Electric supercharging device and multi-stage supercharging system
09644641 ยท 2017-05-09
Assignee
Inventors
Cpc classification
F02B37/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B39/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/4206
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B39/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D17/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B37/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K5/1732
ELECTRICITY
F02B37/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/5806
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02B33/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B39/005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02B33/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B37/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B37/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/58
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B39/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D17/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/42
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B39/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B37/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B39/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
It is intended to provide: an electric supercharging apparatus wherein, with a simple structure, rotor windage loss in an electric motor for driving a compressor is reduced and good cooling performance is produced; and a multi-stage supercharging system using the electric supercharging device. This electric supercharging apparatus is provided with: a first cooling passage formed in a stator along a motor coil and communicating a gas supply port with a gas discharge port in a motor housing; and a first intake passage connecting the gas discharge port to an intake port of a compressor. This electric supercharging apparatus is configured to introduce outside air into the first cooling passage via the gas supply port by applying negative pressure to the first cooling passage via the first intake passage, thereby cooling the inside of the motor housing.
Claims
1. An electric supercharging apparatus which is configured to rotate an electric motor that comprises a rotor shaft rotatably supported in a motor housing to which a motor coil and a stator are fixed, so as to drive and supercharge a compressor connected to one end of the rotor shaft, the electric supercharging apparatus comprising: a gas supply port and a gas discharge port which are provided in the motor housing; wherein the gas discharge port in the motor housing is connected to an intake passage, and wherein the gas supply port opens to another end side of the motor housing opposite to one end side at which the motor housing is connected to the compressor, a cooling passage which connects the gas supply port and the gas discharge port in the motor housing and which is formed in the stator along the motor coil in an outer periphery of the motor coil; wherein outside air is introduced to the cooling passage from the gas supply port by a negative pressure of an inlet port of the compressor applied to the cooling passage via the intake passage; and an inverter unit comprising an element circuit board housed in an inverter housing, the inverter unit being mounted on a side of the motor housing where the gas supply port is formed.
2. The electric supercharging apparatus according to claim 1, wherein the cooling passage includes a plurality of cooling passages each of which connects the gas supply port and the gas discharge port, each of the plurality of cooling passages surrounds the motor coil in a section orthogonal to the rotor shaft.
3. The electric supercharging apparatus according to claim 1, wherein the cooling passage is configured in part to include an outer wall surface of the motor coil.
4. An electric supercharging apparatus which is configured to rotate an electric motor that comprises a rotor shaft rotatably supported in a motor housing to which a motor coil and a stator are fixed, so as to drive and supercharge a compressor connected to one end of the rotor shaft, the electric supercharging apparatus comprising: a gas supply port and a gas discharge port which are provided in the motor housing; wherein the gas discharge port in the motor housing is connected to an intake passage, and wherein the gas supply port opens to another end side of the motor housing opposite to one end side at which the motor housing is connected to the compressor; a first cooling passage which connects the gas supply port and the gas discharge port in the motor housing and which is formed in the stator along the motor coil in an outer periphery of the motor coil; and a second cooling passage which connects the gas supply port to the gas discharge port in the motor housing and which is formed along the rotor shaft between the rotor shaft and the motor coil, wherein the second cooling passage joins the first cooling passage in the motor housing and outside air is introduced to the first cooling passage and the second cooling passage from the gas supply port by a negative pressure of an inlet port of the compressor applied to the first cooling passage via the intake passage.
5. The electric supercharging apparatus according to claim 4, wherein the first cooling passage includes a plurality of cooling passages each of which connects the gas supply port and the gas discharge port, each of the plurality of cooling passages surrounds the motor coil in a section orthogonal to the rotor shaft.
6. The electric supercharging apparatus according to claim 4, wherein the first cooling passage is configured in part to include an outer wall surface of the motor coil.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
DETAILED DESCRIPTION
(7) The present invention will now be described in detail using embodiments shown in the accompanying drawings. It is intended, however, that unless particularly specified in these embodiments, dimensions, materials, and shapes of components, their relative positions and the like shall be interpreted as illustrative only and not limitative of the scope of the present invention.
First Embodiment
(8)
(9) The inverter unit 4 and the electric motor 3 are integrally connected so as to reduce the distance between the inverter unit 4 and the electric motor 3, thereby minimizing electrical loss of the power supplied to the electric motor 3. In the case where the electrical loss is not an issue, the electric motor 3 and the inverter unit 4 may be arranged away from each other as separate units.
