CN109600052B - 电力变换器的车载构造 - Google Patents

电力变换器的车载构造 Download PDF

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CN109600052B
CN109600052B CN201811086027.1A CN201811086027A CN109600052B CN 109600052 B CN109600052 B CN 109600052B CN 201811086027 A CN201811086027 A CN 201811086027A CN 109600052 B CN109600052 B CN 109600052B
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power converter
casing
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CN109600052A (zh
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城岛悠树
岩田秀一
山崎宏美
山葺伦央
井村仁史
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Toyota Motor Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
    • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
    • B60K6/22—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
    • B60K6/40—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the assembly or relative disposition of components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/51—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells characterised by AC-motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H02M3/1584—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load with a plurality of power processing stages connected in parallel
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/02—Conversion of dc power input into dc power output without intermediate conversion into ac
    • H02M3/04—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters
    • H02M3/10—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • H02M3/1588—Conversion of dc power input into dc power output without intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load comprising at least one synchronous rectifier element
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
    • H05K7/1427—Housings
    • H05K7/1432—Housings specially adapted for power drive units or power converters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
    • B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
    • B60K2001/0411—Arrangement in the front part of the vehicle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2210/00—Converter types
    • B60L2210/10—DC to DC converters
    • B60L2210/14—Boost converters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2306/00—Other features of vehicle sub-units
    • B60Y2306/01—Reducing damages in case of crash, e.g. by improving battery protection
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2207/00—Indexing scheme relating to details of circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J2207/20—Charging or discharging characterised by the power electronics converter
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2310/00—The network for supplying or distributing electric power characterised by its spatial reach or by the load
    • H02J2310/40—The network being an on-board power network, i.e. within a vehicle
    • H02J2310/48—The network being an on-board power network, i.e. within a vehicle for electric vehicles [EV] or hybrid vehicles [HEV]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/14—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
    • H02J7/1423—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle with multiple batteries
    • Y—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
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Abstract

本说明书公开了一种电力变换器的车载构造，在电力变换器中，分别包含电抗器的多个电压转换电路以并联方式连接。电力变换器(10)具备主箱体(12)和副箱体(13)，主箱体(12)容纳有至少一个电抗器和电压转换电路的开关元件，副箱体(13)容纳有其余的电抗器。主箱体(12)在前舱(99)经由托架(45、46a、46b)在下方设置有空隙SP地固定于车体。副箱体(13)以与主箱体(12)对齐前端的方式连结于主箱体(12)的车宽度方向上的侧方。

Description

电力变换器的车载构造
技术领域
本说明书所公开的技术涉及电力变换器的车载构造，在该电力变换器中分别包含电抗器的多个电压转换电路以并联方式进行连接。
背景技术
电动汽车具备将直流电源的电力变换为行驶用马达的驱动电力的电力变换器。电力变换器通常搭载于车辆的前舱(front compartment)。电力变换器中有具备以并联方式连接的多个电压转换电路的类型(例如专利文献1)。电压转换电路是斩波器类型(choppertype)，各个电压转换电路包含电抗器。由于电抗器的发热量大，所以通过多个电压转换电路的并联连接，能够抑制各电抗器的负荷(发热量)。另外，例如在专利文献2中公开了将电力变换器固定在变速器上并且仅将电抗器容纳在变速器的箱体内的技术。电抗器与齿轮一起被变速器内的制冷剂冷却。
现有技术文献
专利文献1：日本特开2006-33934号公报
专利文献2:US2014/0175867号公报
发明内容
构成电压转换电路的部件中，电抗器尤为体型大。另一方面，电力变换器除了具备电抗器以外还具备电压转换电路的开关元件、控制基板等部件。若想要将多个体型大的电抗器和其他各种部件容纳在一个箱体中，则箱体内部的空间会产生浪费，箱体会大型化。在该情况下，考虑将几个电抗器容纳于其他的箱体。例如，将能够尽可能高空间效率地配置的数目的电抗器和开关元件等一起容纳于主箱体中。无法高空间效率地容纳于主箱体的其余的电抗器容纳于其他的箱体(副箱体)，并用电缆将两者进行连接。这样一来，能够得到以主箱体和副箱体整体提高了空间效率的电力变换器。
