present invention is a controller-integrated dynamoelectric machine in which a control device for controlling the output of a dynamo-electric machine is integrated on the non-load side of the dynamoelectric machine. A heat sink fixed to a housing forming an outer shell of the rotating electric machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electric machine, and extended from the switching element A control device-integrated dynamoelectric machine having a metal terminal portion joined to a lead terminal and a terminal member fixed to the heat sink via an insulating member, the lead terminal and the metal terminal of the terminal member substantially parallel surface portions and the bonding surfaces of the parts the insulating member is in contact with the heat sink, further the lead terminals The joining surface of the terminal member with the metal terminal portion, the joining surface of the predetermined electrode of the switching element and the heat sink, the fixing direction of the heat sink and the terminal member, and the fixing direction of the heat sink and the housing It is characterized by constituting in a substantially vertical direction.

Further, the manufacturing method of the controller-integrated rotating electrical machine according to the present invention is a method of manufacturing a controller-integrated rotating electrical machine in which a control device for controlling the output of the rotating electrical machine is integrated on the non-load side of the rotating electrical machine. A heat sink fixed to a housing forming an outer shell of the rotating electric machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electric machine, and extended from the switching element And a terminal member fixed to the heat sink via an insulating member, and a switching device of the heat sink, wherein the switching element of the heat sink includes: the plane substantially parallel to surface that are joined through the insulating member assembled by contacting the terminal member, heating A first step of forming an assembly of a sink and a terminal member; and after the first step, mounting the switching element on the heat sink, joining a predetermined electrode of the switching element and the heat sink, and the switching element A second step of simultaneously joining the lead terminal extending from the metal terminal portion of the terminal member, and a surface portion substantially parallel to the surface of the heat sink to which the switching element is joined after the second step In a state where the terminal member is in contact with the insulating member, the bonding surface between the predetermined electrode of the switching element and the heat sink, and the bonding surface between the lead terminal and the metal terminal portion of the terminal member are approximately The assembly of the heat sink and the terminal member is mounted on the housing from the vertical direction. Characterized by comprising the step of including a third step of constant, the.

Another method of manufacturing a controller-integrated electric rotating machine invention, producing a control device for controlling the output of the rotary electric machine controller-integrated electric rotating machine that is integrated into the anti-load side of the rotating electrical machine of the present invention A heat sink fixed to a housing that forms an outline of the rotating electrical machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electrical machine, and the switching In a method for manufacturing a controller-integrated dynamoelectric machine, comprising: a metal terminal portion joined to a lead terminal extending from an element; and a terminal member fixed to the heat sink via an insulating member . set in contact with the terminal member through the insulating member to the surface substantially parallel to the surface of the switching element is bonded A first step of forming an assembly of the heat sink and the terminal member, a second step of fixing the assembly of the heat sink and the terminal member to the housing, and after the second step, And a third step of mounting the switching element and simultaneously joining the predetermined electrode of the switching element and the heat sink, and simultaneously joining the lead terminal and the metal terminal portion of the terminal member. It is characterized by.

According to the present invention , the insulating member contacts the heat sink at a surface portion substantially parallel to the joint surface between the lead terminal extending from the switching element mounted on the heat sink and the metal terminal portion of the terminal member, and further mounted on the heat sink. The joining surface of the desired electrode of the switching element and the heat sink, and the joining surface of the lead terminal extending from the switching element and the metal terminal portion of the terminal member are fixed to the housing constituting the outer shell of the rotating electrical machine. Since the heat sink is fixed in the direction perpendicular to the fixing direction of the heat sink and the terminal member fixed to the heat sink, stress is applied to the joint surface in the shearing direction when the heat sink and the terminal member are fixed by fastening. Will not be applied and force will be applied in the compression direction. It is possible to prevent di.

  Further, since the heat sink, the terminal member, and the switching element can be assembled to the housing from one direction and can be joined in the same process, productivity can be improved.

  Exemplary embodiments of a controller-integrated dynamoelectric machine and a method for manufacturing the same according to the present invention will be explained below in detail with reference to the accompanying drawings.