(10) In the compressor 2, the gas drawn from the inlet port 5 is pressurized by a compressor wheel 6 which is rotated by the electric motor 3 and then discharged from a discharge port (not shown) through an interior of the compressor cover 7, so as to supercharge to an intake system of the internal combustion engine such as an engine. The compressor wheel 6 is accommodated in an inner central portion of the compressor cover 7. The compressor wheel 6 is connected to one end of a rotor shaft of the electric motor 3 to be rotationally driven.
(11) The electric motor 3 is provided with a stator 9 (a stator) which is fixed to the interior of the motor housing 8 and a rotor shaft 10 (a rotator) which is rotatable around the rotor shaft 10. Inside the motor housing 8, the rotor shaft 10 is supported by rolling bearings 12a and 12b from both sides thereof to be rotatable around the rotation shaft.
(12) Particularly in this embodiment, used as the rolling bearings 12a and 12b are grease enclosed rolling bearings with seal which are provided with grease leakage prevention measures at high rotation speed. By using the grease enclosed rolling bearings with seals as described above, it is no longer necessary to supply lubricating oil from outside of the electric supercharging apparatus 1 (e.g. from the engine) as in the case of using rolling bearings of oil-lubricated type. Thus, it is possible to omit an introduction path for lubricating oil and also simply the internal structure of the electric motor 3.
(13) In this embodiment, described is a two-end support type where both ends of the rotor shaft 10 of the electric motor 3 are respectively supported by the rolling bearings 12a and 12b. This is, however, not limitative and the present invention is also applicable to a one-end support type where only one end of the rotor shaft 10 is supported by a rolling bearing.
(14) If the lubricating oil is used in the rolling bearing 12, the lubricating oil is supplied from the engine or the like and thus, it is necessary to arrange the electric supercharging apparatus 1 at a position near the engine, where it is subjected to high temperature and frequent vibration. However, by using the grease enclosed rolling bearing described in this embodiment, supply of the lubricating oil is no longer necessary and thus, the installation location of the electric supercharging apparatus 1 is not subject to the above limitation. Therefore, the electric supercharging apparatus 1 can be mounted to a vehicle body or the like with little vibration and good ventilation which is far from the engine and suitable for cooling. This improves the degree of freedom of installation layout.
(15) Further, the electric power energy supplied from the inverter unit 4 is mainly used to drive the electric motor 3 and is at least in part converted into heat energy as heating. In particular, heat generation is likely to occur in a motor coil 11 under high loads and acceleration of the electric motor 3 and thus, cooling thereof is important. In the present embodiment, cooling passages are formed in the motor housing 8, and cooling is performed by the outside air introduced to the cooling passages as described below.
(16) In the motor housing 8, a gas supply port 13 and a gas outlet 14 are formed to introduce and discharge the outside air into and from the cooling passage. The gas supply port 13 is provided on the side of the motor housing 8 facing the inverter unit 4, and a plurality of the supply ports is formed corresponding to the inlets of the first cooling passage and the second cooling passage which are described later (in
(17) An intake passage 15 is an example of the first intake passage according to the present invention. The intake passage 15 is provided so as to connect the gas discharge port 14 and the negative-pressure outlet port 16 which is formed by opening a hole on the side of the compressor cover 7. The intake passage 15 is, for example, made of a tubular member such as a rubber hose, but the material is not particularly limited. On the side wall of the compressor cover 7, the negative-pressure outlet port 16 is formed so as to communicate with the interior of the compressor cover 7, and the negative pressure generated inside the compressor cover 7 is drawn out from one end of the intake passage 15 by rotation of the compressor wheel 6. The other end of the intake passage 15 is connected to the gas discharge port 14 provided in the motor housing 8 and is configured so that the negative pressure is applied to the cooling passage formed inside the motor housing 8 from the gas discharge port 14.