另一方面，在将上述的主箱体和副箱体搭载于车辆的前舱的情况下，存在若因碰撞的冲击导致副箱体与主箱体分离则连接着两者的电缆会切断的担忧。向与电抗器连接的电缆施加了马达驱动用高电压。不希望被施加了高电压的电缆被切断。关于将被施加了高电压的电抗器容纳于副箱体的电力变换器，提供一种在碰撞时副箱体不易与主箱体分离的车载构造。
本说明书公开一种电力变换器的车载构造，在该电力变换器中，分别包含电抗器的多个电压转换电路以并联方式进行连接。电力变换器具备主箱体和副箱体，主箱体容纳有至少一个电抗器和电压转换电路的开关元件，副箱体容纳有其余的电抗器。主箱体在前舱经由托架在下方设置有空隙地被固定于车体。副箱体以与主箱体对齐前端的方式连结于主箱体的车宽度方向上的侧方。
在本说明书所公开的车载构造中，主箱体以在下方设置有空隙的方式固定于车体，副箱体以对齐前端的方式连结于主箱体的侧方。通过将主箱体和副箱体的前端对齐，在障碍物从前方碰撞了时由主箱体和副箱体双方承受碰撞载荷，将载荷分散，减少各箱体所受的损伤。另外，通过以在下方设置有空隙的方式将箱体支承于车体，由此确保受到了冲击的箱体(主箱体和副箱体)能够后退的余地，缓和碰撞的冲击。特别是通过将主箱体和副箱体的前端对齐而两者一起后退，所以能够降低副箱体从主箱体脱离的可能性。
本说明书所公开的技术的详细内容和进一步的改进，将在下面的“具体实施方式”中进行说明。
附图说明
图1是应用了实施例的车载构造的电动汽车的电力系统的框图。
图2是对实施例的车载构造进行说明的俯视图。
图3是对实施例的车载构造进行说明的侧视图。
图4是对实施例的车载构造进行说明的主视图。
图5是以包含图中的H轴和V轴的平面剖开而得到的电力变换器的剖视图。
图6是以包含图中的F轴和H轴的平面剖开而得到的电力变换器的剖视图。
附图标记的说明
2：车载构造；3：滤波电容器；4：电抗器；4a：线圈；4b：芯；5a、5b：开关元件；6a、6b：二极管；7：平滑电容器；8：变换器电路；9a-9f：电压转换电路；10：电力变换器；11：控制器；12：主箱体；13：副箱体；20：层叠单元；21：半导体模块；22：冷却器；24：控制端子；25：功率端子；26：控制基板；27：电容器单元；28：内隔板；41：纵梁(side member)；42：散热器架；43：横板；45：前托架；46a、46b：后托架；49：电缆；90：电池；91：马达；99：前舱(frontcompartment)；100：电动汽车。
具体实施方式
参照附图对实施例的车载构造进行说明。实施例的车载构造被应用于电动汽车100的电力变换器10。首先，对电力变换器10的电路进行说明。图1表示包含电力变换器10的电动汽车100的电力系统的框图。电动汽车100具备电池90、行驶用马达91、电力变换器10。电力变换器10将电池90的直流电力变换成适合于马达91的驱动的交流电力。电动汽车100的马达91在驾驶员踩踏了制动器踏板时利用车辆的动能进行发电。通过发电得到的电力被称为再生电力。电力变换器10也具有将交流的再生电力变换为直流而对电池90进行充电的功能。
电力变换器10具备滤波电容器3、平滑电容器7、变换器电路8、六个电压转换电路9a-9f。六个电压转换电路9a-9f以并联方式连接在共同的低电压端92a、92b与共同的高电压端92c、92d之间。滤波电容器3连接于共同的低电压端92a、92b之间，平滑电容器7连接于共同的高电压端92c、92d之间。
对电压转换电路9a进行说明。电压转换电路9a具备两个开关元件5a、5b、两个二极管6a、6b以及电抗器4。两个开关元件5a、5b以串联方式连接于高电压端92c、92d之间。开关元件5a、5b是电力变换用晶体管，例如是绝缘栅型双极晶体管(Insulated Gate BipolarTransistor：IGBT)。二极管6a以反并联方式与开关元件5a连接，二极管6b以反并联方式与开关元件5b连接。电抗器4的一端与低电压端92a(正极)连接，电抗器4的另一端与两个开关元件5a、5b串联连接的中点连接。负极的低电压端92b与负极的高电压端92d直接连接。
电压转换电路9a具备将施加于低电压端92a、92b的电力的电压进行升压并向高电压端92c、92d输出的升压功能。电压转换电路9a还具有将施加于高电压端92c、92d的电力的电压进行降压并向低电压端92a、92b输出的降压功能。电压转换电路9a是所谓的双向DC-DC转换电路。离正极的高电压端92c近的一侧的开关元件5a参与降压工作，离负极的高电压端92d近的一侧的开关元件5b参与升压工作。电压转换电路9a通过开关元件5a、5b的开关工作，或将电能储存于电抗器4，或将所储存的电能释放，改变所输入的电力的电压。若对开关元件5a、5b供给预定占空比的互补PWM信号，则取决于施加至低电压端92a、92b的电力(电池电力)和施加至高电压端92c、92d的电力(再生电力)的大小关系，被动地对升压和降压进行切换。由于图1的电压转换电路9a的电路构成和功能已被熟知，故省略详细说明。