Embodiment 1 FIG.
FIG. 1 is a schematic cross-sectional view of a control apparatus-integrated rotating electrical machine according to the first embodiment.
This controller-integrated rotating electrical machine includes a rotor 2 having a field winding 1, a stator 4 around which a stator coil 3 is wound, a rotor shaft 5, a fan 6 attached to an end of the rotor 2, and an outline thereof. A rotary electric machine 100 including a front housing 7 and a rear housing 8 to be formed is provided, and further, a switching element 9 and a heat sink 10 on which the switching element 9 is mounted (two sets of 10a and 10b are shown in FIG. 1) and the like. And a control circuit 12 for controlling the operation of the rotating electrical machine 100, a case 13 made of, for example, aluminum alloy or resin for housing the control circuit 12, a cover 14 for covering the case 13, and the like. A pulley 15 connected to a load (not shown) is provided outside the front housing 7, and a ventilation hole 16 is formed in the rear housing 8. The control unit 200 is configured by the power unit 11, the control circuit 12, and the case 13 in which the control circuit 12 is housed. The control device 200 is integrated on the non-load side of the rotating electrical machine 100 to be controlled. An integrated rotary electric machine is configured.

  The white arrow in FIG. 1 schematically shows the main flow of cooling air by the fan 6, and the cooling air is sucked into the heat sink 10b from the radial direction of the rotating electrical machine and fins formed on the heat sink 10b. It passes through and reaches the heat sink 10a. Thereafter, it passes through the fin portion formed in the heat sink 10 a, is swung by the fan 6 through the ventilation hole 16 of the rear housing 8, cools the stator coil 3, and is discharged to the outside of the rear housing 8.

  FIG. 2 is a diagram schematically showing a circuit diagram of the controller-integrated rotating electrical machine shown in FIG. In the present embodiment, a rotating electrical machine controlled by three-phase alternating current is shown, and the switching element 9 in FIG. 1 is configured by a total of six-pole switching elements 9a to 9f arm-connected to the UVW phase. . The switching elements 9a to 9f refer to switching elements that collectively refer to both the case where only one element is provided depending on the current capacity and the case where a plurality of elements are arranged in parallel.

  The switching elements 9a to 9f are composed of a combination of a transistor and a diode. Each of the switching elements 9a to 9f is configured as a separate element. The current of the stator coil 3 is controlled from the battery 20 via the 6-pole switching elements 9a to 9f, and the current of the field winding 1 is controlled by the field current control circuit 21 to adjust the magnetic force of the rotor to generate power. Take control. When functioning as an electric motor, the switching elements 9 a to 9 f are repeatedly turned on and off at a desired timing to supply a predetermined amount and a current having a predetermined waveform to the stator coil 3.

  3 is an enlarged cross-sectional view of the power unit 11 including the switching elements 9a to 9f in the circuit diagram of FIG. 2, and is a combination of switching elements on the upper arm side, for example, the switching elements 9a, 9c, and 9e in the circuit diagram of FIG. The lower arm side switching elements, for example, combinations of the switching elements 9b, 9d and 9f in the circuit diagram of FIG. 2 are mounted on the base surfaces 31 of the heat sinks 10a and 10b, respectively.

  The back electrodes of the switching elements 9a, 9c, 9e and 9b, 9d, 9f are joined to a metal pattern formed on the base surface of the heat sinks 10a, 10b via an insulating layer (not shown), or As shown in FIG. 3, the heat sinks 10a, 10b made of metal themselves constitute a part of the conductor corresponding to the metal pattern, and between these and the back electrodes of the switching elements 9a, 9c, 9e and 9b, 9d, 9f. Join.

