CN107785841B

CN107785841B - Support for at least one busbar, method for the production thereof and component arrangement having the same

Info

Publication number: CN107785841B
Application number: CN201710739323.6A
Authority: CN
Inventors: 马库斯·艾希纳; 克里斯托夫·霍伊曼; 克里斯托夫·霍勒尔; 亚历克斯·米勒
Original assignee: Valeo Siemens eAutomotive Germany GmbH
Current assignee: Valeo eAutomotive Germany GmbH
Priority date: 2016-08-25
Filing date: 2017-08-24
Publication date: 2021-07-16
Anticipated expiration: 2037-08-24
Also published as: DE102016216007A1; CN107785841A

Abstract

The invention relates to a support (1) for at least one busbar (2), comprising: at least one fixing element (10) for fixing at the electronic module (9); a first receptacle (3) adapted to the contour of the busbar and a second receptacle (4) for a laminar magnetic flux guide (5). The flux guide (5) arranged in the second receptacle (4) surrounds the busbar (2) arranged in the first receptacle (3) at least in sections on the edge. An electrically insulating section (6) is arranged between the busbar (2) and the flux guide (5). The invention also relates to a component arrangement (13) for power electronics, comprising at least one busbar (2), a magnetic flux guide (5) and such a support (1), and to a method for producing such a support (1).

Description

Support for at least one busbar, method for the production thereof and component arrangement having the same

Technical Field

The invention relates to a support for at least one busbar, a component arrangement for power electronics having such a support, and a method for producing such a support.

Background

Power electronics are used, for example, in electrically driven motor vehicles, in the field of which it is known to transmit electric current by means of a busbar. For example, in the context of regulating and/or controlling electrical components of an electrically driven vehicle, in particular in the context of controlling an electric motor used as an electric drive, the intensity of the current flowing in the busbar must be measured and, if appropriate, monitored. The detection of the current strength is carried out, for example, by using the hall effect by means of a so-called hall sensor. The hall sensors are typically combined with a flux compression device or flux guide that is constructed of a high permeability material and is placed in close proximity to the current carrying bus bar to cause compression of the flux density. The measurement accuracy of the current measurement, which is carried out by means of the hall sensor via a contactless measurement of the magnetic field, can thus be improved. However, when the position of the hall sensor relative to the flux guide changes, the measurement results are distorted, so that a separate holder is typically required in order to reliably hold the hall sensor in the desired position. Such a vibration-resistant fastening is desirable in particular in the case of motor vehicle applications.

Disclosure of Invention

The purpose of the invention is: the current guided in the busbar is measured in a manner and method suitable for mass production.

In terms of the device, the object is achieved by a support or a component arrangement for power electronics having the support according to the invention.

A rack for at least one busbar comprising: at least one fixing element for fixing at a housing portion for an electronic module; a first housing portion that matches the contour of the busbar and a second housing portion for a flux guide of a sheet (blechfoermig). The second receptacle is designed such that the flux guide element arranged in the second receptacle at least partially (abschnittweise) surrounds the busbar arranged in the first receptacle on the edge side.

It is therefore proposed: the current measuring device is integrated in a holder for the busbar. The support is provided for fastening the at least one busbar to an electronic module, which for example comprises a plurality of components, in particular semiconductor elements, and/or current sensors, for example hall sensors, which are connected to one another on a circuit board and which perform evaluation logic operations for the measured values provided by the current sensors or hall sensors. The holder has at least one fastening element, for example a pin or a sleeve for a separate fastening element, which is arranged in particular at a predetermined distance from the second receptacle provided for the flux guide, so that the flux guide is in a position that is always reproducible when the holder is mounted on the electronic module. In other words, the at least one busbar is indirectly connected with the electronic module via the housing portion. The position and orientation of the flux guide relative to the electronic module have only very low tolerances, so that the current sensor, in particular the hall sensor, can thus be integrated directly in the electronic module. For the positionally precise arrangement, no additional components, in particular additional holders for the flux guides, are required, so that the component complexity and the installation effort are reduced. Furthermore, the available installation space is optimally used.

This embodiment is particularly impact-and shock-resistant, so that the current intensity of the current flowing in the at least one busbar can be measured with high accuracy even under difficult operating conditions. The device proposed by the invention is therefore particularly suitable for power electronics of electrically driven motor vehicles, for example for circuit arrangements which interact with a power semiconductor module which assumes the function of a rectifier for the electric drive of the motor vehicle as part of a motor control system.