电压转换电路9b具备与电压转换电路9a相同的电路构成。电压转换电路9c-9f也具备与电压转换电路9a相同的电路构成，因而在图1中关于电压转换电路9c-9f的构成省略了图示。不过，为了表示电压转换电路9c-9f也具备电抗器4，在表示电压转换电路9c-9f的矩形之中以虚线描绘出电抗器4。
变换器电路8将从电压转换电路9a-9f供给的直流电力变换为交流电力并输出至马达91。也存在变换器电路8将马达91所生成的交流的再生电力变换成直流并输出至电压转换电路9a-9f的情况。变换器电路8具备多个开关元件。由于变换器电路8的构成已被熟知，所以省略详细说明。
电压转换电路9a-9f的开关元件5a、5b和变换器电路8的开关元件由控制器11进行控制。控制器11接收来自未图示的上级控制器的指令，生成使开关元件工作的驱动信号。上级控制器根据车速和加速器开度，算出马达91的目标输出，并发送给控制器11。控制器11生成开关元件5a、5b、变换器电路8的开关元件的驱动信号，以使得目标输出得以实现。
电池90与马达91之间流动几十千瓦的电力。或储存或释放如此的大电力的能量的电抗器4与其他电子部件相比体型大。电力变换器10具备六个电抗器4。若将六个的电抗器4与其他电子部件收纳于一个箱体，则空间效率会变差。电力变换器10具备两个箱体(主箱体12和副箱体13)，将六个电抗器4分散收纳于两个箱体。
参照图2至图6，对电力变换器10的车载构造2进行说明。图2-图4示出搭载于电动汽车100的电力变换器10。图2-图4仅示出对车载构造2进行说明所必需的部件，省略了其他部件的图示。在图2-图4中，以虚拟线描绘出电动汽车100的车身和车轮。在图2-图6中还示出表示电动汽车100的车身的朝向的坐标系。坐标系的F轴的正方向相当于车辆的前方。V轴的正方向相当于车辆的上方。H轴的正方向相当于车辆的左侧面方向。
图2是对车载构造2进行说明的俯视图。图3是对车载构造2进行说明的侧视图。图4是对车载构造2进行说明的主视图。在图2和图3中，省略了车辆的后部的图示。
电力变换器10搭载于车辆的前舱99。如上所述，电力变换器10具备两个箱体即主箱体12和副箱体13。主箱体12和副箱体13被配置成在车宽度方向上相邻，且相互连结。主箱体12和副箱体13以前端对齐的方式相互固定。图2和图3的直线L表示主箱体12和副箱体13共同的前端。主箱体12和副箱体13通过电缆49电连接。
主箱体12和副箱体13通过前托架45和后托架46a、46b具有空隙SP地被固定在横板43上。前托架45和后托架46a、46b的下端被固定于横板43，前托架45和后托架46a、46b的上端与主箱体12和副箱体13连结。
如上所述，主箱体12的前端和副箱体13的前端在车辆前后方向上处于相同的位置，与共同的前托架45连结。副箱体13的长度比主箱体12短，主箱体12的后端与后托架46a连结，副箱体13的后端与后托架46b连结。
横板(cross plate)43架设于沿车辆前后方向延伸的一对纵梁41。一对纵梁41的前端与散热器架42连结。此外，在图4中，省略了散热器架42的图示。马达91经由未图示的防振座被悬架于一对纵梁41。电力变换器10由于向马达91供给电力，因此，配置在马达91的附近，有利于抑制电力的传送损失。
图5表示将主箱体12和副箱体13以包含图中的坐标系的V轴和H轴的平面剖开而得到的剖视图，图6表示将主箱体12和副箱体13以包含F轴和H轴的平面剖开而得到的剖视图。图5是将主箱体12和副箱体13的前侧板进行剖开而得到的剖视图。图6表示在内隔板28之下剖开而得到的主箱体12的剖面和对上板进行剖开而得到的副箱体13的剖面。
主箱体12中容纳有控制基板26、层叠单元20、电容器单元27、三个电抗器4。层叠单元20是将多个冷却器22和多个半导体模块21逐个地交替层叠而成的单元。一个半导体模块21中密封有两个开关元件和两个二极管。两个开关元件以串联方式连接，各个二极管与各个开关元件以反并联方式连接。一个电压转换电路9a(参照图1)的开关元件5a、5b和二极管6a、6b容纳于半导体模块21。电力变换器10具备六个电压转换电路9a-9f，层叠单元20包含与六个电压转换电路9a-9f的每一个对应的六个半导体模块21。另外，变换器电路8还具备多个开关元件，层叠单元20还包含容纳有变换器电路8的开关元件的半导体模块21。各半导体模块21的两侧与冷却器22接触。各个半导体模块21从两侧被冷却器22进行冷却。
在控制基板26安装有图1所示的控制器11。半导体模块21的控制端子24与控制基板26连接。多个控制端子24包括与容纳于半导体模块21的开关元件的栅极连接的端子和包含于半导体模块21的温度传感器的端子。