(18) The gas supply port 13 communicates with the gas discharge port 14 inside the motor housing 8 via the first cooling passage 17, and the first cooling passage 17 is formed along the motor coil 11 in the stator 9. This first cooling passage 17 communicates with the intake passage 15 via the gas discharge port 14. As the negative pressure transmitted from the negative-pressure outlet port 16 is applied to the first cooling passage 17, the outside air is drawn into the first cooling passage 17 from the gas supply port 13. The outside air introduced into the first cooling passage 17 flows through the motor housing 8 as indicated by arrows in
(19) The first cooling passage 17 is formed as described above to extend along the motor coil 11 which generates a large amount of heat, and thus by allowing the flow of the outside air therein, good cooling performance can be obtained. In particular, the outside air is introduced by the negative pressure of the compressor 2 without an energy-consuming structure such as a pump and thus, it is possible to effectively cool the interior of the motor housing 8 which generates a large amount of heat, with a simple configuration in the present invention. The air introduced into the first cooling passage 17 is not supercharged air of high temperature but is the outside air. Thus, it is possible to obtain an excellent cooling effect.
(20) Referring to
(21) Further, as illustrated in
(22) The shape, number and area of the first cooling passage 17 illustrated in
(23) Returning to
(24) Generally, there is at least a small gap formed around the rotor shaft 10 to prevent contact (or collision) with the peripheral member when the rotor shaft 10 is rotated. The second cooling passage 18 is configured to also serve as the gap, and by applying a negative pressure to the second cooling passage 18, the outside air is introduced from the gas supply port 13 into the second cooling passage 18, thereby cooling the vicinity of the rotor shaft 10 to which the heat is easily transferred from the motor coil 11 and the stator 9 with high heat value. Further, the second cooling passage 18 is reduced in pressure by the negative pressure applied thereto and thus, it is possible to reduce air resistance of the rotor shaft 10, thereby also reducing the windage loss simultaneously.
(25) The second cooling passage 18 joins the first cooling passage 17 inside the motor housing 8, and the negative pressure is applied to the second cooling passage 18 as well as the first cooling passage 17 from the intake passage 15, thereby introducing the outside air from the gas supply port 13. By configuring the first cooling passage 17 and the second cooling passage 18 so as to join together in the motor housing 8, it is possible to introduce the outside air into these two cooling passages 17 and 18 by applying the negative pressure by means of a single intake passage 15. As a result, it is possible to obtain a large cooling effect with a simple structure.
(26) Further, the second cooling passage 18 is formed so as to run through the periphery of the rolling bearing 12 supporting the rotor shaft 10. Furthermore, the second cooling passage 18 is configured to cool the rolling bearing 12 in addition to the rotor shaft 10. The interior of the electric motor 3 is basically made of a metal material having good thermal conductivity and thus, the heat is easily transferred to the rolling bearing 12 from the motor coil 11 side and the temperature rises easily. In the present embodiment, by providing the second cooling passage 18 passing through the rolling bearing 12 as well as the rotor shaft 10, it is possible to realize efficient cooling of these parts with simple configuration.
(27) In the intake passage 15, a control valve 19 for adjusting the opening of the intake passage 15 is provided. The control valve 19 is an example of a first control valve according to the present invention, and by adjusting the opening degree of the control valve 19, the flow rate of the gas through the intake passage 15 is regulate, and the value of the negative pressure transmitted to the first cooling passage 17 and the second cooling passage 18 is controlled. As a result, the flow rates of the gas in the first cooling passage 17 and the second cooling passage 18 are adjusted to perform the cooling according to the heat value of the motor coil 11.
(28) The opening degree of the control valve 19 is adjusted based on a control signal from a controller 20. The controller 20 is an example of the controller according to the present invention. For instance, the temperature of the motor coil 11 which is a cooling object is detected by a temperature sensor (not shown) attached to the motor coil 11 and the control signal is transmitted to the control valve 19 based on the detection value so as to adjust the opening degree of the control valve 19. In the present invention, cooling is performed by drawing in the outside air by applying the negative pressure to the first cooling passage 17 and the second cooling passage 18, and as the negative pressure is applied from the inlet port 5 of the compressor 2, the supercharging efficiency of the compressor 2 decreases to some extent. However, by adjusting the opening degree of the control 19 appropriately in accordance with the temperature of the motor coil 11 in the above manner, it is possible to avoid application of the negative pressure more than necessary. Therefore, it is possible to prevent decline of the supercharging efficiency of the compressor 2 and perform efficient cooling inside the electric motor 3. Typically, it is preferable to introduce the outside air by adjusting the control valve 19 so that the temperature of the motor coil 11 is in the range of 150 to 200 C.