Preferably, the magnetic flux guide is substantially U-shaped and is arranged in relation to the busbar in such a way that the magnetic flux guide extends past one of the two flat sides of the busbar. The magnetic flux guide is therefore oriented substantially at least segment by segment along the magnetic field lines surrounding the busbar in order to optimize the compression of the magnetic flux and thus the measurement accuracy. Furthermore, the flux guide can be arranged in a particularly simple manner with respect to the already installed busbar due to the U-shaped structure which is open to one side. In particular, the assembly is simplified in relation to a closed magnetic flux compression device which completely surrounds the busbar.

Between the bus bar and the magnetic flux guide, a lower section of the holder is preferably arranged, which electrically insulates the bus bar and the magnetic flux guide from one another.

The flux guide is preferably made of a high permeability material, for example soft iron or of a sintered material.

Particularly preferably, the carrier is formed by injection molding at least one busbar with plastic. The positive and material-locking connection between the holder and the busbar is thus produced in one production step, in order to minimize production costs. In particular, the subsequent bonding of the busbar to the carrier can thus be dispensed with. The flux guide can be connected to the bracket, for example, by means of a locking connection. The locking means required for this purpose, such as, in particular, locking shoulders or the like, are preferably provided on the carrier itself and are particularly preferably formed during injection molding of the carrier.

The fastening element is preferably also a sleeve integrated in the carrier, in which sleeve, for example, a fastening screw is guided, which engages into the housing part carrying the electronic module for fastening the carrier to the electronic module.

According to a preferred embodiment, a plurality of first receptacles for busbars and corresponding second receptacles for flux guides are arranged alongside one another. In a particularly preferred embodiment, three busbars are guided next to one another in a single carrier, which has one or more fastening elements for connecting to an electronic module. Such an embodiment can be designed in particular for the transmission of three-phase alternating current. In order to detect the current intensity, a flux guide is assigned to each busbar provided for transmitting a phase. The three-phase alternating current can be provided, for example, by an inverter of the power electronics and transmitted to an electric drive of the motor vehicle by means of the busbar.

An electrically driven motor vehicle is understood to mean a motor vehicle which has at least one electric drive which is designed for the propulsion of the motor vehicle. This definition includes, in particular, so-called hybrid vehicles, in which an internal combustion engine is typically provided in addition to an electric drive.

Preferably, a locking mechanism and/or at least one pressing element for non-positively and/or positively fixing the magnetic flux guide at the holder is provided. Particularly preferably, the locking mechanism and/or the pressing element are integrated in the holder. The flux guide is fixed in the second receptacle of the holder by pressing in, wherein the flux guide and/or the holder are slightly clamped and then clamped in a force-fitting and, if applicable, a form-fitting manner.

The component arrangement for power electronics, in particular for electrically driven motor vehicles, comprises at least one busbar and a magnetic flux guide, the position of which is fixed in a positionally fixed manner relative to the electronic module by means of the above-described support. The at least one busbar, the flux guide and the electronic module are connected at least indirectly via a housing part carrying the electronic module. The advantages obtained thereby result directly from the description so far. Thus, for example, the arrangement of the magnetic flux guide relative to the electronic module or a current sensor or a hall sensor of the electronic module is fixedly predefined, thereby ensuring the required measurement accuracy.

In a preferred embodiment, at least one end of the flux guide projects laterally from the second receptacle. In the region of the laterally projecting end, a hall sensor is arranged for measuring the current flowing through the busbar. For this purpose, the hall sensor is arranged in a contactless manner in the immediate vicinity of the protruding end. The hall sensor can be designed as a one-dimensional or multidimensional hall sensor.

In a development of the invention, provision is made for two opposite ends of the flux guide each to project laterally from the second receptacle. A hall sensor is arranged on each laterally projecting end. The sensors provide redundant measurements to at least reduce the probability of a complete failure due to a fault. An alternative measuring method is the exemplary embodiment with a plurality of hall sensors in the busbar provided for current measurement. Thus, for example, differences in the detected measured values can be formed in order to draw conclusions about the reliability of the determined current strength.

In terms of method, the previously set object is solved by a method for manufacturing a stent as already described.

For producing the carrier, the at least one busbar is inserted into an injection molding tool, which has a complementary shape to the carrier. In a subsequent injection molding process, the injection molding tool or the injection mold is filled with a plastic material.

The bracket is therefore formed directly on the busbar at the predetermined location, wherein a form-and material-locking connection to the busbar is already formed during the injection molding, in order to minimize the production costs. Additional method steps for connecting the bus bar to the carrier can be eliminated.