  Further, lead terminals 30 having polarities different from those of the back electrodes of the switching elements 9a, 9c, 9e, and 9b, 9d, 9f extend from the package side surfaces of the switching elements 9a, 9c, 9e, and 9b, 9d, 9f. In addition, the base surfaces 31 of the heat sinks 10 a and 10 b are joined to the metal terminal portion 34 of the terminal member 33 provided via the insulating member 32. The joint surface of the metal terminal portion 34 with the lead terminal 30 is a joint surface between the back electrodes of the switching elements 9a, 9c, 9e and 9b, 9d, 9f and the heat sinks 10a, 10b, that is, the base surface 31 of the heat sinks 10a, 10b. The insulating member 32 is in contact with the heat sinks 10a and 10b at a surface portion 35 substantially parallel to the joint surface of the metal terminal portion 34.

  The terminal member 33 includes a plurality of conductors 36 having metal terminal portions 34 joined to the lead terminals 30, and an insulator 37 for ensuring insulation between the plurality of conductors 36, or between the conductor 36 and the heat sinks 10a and 10b. It consists of an insulating member 32 for ensuring insulation and may be assembled as a separate member. However, if a plurality of conductors 36 including the metal terminal portions 34 are insert-molded with an insulating resin, the handling property and the insulation reliability are achieved. Mechanical properties such as vibration resistance are greatly improved.

FIG. 4 is a side view for explaining the structure for fixing the heat sink to the rear housing, and shows the control device 200 side from the rear housing 8 shown in FIG. Yes.
That is, the heat sink 10 is arranged so that the base surface 31 on which the switching element 9 is mounted is parallel to the upper surface 40 side of the rear housing 8, and the bolt 41 extends in the direction of the one-dot chain line to the flange portion 41 integrally formed with the heat sink 10. 42 is passed through and fixed to the rear housing 8. The terminal member 33 is also fastened together with the heat sink 10 by the same flange portion 41 and fixed to the rear housing 8.

  At this time, as understood from FIGS. 1 and 3, the joint surface between the switching element 9 and the base surface 31 of the heat sink 10, and the lead terminal 30 and the metal terminal portion 34 of the switching element 9, that is, the terminal member 33 Both of the joint surfaces are configured to be substantially perpendicular to the direction of fixing to the rear housing 8. For this reason, a force is applied to these joint surfaces in the compression direction at the time of fixing, and no excessive stress is generated in the shearing direction. In the assembly work of the heat sink 10 to the rear housing 8, There is an effect of preventing damage to the joint portion between the base surface 31 of the heat sink 10 and the metal terminal portion 34.

  In addition, although the lead terminal 30 of the switching element 9 shown in FIG. 3 has a shape bent at two locations, it is joined in parallel with the joining surface of the back electrode of the switching element 9 such as a straight shape without bending. Any shape that forms a surface has the same effect.

  Also, the bolt 42 shown in FIG. 4 has a shape in which screws are provided on both sides, and the case 13 is fixed with the nut 43 after the case 13 is attached above the heat sink 10. Space saving can be achieved as compared with the case where the fixing to 8 and the fixing of the case 13 to the rear housing 8 are performed at different locations.

  Further, since the cooling air of the controller-integrated dynamoelectric machine according to the present embodiment is sucked from the radial direction as described with reference to FIG. The case 13 does not require a space for ventilation. In addition, when providing the ventilation hole in the case 13, the size of the ventilation hole is limited so as not to interfere with the control circuit 12. However, in the present embodiment, since the ventilation hole of the case 13 is not provided, It is not necessary to consider the pressure loss, so that a large air volume can be secured and the cooling performance is improved.

Embodiment 2. FIG.
FIG. 5 is a schematic cross-sectional view of a controller-integrated rotating electrical machine according to the second embodiment. In the second embodiment, the layout of the power unit 50 is different from that described in the first embodiment, and the heat sink 10a on the upper arm side and the heat sink 10b on the lower arm side are stacked in the axial direction of the rotary shaft 5. The arrangement is arranged. The terminal members 51 and 52 are divided and attached to the base surfaces of the heat sinks 10a and 10b, respectively, and the switching elements 9a and 9b are mounted in the same manner as in the first embodiment described above, and the respective back electrodes are mounted. Joined to the mounted heat sink. A control device 500 includes the power unit 50, the control circuit 12, and the case 13 in which the control circuit 12 is housed. Other configurations are the same as those described in the first embodiment, and the description thereof is omitted by giving the same reference numerals.