(29) In the above described case, the opening degree of the control valve 19 is controlled based on the detection value of the temperature sensor attached to the motor coil 11, but a control example is not limited to this. For example, if it is difficult to install the temperature sensor to the motor coil 11, the temperature sensor may be installed in other location and estimate the temperature of the motor coil 11. Alternatively, the temperature sensor may be installed in the inverter unit 4 which is another component that easily generates heat, or the opening degree of opening degree of the control valve 19 may be controlled based on parameters other than the temperature, such as the motor rotation speed.
(30) The inverter unit 4 is attached to the side of the motor housing 8 where the gas supply port 13 is formed, and the element circuit board 22 is accommodated in the inverter housing 21. The element circuit board 22 is incorporated with elements constituting the inverter circuit and is vertically fixed to the inside of the inverter housing by a support (not shown). By providing a plurality of through holes in the element circuit board 22 and fixing the element circuit board 22 to the support, the outside air passes through the inverter unit 4 and then enters the first cooling passage 17 and the second cooling passage 18 smoothly from the gas supply port 13 provided in the motor housing 8.
(31) Particularly, an air hole 23 is formed in the element circuit board 22 at a location corresponding to the gas supply port 13 provided in the motor housing 8. Further, an opening hole 24 is formed in the inverter housing 21 at a location corresponding to the air hole 23. As a result, it is configured so that the outside air can be introduced more smoothly to the first cooling passage 17 and the second cooling passage 18 from the outside of the inverter unit 4.
(32) Cooling pins 25 are provided on the side wall surface of the inverter housing 21 and motor housing 8. The cooling pins 25 serve as radiating fins. By increasing the surface area of the side wall surface for contact with the outside air, heat dissipation is improved, thereby further enhancing the above cooling performance.
(33) The suction force of the negative pressure for drawing in the outside air weakens if the above-described cross-sectional areas of the first cooling passage 17 and the second cooling passage 18 are set wide. Thus, the cross-sectional areas of the first cooling passage 17 and the second cooling passage 18 are arbitrarily set according to the cooling performance required by the electric motor 3, the value of the negative pressure at the inlet port 5, etc. More specifically, from the viewpoint of increasing the suction force for drawing in the outside air, it is preferable to set the cross-sectional areas of the first cooling passage 17 and the second cooling passage 18 as small as possible.
(34) In the case where it is difficult to apply a sufficient negative pressure to the first cooling passage 17 and the second cooling passage 18 using a single gas discharge port 14, a plurality of the gas discharge ports 14 may be provided in the motor housing 8 and each of the gas discharge ports 14 may be connected to a separate suction passage.
(35) As described above, according to the electric supercharger 1 of the present embodiment, by applying a negative pressure from the intake passage 15 to the cooling passages 17 and 18, it is possible to introduce the outside air from the gas supply port 13 and cool the peripheral part of the cooling passages 17 and 18 which easily produce heat. In the electric supercharger apparatus 1 according to this embodiment, the outside air is introduced using the negative pressure of the compressor 2 without the configuration that accompanies energy consumption, such as a pump. Thus, the interior of the motor housing 8 with a large calorific value can be effectively cooled with the simple structure. Particularly, as the outside air is introduced to the cooling passages 17 and 18, instead of supercharged air of high temperature, excellent cooling effect can be achieved. Especially, the second cooling passage 18 is reduced in pressure by the negative pressure applied thereto and hence, air resistance of the rotor shaft is reduced. As a result, it is possible to achieve reduction of windage loss at the same time.
Second Embodiment
(36)
(37) In the second embodiment, an auxiliary vacuum pump 26 not shown (hereinafter referred to as negative pressure pump 26) for the engine (not shown) to which the electric supercharging apparatus 1 supercharges, the negative pressure is supplied to the gas exhaust port 14 and the outside air is introduced into the first cooling passage 17 and the second cooling passage 18 to perform the cooling. The negative pressure pump 26 is connected to the gas discharge port 14 via the second intake passage 27, and a second control valve 28 is for adjusting an opening degree is provided in the second intake passage 27. Together with the first control valve 19, the opening degree of the second control valve 28 is controlled by the controller 20 so as to adjust the negative pressure value transmitted to the first cooling passage 17 and the second cooling passage 18.