In particular, it is preferred that, during the injection molding, locking means, for example locking shoulders, locking hooks or the like, are formed at the same time, which serve to fix the flux guide in a form-fitting manner in the second receptacle at the bracket.

In an alternative method for producing a carrier, the at least one busbar together with the magnetic flux guide is inserted into an injection molding tool, which is filled with a plastic material during a subsequent injection molding. In this embodiment, the positive and material-locking connection between the carrier and the at least one busbar and between the carrier and the flux guide is formed in a single production step.

Drawings

For further description of the invention, reference is made to the embodiments illustrated in the drawings. It is shown in schematic view:

figure 1 shows a perspective view of a rack for a plurality of busbars arranged alongside one another,

figure 2 shows a perspective view of a component arrangement comprising a carrier and an electronic module,

FIG. 3 shows a sectional view of a holder for a single busbar, an

Fig. 4 shows another cross-sectional view of the stent.

Parts that correspond to each other are provided with the same reference numerals throughout the figures.

Detailed Description

Fig. 1 and 2 show perspective views of a rack 1, in which three busbars 2 are correspondingly guided in a first receptacle 3. The busbars 2 are arranged alongside one another such that their flat sides are each aligned in a plane. The bus bar 2 extends at right angles in the exemplary embodiment shown, wherein the laterally projecting end of the bus bar 2, which is shown in fig. 1 at the lower edge of the carrier 1, is connected in the mounted state to a power semiconductor module, which comprises a plurality of connected power semiconductors, in particular bipolar transistors (IGBTs) having insulated gates. In terms of manufacturing technology, the joining is preferably performed by means of butt welding.

The busbar 2 is held in the first receptacle 3 with a material fit. The holder 1 further comprises a second receptacle 4 which is slit-shaped and is arranged in the region of the first receptacle 3. In the second receptacles 4, magnetic flux guides 5 are arranged in each case, which have a U-shaped outer shape and extend around a part of the outer circumferential surface of the respective busbar 2. Between the magnetic flux guide 5 and the busbar 3 there is an electrically insulating section 6 of the holder 1, which is made of plastic. The magnetic flux guide 5 is pressed into the second receptacle 4 in a positive and non-positive manner and is fixed by means of a locking mechanism, not shown in detail, which has the shape of a locking shoulder.

The flux guide 5 is formed from a high-permeability material, in the example shown by way of example from soft iron, and serves in a known manner and method for compressing the flux density, so that the current guided in the respective busbar 2 can be detected particularly precisely via the magnetic field measuring device.

The ends 7 of the U-shaped flux guide 5 each project laterally from the second receptacle 4. In each case a hall sensor 8 is arranged in this region, the position of which is shown in fig. 2. The hall sensor 8 is connected as part of an electronics module 9 with other electronic components on the circuit board.

The position of the hall sensor 8 arranged on the circuit board relative to the free end 7 of the magnetic flux guide 5 is provided by a fixing element 10, which in the embodiment shown is a sleeve 11. In the sleeve 11, fastening screws, not shown in detail, are guided, which engage into the housing part, to which the electronic module 9 is also fastened. The support 1 is therefore screwed as shown in fig. 1 to a housing part which accommodates the electronic module 9, so that the position and orientation of the hall sensor 8, which is coupled contactlessly to the magnetic flux guide 5, is fixed in a defined manner and method. The busbars 2 guided in the carrier 1 combine with the electronic modules 9 to form a crash-and shock-resistant component arrangement 13 which ensures reliable detection of the current intensity flowing in the respective busbar 2.

In particular, the embodiments shown in the figures are for use in electrically driven motor vehicles. The embodiment of fig. 1 or 2 with three bus bars 2 shown serves for supplying alternating current to an electric motor, which is designed for propelling a motor vehicle. An electronic module 9 with hall sensors 8 measures the current intensity flowing in the respective busbar 2 separately for each phase.

Fig. 3 shows a schematic cross-sectional view of another embodiment of the invention. Only a single bus bar 2 is guided in the illustrated rack 1. Furthermore, the illustrated embodiment corresponds to the first example of fig. 1 and 2. In particular, the U-shaped magnetic flux guide 5 is pressed into the first receptacle 4 such that the end 7 protrudes from the bracket 1 on the edge side. The flux guide 5 is held in a force-fitting manner by pressure elements 14 which are arranged in each case on opposite sides of the flux guide 5. When the magnetic flux guide 5 is pressed into the holder 1, the magnetic flux guide grips in one direction and is thus clamped in the receptacle 5.