  The white arrows in FIG. 5 indicate the main flow of cooling air that cools the power unit 50 and the stator 4. The cooling air sucked from the entrances of the heat sinks 10 a and 10 b by the fan 6 is stacked. It passes between the fins of the heat sinks 10 a and 10 b, passes through the ventilation holes 16 of the rear housing 8, and is discharged to the outside of the rear housing 8 through the stator coil 3.

  Black arrows in FIG. 5 indicate the mounting direction of the heat sinks 10a and 10b to the rear housing 8 and the mounting direction of the terminal members 51 and 52 to the heat sinks 10a and 10b. Switching is performed in the same manner as in the first embodiment. It is possible to avoid stress in the shearing direction on the junction between the element 9a and the base surface of the heat sink 10a or the junction between the switching element 9b and the base surface of the heat sink 10b. Moreover, since it can arrange | position in a radial direction only by one arm part, the area of heat sink 10a, 10b can be enlarged, and low thermal resistance can be achieved. Furthermore, the wiring of the terminal members 51 and 52 can be wired in parallel with the base surfaces of the heat sinks 10a and 10b, so that the height can be reduced.

  Regarding cooling performance, by arranging the heat sinks 10a and 10b in a stacked manner, it is possible to increase the area where the brackets (not shown) formed in the heat sinks 10a and 10b and the ventilation holes 16 do not wrap, so that the vicinity of the ventilation holes 16 The pressure loss is reduced, the air volume is increased, and the cooling effect of the power unit 50 and the stator 4 is increased. Further, since the cooling air flows in parallel to the heat sinks 10a and 10b of the upper and lower arms, unlike the case of the first embodiment that flows in series, there is no temperature increase due to the sensible heat of the cooling air in the front heat sink 10a, and the cooling Performance is improved.

  As for the stacking arrangement of the heat sinks 10a and 10b in the axial direction of the rotating shaft 5, for example, as shown in FIG. 6, the joint surfaces between the heat sinks 10a and 10b and the switching elements 9a and 9b and the lead terminals 30a and 30b. Further, the joint surfaces of the terminal members 33a and 33b may be arranged facing each other.

Embodiment 3 FIG.
FIG. 7 is a schematic diagram for explaining the third embodiment, and shows a layout of a heat sink arranged on the non-illustrated rear housing on the side opposite to the load. A heat sink (hereinafter referred to as P heat sink) 72 on which an upper arm side switching element 71 (corresponding to 9a, 9c, 9e in FIG. 2) is mounted is disposed on the inner peripheral side near the center 70 of the rotating shaft (not shown). On the outer peripheral side, heat sinks (hereinafter referred to as AC heat sinks) 74, 75, 76 on which switching elements 73 on the lower arm side (corresponding to 9b, 9d, 9f in FIG. 2) are mounted are arranged. Originally, the structure is such that the terminal member is mounted on the surface of the heat sink. However, in this figure, the terminal member is not shown for convenience, and only the switching elements 71 and 73 are drawn in parallel.

  The P heat sink 72 has the same potential as the positive electrode side of the battery (reference numeral 20 in FIG. 2), and integrates a terminal 77 connected to a harness from the battery in addition to a fixing portion to the rear housing, and each phase. All the switching elements 71 on the upper arm side are mounted. On the other hand, the AC heat sinks 74, 75, and 76 are three heat sinks insulated from each other at the same potential as each phase of a three-phase winding of a stator (not shown). Flange portions 74a, 75a, and 76a for ensuring electrical continuity with the winding and the grounded rear housing are provided and fixed by bolts (not shown). The back electrode provided on the back surface of the switching elements 71 and 73 and the base surface of the heat sink are conductively joined, and the P heat sink 72 serves as a wiring member from the terminal 77 to the back electrode of the switching element 71 on the upper arm side. The AC heat sinks 74, 75, and 76 are wiring members that extend from the three-phase windings of the stator through a terminal member (not shown) to the back electrode of the switching element 73 on the lower arm side. Since other configurations are the same as those in the first embodiment, the description thereof is omitted.