(38) Herein, a control example of the second embodiment is described in details. First, it is assumed that the second control valve 28 is basically set to closed and that application of the negative pressure to the first cooling passage 17 and the second cooling passage 18 is performed using the first control valve 19. In such a case, the temperature inside the motor housing 8 rises depending on the operating state of the electric motor 3 and it is sometimes difficult to obtain the cooling performance required for cooling solely by the negative pressure from the negative pressure outlet port 16 (That is, it may not be possible to introduce enough outside air into the first cooling passage 17 and the second cooling passage 18 solely by the negative pressure from the negative pressure outlet port 16). In such a case, the controller 20 controls the second control valve 28 to open so as to make up shortage of the negative pressure from the negative pressure outlet port 16 with the negative pressure from the negative pressure pump 26.
(39) In the present embodiment, by providing a plurality of negative pressure supply sources (the negative pressure outlet port 16 and the negative pressure pump 26), if enough outside air cannot be introduced by the negative pressure from one of the negative pressure supply sources, the negative pressure from the other can be supplied supplementarily so as to enhance the cooling performance. This type of control for the first control valve 29 and the second control valve 28 may be performed by detecting a temperature of the motor coil 11, the element circuit board 22 in the inverter unit 4, etc. using a temperature sensor such as a thermistor and a thermocouple and adjusting the opening degree of each of the first control valve 29 and the second control valve 28 based on the detection value.
Third Embodiment
(40) Next, in reference to
(41) The electric 2-stage supercharging system according to the present embodiment comprises a turbocharger 110 on a low pressure side (a downstream side) as a supercharging unit for the engine 100. The turbocharger 110 has a compressor 112 which operates in conjunction with an exhaust turbine 111 driven by the exhaust gas from the engine 100. Further, the electric supercharging apparatus 1 which is powered by the electric motor described in the above embodiments is provided on a high pressure side (an upstream side). On the exhaust turbine 11 side of the turbocharger 110, a wastegate valve 113 is provided. On the intake side of the electric supercharging apparatus 1, a bypass passage 121 equipped with a bypass valve 120 is provided. Further, the compressed gas discharged from the electric supercharging apparatus 1 arranged on the high pressure side is cooled by an intercooler 130 and then supplied to the engine 100.
(42) In this electric 2-stage supercharging system, the compressed gas is supercharged in the turbocharger and then further compressed in the electric supercharging apparatus 1. The compressed gas undergoes two stages of supercharging, and the supercharging pressure can be enhanced. As a result, compared to the case where only the turbocharger 110 is provided as a supercharging unit, it is possible to obtain high supercharging pressure and thus, it is possible to realize the system capable of performing even when the required output is large, such as during acceleration.
(43) In this embodiment, the negative pressure outlet port 16 (see
(44) In the case shown in
(45) Further, as described above, by using the grease-enclosed rolling bearing as the rolling bearing 12 for supporting the rotor shaft 10 of the electric motor 3 belonging to the electric supercharging apparatus 1, unlike the case of the rolling bearing using the lubricating oil, the engine 100 does not need to be supplied with lubricating oil. Therefore, the electric supercharging apparatus 1 does not need to be installed near the engine 100 in consideration of the supply of the lubricating oil and can be mounted on a place away from the engine, such as a vehicle body, with less vibration and breathability which is suitable for cooling. More preferably, by arranging the electric supercharging apparatus 1 near the power supply system such as a battery, wiring resistance is less which leads to improved performance. There is an advantage that the electric supercharging apparatus 1 according to the present invention has less restricted installation position within the vehicle body as described above and high flexibility of the layout.
INDUSTRIAL APPLICABILITY
(46) The present invention is applicable to an electric supercharging apparatus and a multi-stage supercharging system using the electric supercharging apparatus, which is driven by an electric motor for supercharging an internal combustion engine such as an engine.
REFERENCE SIGNS LIST
(47) 1 Electric supercharging apparatus 2 Compressor 3 Electric motor 4 Inverter unit 5 Inlet port 6 Compressor wheel 7 Compressor cover 8 Motor housing 9 Stator 10 Rotor shaft (Rotator) 11 Motor coil 12 Rolling bearing 13 Gas supply port 14 Gas discharge port 15 Intake passage (First intake passage) 16 Negative pressure outlet port 17 First cooling passage 18 Second cooling passage 19 Control valve (First control valve) 20 Controller 21 Inverter housing 22 Element circuit board 23 Air hole 24 Opening hole 25 Cooling pin 26 Negative pressure pump 27 Second intake passage 28 Second control valve 100 Engine 110 Turbocharger 111 Exhaust turbine 112 Compressor 113 Waste gate valve 120 Bypass valve 121 Bypass passage 130 Intercooler