In the direction extending perpendicular to the drawing plane of fig. 3, the flux guide 5 is held in a positive and/or non-positive manner by a locking mechanism, which in the exemplary embodiment shown in fig. 4 is embodied as a locking shoulder, which overlaps the rear edge of the upper part of the flux guide 5.

The pressing element 14 and the locking mechanism 15 are formed integrally with the holder.

The carrier 1 is a plastic extruded encapsulation of one or more busbars 2, i.e. the carrier 1 is produced by means of an injection molding method, wherein the busbars 2 are inserted into an injection molding tool during the shaping of the carrier 1, which is subsequently filled with plastic. During the injection molding, a locking mechanism and a pressing element are formed to fix the magnetic flux guide 5 at the bracket 1, i.e. the locking mechanism is integrated in the bracket 1. The flux guide 5 is then pressed into the holder 1 thus produced, which in turn produces plastic deformation of the holder 1.

Although the invention has been illustrated and described in detail by means of preferred embodiments, the invention is not limited to the disclosed examples and other variants can be derived therefrom by the person skilled in the art without departing from the scope of protection of the invention.

Claims

1. A rack (1) for at least one busbar (2), comprising: at least one fixing element (10) for fixing at a housing portion for an electronic module (9); a first receptacle (3) adapted to the contour of the busbar and a second receptacle (4) for a laminar magnetic flux guide (5), which second receptacle is such that the magnetic flux guide (5) arranged in the second receptacle (4) at least partially surrounds the busbar (2) arranged in the first receptacle (3) on the edge side, wherein the holder (1) is provided for fixing the at least one busbar (2) at the electronic module (9), wherein the carrier (1) is formed by injection-molding at least one of the bus bars (2) with plastic, wherein a locking mechanism (15) for fixing the magnetic flux guide (5) in a non-positive and/or positive manner and/or at least one pressing element (14) are provided, wherein the magnetic flux guide (5) is pressed into the bracket (1).

2. The rack (1) according to claim 1, characterized in that the flux guide (5) is configured in a U-shape and is arranged in relation to the busbar (2) in such a way that the flux guide (5) extends past one of the two flat sides of the busbar (2).

3. A bracket (1) according to claim 1 or 2, characterized in that the flux guide is made of a high permeability material.

4. Stent (1) according to claim 1 or 2, wherein the fixing element (10) is a sleeve (11) integrated in the stent (1).

5. Stent (1) according to claim 3, wherein the fixing element (10) is a sleeve (11) integrated in the stent (1).

6. The rack (1) according to claim 1 or 2, characterized in that a plurality of said first housings (3) for the busbars (2) and the corresponding second housings (4) for the flux guides (5) are arranged alongside one another.

7. The rack (1) according to claim 5, characterized in that a plurality of said first housings (3) for the busbars (2) and the corresponding second housings (4) for the flux guides (5) are arranged alongside one another.

8. Support (1) according to claim 7, characterized in that a locking mechanism (15) and/or at least one pressing element (14) for non-positively and/or positively fixing the flux guide (5) is provided.

9. A component arrangement (13) for power electronics, comprising at least one busbar (2) and a flux guide whose position is fixed in relation to an electronic module (9) by means of a holder (1) according to any one of the preceding claims.

10. Component arrangement (13) according to claim 9, characterized in that the power electronics are power electronics for an electrically driven motor vehicle.

11. Component arrangement (13) according to claim 9, characterized in that at least one end (7) of the magnetic flux guide (5) projects laterally from the second receptacle (4) and in the region of the laterally projecting end (7) a hall sensor (8) is arranged for measuring the current flowing through the busbar (2).

12. A method for manufacturing a bracket (1) according to any one of claims 1 to 7, characterized in that at least one busbar (2) is inserted into an injection moulding tool which has a complementary shape to the bracket (1) and which is filled with plastic material at the subsequent injection moulding.

13. Method according to claim 12, characterized in that, during injection molding, a locking mechanism (15) is formed for non-positively and/or positively fixing a magnetic flux guide (5) in the second receptacle (4) at the bracket (1).

14. Method according to claim 12 or 13, characterized in that at the time of injection molding at least one pressing element (14) is formed for non-positively fixing the magnetic flux guide (5) at the holder (1).

15. Method according to claim 14, characterized in that the pressing element serves for non-positively fixing the magnetic flux guide (5) in the region of the second receptacle (4).