  As a joining method of the switching elements 71 and 73 and the P and AC heat sinks 72, 74, 75, and 76, solder joining can be easily performed at a low temperature, and this joining method is preferable from the switching elements 71 and 73. There is an effect that the thermal resistance to the P and AC heat sinks 72, 74, 75, 76 can be reduced.

  Further, by providing means for preventing wetting and spreading outside the region where the back electrodes of the switching elements 71 and 73 are joined to the base surfaces of the P and AC heat sinks 72, 74, 75 and 76, the solder alignment effect is utilized. Thus, positioning after soldering can be performed. Examples of the means include a method of partial plating only on a groove, a step, a protrusion, or an area to be soldered.

  On the other hand, as a joining method of the lead terminal and the metal terminal portion of the terminal member, by using soldering similarly to the joining of the switching elements 71, 73 and P and the AC heat sinks 72, 74, 75, 76, Joining is possible in the same process.

  Also, since solder bonding can be performed at a relatively low temperature, it is possible to prevent the thermal effect on the insulating member between the P and AC heat sinks 72, 74, 75, 76 and the terminal member, Due to the alignment effect at the time of melting the solder, the positions of the plurality of lead terminals are each positioned so as to follow the terminal member, and a short circuit with the adjacent terminal member can be prevented.

  By constructing the P heat sink 72 from a single heat sink having the same potential as the positive side of the battery (reference numeral 20 in FIG. 2), the number of heat sinks can be reduced, and assembling errors can be reduced as much as possible. Avoid excessive stress. Further, since the number of fixed points can be reduced, the heat resistance can be reduced by increasing the surface area of the heat sink. Furthermore, vibration resistance can be improved by increasing the rigidity of the heat sink portion.

  Further, an integrated P heat sink 72 having a small number of fixing points is arranged on the inner peripheral side, and AC heat sinks 74, 75, and 76, each of which is divided into three and provided with fixing points 74a, 74b, and 74c, have a large outer diameter. By disposing on the side, the heat sink surface area on the outer peripheral side can be secured, and the degree of integration can be increased. Further, by dividing AC heat sinks 74, 75, and 76 on the outer peripheral side where the outer diameter is increased, it is possible to relieve stress on the solder joint.

  The base area of the P heat sink 72 on the inner peripheral side and the AC heat sinks 74, 75, 76 on the outer peripheral side can be arbitrarily set. In particular, the inflow air temperature of the inner peripheral side P heat sink 72 rises due to sensible heat at the outer peripheral side AC heat sinks 74, 75 and 76. Considering this, the temperature balance of all the switching elements 71 and 73 can be achieved by increasing the base area of the P heat sink 72 on the inner peripheral side.

Embodiment 4 FIG.
FIG. 8 is a flowchart showing an embodiment of the manufacturing process of the controller-integrated rotating electrical machine according to the present invention, and the controller-integrated rotating electrical machine according to Embodiment 1 will be described as an example.
First, the heat sink 10 and the terminal member 33 are assembled, and the power block 80 that is an assembly of the heat sink 10 and the terminal member 33 is configured. At this time, the heat sink 10 and the terminal member 33 are fixed so as not to be displaced from each other. Since the flange portion 81 of the heat sink 10 has a potential on the positive electrode side of the battery 20 (see FIG. 2) or the stator coil 3 (see FIG. 1) side of the rotating electrical machine, an insulating member 82 is attached as necessary. . The terminal member 33 is joined and attached to the base surface side of the heat sink 10. As described with reference to FIG. 3, the terminal member 33 is manufactured by insert-molding the conductor 36 with an insulating resin in advance, and the conductor 36 is provided with a metal terminal portion 34 that is joined to the lead terminal 30 of the switching element 9. Yes.

  Next, the switching element 9 is mounted on the heat sink 10. At this time, the back electrode of the switching element 9 and the heat sink 10, and the lead terminal 30 and the metal terminal portion 34 of the switching element 9 are joined as shown in FIG. The back electrode of the switching element 9 and the heat sink 10 are surface-bonded by soldering in order to reduce thermal resistance and impart conductivity. On the other hand, a soldering or welding method is used for joining the lead terminal 30 and the metal terminal portion 34 of the switching element 9. In particular, a heat-sensitive material such as a resin is used as the insulator 37 (see FIG. 3). In some cases, soldering that allows bonding at a relatively low temperature is good.

  As a heat source for soldering, there are methods such as heater heating, light beam heating, radiation heating, hot air heating, induction heating, and the number of processes can be increased by soldering simultaneously with joining of the back electrode of the switching element 9 and the heat sink 10. The number of manufacturing steps can be reduced.

  Further, when soldering the heat sink 10 and the back electrode of the switching element 9 and the lead terminal 30 of the switching element 9 and the metal terminal portion 34 together, for example, reflow of a hot air heating method or a radiant heating method. If passed through the furnace, not only can it be heated efficiently, but also the work can be conveyed on a conveyor, making it easy to form a line. Further, if the workpiece is heated by self-heating of the workpiece by induction heating, it can be efficiently heated and soldered.

  Next, the power block 80 on which the switching element 9 is mounted is attached to the rear housing 8 and firmly fixed with the bolt 83. Thereafter, the case 13 is attached above the power block 80 and firmly fixed with the nut 84, and the control circuit 12 is accommodated in the case 13 and soldered at a desired location, and covered with the cover 14.

  According to the above manufacturing method, since the joining process of the back electrode of the switching element 9 and the heat sink 10 and the lead terminal 30 of the switching element 9 and the metal terminal portion 34 can be made the same, the manufacturing process can be reduced and the cost can be suppressed. it can. In addition, since the power block 80 including the heat sink 10 and the terminal member 33 attached in contact with the base surface side in a direction substantially perpendicular to the joint surface parallel to the base surface of the heat sink 10 is fixed, the stress applied to the joint portion The compression direction is dominant, and fatal damage such as solder removal can be prevented.

  Further, by manufacturing the conductor 36 including the metal terminal portion 34 of the terminal member 33 by insert molding with a resin, not only the handling of the conductor 36 is facilitated, but also a plurality of conductors 36 having different potentials are securely formed with a resin layer. In addition, since it can be firmly held by the resin, it is possible to manufacture a controller-integrated rotating electrical machine having excellent structural reliability.

  The terminal member 33 is divided for each heat sink 10, the terminal member 33 is assembled to each heat sink 10 to produce a subassembly structure in which the switching element 9 is joined, and each subassembly structure is attached to the rear housing 8. However, by integrating the terminal member 33 across the heat sink 10, the number of parts can be reduced, and concerns such as the displacement of the lead terminal 30 due to assembly tolerances can be minimized.

Embodiment 5 FIG.
FIG. 9 is a flowchart showing a manufacturing process according to another embodiment of the controller-integrated dynamoelectric machine according to the present invention.
First, the heat sink 10 and the terminal member 33 are firmly fixed to the rear housing 8 with the bolts 83. Thereafter, the switching element 9 is mounted, and the back electrode of the switching element 9 and the heat sink 10, the lead terminal 30 (see FIG. 3) of the switching element 9, and the metal terminal portion 34 (see FIG. 3) are joined. The back electrode of the switching element 9 and the heat sink 10 are surface-bonded by soldering in order to reduce the thermal resistance. Moreover, if the lead terminal 30 and the metal terminal part 34 are also soldered, they can be joined in the same process. The subsequent steps of attaching the case 13, which is a subsequent step, are the same as those in the above-described fourth embodiment, and a description thereof will be omitted.

  Examples of the heat source for simultaneous soldering of the back electrode of the switching element 9 and the heat sink 10 and the lead terminal 30 and the metal terminal portion 34 of the switching element 9 include heater heating, light beam heating, radiation heating, hot air heating, and induction heating. However, if it is passed through a reflow furnace of a hot air heating method or a radiant heating method, not only can it be heated efficiently, but it can also be conveyed by a conveyor, so it is easy to make a line. Moreover, in the case of the induction heating method, since the workpiece is heated by self-heating of the workpiece, it can be efficiently heated and soldered even when the rear housing 8 having a large heat capacity is attached.

  According to the above manufacturing method, the external force required when fixing the heat sink 10 and the terminal member 33 to the rear housing 8 is not applied to the joint portion of the switching element 9, and therefore there is no risk of damage to the joint portion. It is possible to manufacture a control device-integrated rotary electric machine having a high height.

  In addition, the switching element in each embodiment has a structure in which the semiconductor chip is mounted on a heat sink and connected by the lead terminal regardless of the package in which the semiconductor chip is sealed with resin and the lead terminal protrudes from the side surface. There may be. If the base surface of the heat sink to be joined to the back electrode of the switching element and the joint surface between the lead terminal and the terminal member are in a direction substantially perpendicular to the fixing direction, the same effect is obtained.

  The present invention has the same effect when applied not only to a rotating electric machine having a control device having an inverter function and operating as a motor but also to an AC generator having a power generation and rectification function. The present invention can be applied to any rotating electrical machine in which a control device for controlling is integrated.

  As described above, the controller-integrated dynamoelectric machine and the method for manufacturing the same according to the present invention are highly reliable and can realize an improvement in productivity, which greatly increases industrial applicability.

1 is a schematic cross-sectional view of a control device-integrated rotating electrical machine according to Embodiment 1 of the present invention. It is the figure which showed typically the circuit diagram of the control apparatus integrated rotary electric machine shown in FIG. FIG. 3 is an enlarged cross-sectional view of a power unit including an arbitrary switching element in the circuit diagram of FIG. 2. It is a side view explaining the structure which fixes a heat sink. FIG. 3 is a schematic cross-sectional view of a control apparatus-integrated dynamoelectric machine according to Embodiment 2 of the present invention. It is a schematic diagram explaining another Example which laminates | positions a heat sink. It is a schematic diagram explaining the layout of the heat sink by Embodiment 3 of this invention. It is a flow which shows one Embodiment of the manufacturing process of the control apparatus integrated rotary electric machine by this invention. It is a flow which shows the manufacturing process of another embodiment of the control apparatus integrated rotary electric machine by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Field winding 2 Rotor 3 Stator coil 4 Stator 5 Rotor shaft 6 Fan 7 Front housing 8 Rear housing 9, 71, 73 Switching element 10, 72, 74, 75, 76 Heat sink 11, 50 Power part 12 Control circuit 13 Case 14 Cover 15 Pulley 16 Ventilation hole 20 Battery 21 Field current control circuit 30 Lead terminal 31 Heat sink base surface 32 Insulating portion 33, 51, 52 Terminal member 34 Metal terminal portion 35 Surface portion 36 Conductor 37 Insulator 40 Upper surface 41 of rear housing , 74a, 75a, 76a, 81 Flange portion 42, 83 Bolt 43, 84 Nut 70 Center of rotating shaft 77 Terminal 80 Power block 82 Insulating member 100 Rotating electrical machine main body 200, 500 Control device

Claims (11)

A controller-integrated dynamoelectric machine in which a controller for controlling the output of the dynamoelectric machine is integrated on the anti-load side of the dynamoelectric machine,
A heat sink fixed to a housing that forms an outer shell of the rotating electrical machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electrical machine, and extending from the switching element A control device-integrated dynamoelectric machine having a metal terminal portion joined to a lead terminal and a terminal member fixed to the heat sink via an insulating member,
The insulating member is in contact with the heat sink at a surface portion substantially parallel to the joint surface between the lead terminal and the metal terminal portion of the terminal member, and the joint surface between the lead terminal and the metal terminal portion of the terminal member; The joining surface of the predetermined electrode of the switching element and the heat sink is configured in a direction substantially perpendicular to the fixing direction of the heat sink and the terminal member and the fixing direction of the heat sink and the housing. Control device-integrated rotating electrical machine.   2. The controller-integrated rotating electrical machine according to claim 1, wherein the heat sink is composed of a plurality of heat sinks arranged in a stacking direction in the fixing direction to the housing.   The heat sink includes a first heat sink having the same potential as the positive electrode of the battery that supplies power to the control device, and a second heat sink having the same potential as the stator winding of the rotating electrical machine, and is mounted on each heat sink. The control device-integrated dynamoelectric machine according to claim 1 or 2, wherein a predetermined electrode of the switching element is soldered to the mounted heat sink.   4. The controller-integrated rotating electrical machine according to claim 3, wherein the first heat sink is composed of one heat sink, and the second heat sink is composed of three heat sinks.   5. The controller integrated type according to claim 3, wherein the first heat sink is disposed radially inside the housing, and the second heat sink is disposed radially outside the housing. Rotating electric machine.   6. The control device-integrated dynamoelectric machine according to claim 1, wherein a lead terminal of the switching element and a metal terminal portion of the terminal member are joined by solder.   The control device-integrated dynamoelectric machine according to any one of claims 1 to 6, wherein the terminal member and the insulating member are integrally formed. A control device-integrated rotating electrical machine manufacturing method in which a control device for controlling the output of the rotating electrical machine is integrated on the anti-load side of the rotating electrical machine,
A heat sink fixed to a housing that forms an outer shell of the rotating electrical machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electrical machine, and extending from the switching element In the method of manufacturing a controller-integrated dynamoelectric machine comprising a metal terminal portion joined to a lead terminal and a terminal member fixed to the heat sink via an insulating member,
A first step in which the terminal member is brought into contact with and assembled to a surface portion of the heat sink that is substantially parallel to a surface to which the switching element is joined , to form an assembly of the heat sink and the terminal member;
After the first step, the switching element is mounted on the heat sink, a junction between a predetermined electrode of the switching element and the heat sink, a lead terminal extending from the switching element, and a metal terminal portion of the terminal member, A second step of simultaneously bonding
After the second step, in a state where the terminal member is in contact with a surface portion of the heat sink that is substantially parallel to a surface to which the switching element is joined , the predetermined electrode of the switching element and the heat sink And a third step of fixing the assembly of the heat sink and the terminal member to the housing from a substantially vertical direction with respect to the bonding surface and the bonding surface between the lead terminal and the metal terminal portion of the terminal member. A control device-integrated dynamoelectric machine manufacturing method characterized by comprising steps. A control device-integrated rotating electrical machine manufacturing method in which a control device for controlling the output of the rotating electrical machine is integrated on the anti-load side of the rotating electrical machine,
A heat sink fixed to a housing that forms an outer shell of the rotating electrical machine, a switching element mounted on the heat sink, and a predetermined electrode joined to the heat sink to adjust the output of the rotating electrical machine, and extending from the switching element In the method of manufacturing a controller-integrated dynamoelectric machine comprising a metal terminal portion joined to a lead terminal and a terminal member fixed to the heat sink via an insulating member,
A first step in which the terminal member is brought into contact with and assembled to a surface portion of the heat sink that is substantially parallel to a surface to which the switching element is joined , to form an assembly of the heat sink and the terminal member;
A second step of fixing the assembly of the heat sink and the terminal member to the housing;
After the second step, the switching element is mounted on the heat sink, and the bonding between the predetermined electrode of the switching element and the heat sink and the bonding between the lead terminal and the metal terminal portion of the terminal member are performed simultaneously. And a control device-integrated dynamoelectric machine manufacturing method comprising the steps of:   The joining process for joining the predetermined electrode of the switching element and the heat sink and joining the lead terminal and the metal terminal of the terminal member at the same time is performed by soldering by hot air heating, radiation heating, or induction heating. 10. The method of manufacturing a controller-integrated dynamoelectric machine according to claim 8 or 9, wherein:   11. The method of manufacturing a controller-integrated dynamoelectric machine according to claim 8, wherein the metal terminal portion of the terminal member and the insulating member are integrally formed in advance.

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