三个功率端子25从半导体模块21的下表面延伸。三个功率端子25分别与开关元件的串联连接的高电位侧、中点、低电位侧连接。三个功率端子25通过汇流条与电容器单元27、电抗器4连接，省略了汇流条的图示。
电容器单元27中容纳有多个电容器元件，这些电容器元件与图1的滤波电容器3和平滑电容器7对应。
主箱体12中除了容纳有控制基板26、容纳了开关元件的半导体模块21、电容器单元27以外还容纳有三个电抗器4(参照图6)。图6由于是在图5所示的内隔板28之下进行剖开而得到的剖面，因此，控制基板26和层叠单元20未被描绘出。
副箱体13中容纳有其他三个电抗器4(参照图6)。各个电抗器4由环状的芯4b和两个线圈4a构成。两个线圈4a以成为平行的方式安装于环状的芯4b。两个线圈4a由一根绕组线制作，在电上为一个线圈。由于在电抗器4中流动几十千瓦的电力，所以电抗器4比其他电子部件体格大。
主箱体12和副箱体13通过电缆49连接。电缆49连接于副箱体13的后侧板和主箱体12的横侧板。电缆49在主箱体12和副箱体13各自的内部与电抗器4连接，但关于电缆在箱体内的布设，省略了图示。在电缆49中流动驱动行驶用马达91的几十千瓦的电力。
对上述的车载构造2的特征进行说明。电力变换器10搭载于车辆的前舱99。电力变换器10包括分别包含电抗器4的多个电压转换电路9a-9f，多个电压转换电路9a-9f以并联方式进行连接。将构成电力变换器10的电路的部件分散容纳于两个箱体(主箱体12和副箱体13)。在主箱体12中容纳有电压转换电路9a-9f和变换器电路8的开关元件(半导体模块21)、控制基板26、电容器单元27、三个电抗器4。在副箱体13中容纳有其余的三个电抗器4。将主箱体12与副箱体13连接的电缆49连接于副箱体13的后部和主箱体12的侧面后部。
主箱体12与副箱体13以在车宽度方向上相邻的方式连结。主箱体12和副箱体13以前端对齐的方式连结。主箱体12和副箱体13在通过前托架45和后托架46a、46b在箱体的下方确保空隙SP的同时被固定于车辆(横板43)。
电抗器4比其他电子部件体格大。在主箱体12中容纳几个电抗器4和其他部件(半导体模块21、控制基板26等)。将其他部件和能尽可能高空间效率地容纳的数量的电抗器4容纳于主箱体12。主箱体12无法高效率地容纳的其余的电抗器4容纳于副箱体13。将体格大的多个电抗器4分散容纳于两个箱体(主箱体12和副箱体13)，由此能够将多个电抗器4高空间效率地进行容纳。
主箱体12与副箱体13通过电缆49进行连接。在车辆发生了正面碰撞时，电力变换器10有可能会从前方受到冲击。主箱体12和副箱体13在下方具有空隙地被前托架45和后托架46a、46b支承。在从前方受到冲击时，主箱体12与副箱体13有后退的余地。即，主箱体12和副箱体13若从前方受到碰撞载荷，则托架45、46a、46b发生变形而向后下方移动。主箱体12和副箱体13通过后退来缓和冲击。
另外，主箱体12与副箱体13以前端对齐的方式连结。图2、图3、图6所示的直线L表示主箱体12和副箱体13的共同的前端的位置。如图6所示，在车辆发生了正面碰撞时，障碍物OB有可能从电力变换器10的前方与电力变换器10碰撞。障碍物OB与主箱体12的前端和副箱体13的前端同时接触。来自前方的冲击由于被主箱体12和副箱体13这两方承受，所以冲击力分散，副箱体13不易与主箱体12脱离。因此，被施加高电压的电缆49不易脱离。电缆49连接于副箱体13的后端(后侧板)也有助于在发生正面碰撞时使电缆49不易脱离。
对与实施例中说明了的技术相关的注意点进行叙述。电力变换器10包括六个电抗器4。本说明书所公开的技术能够应用于包括两个以上的电抗器的电力变换器的车载构造。在主箱体中容纳至少一个电抗器和开关元件等电子部件，在副箱体中容纳其余的电抗器。
本说明书所公开的技术涉及将直流电源的电力变换为行驶用马达的驱动电力的电力变换器的车载构造。搭载电力变换器的电动汽车包括具备马达和发动机的混合动力车和具备燃料电池作为直流电源的汽车。
以上，对本发明的具体例详细地进行了说明，但这些仅仅为示例，并不对权利要求书进行限定。权利要求书中记载的技术包括对以上例示的具体例进行各种变形、变更后的技术方案。本说明书或者附图中说明的技术要素可单独或通过各种组合来发挥技术有用性，并不局限于申请时权利要求所记载的组合。另外，本说明书或者附图中例示的技术能够同时实现多个目的，只要实现其中一个目的，其本身就具有技术有用性。

Claims (2)

1.一种电力变换器的车载构造，在所述电力变换器中，分别包含电抗器的多个电压转换电路以并联方式连接，
所述电力变换器具备主箱体和副箱体，所述主箱体容纳有至少一个电抗器和所述电压转换电路的开关元件，所述副箱体容纳有其余的电抗器,并且与所述主箱体通过电缆进行连接，
所述主箱体在前舱经由托架在下方设置有空隙地固定于车体，
所述副箱体以与所述主箱体对齐前端的方式连结于所述主箱体的车宽度方向上的侧方。
2.根据权利要求1所述的电力变换器的车载构造，
将所述主箱体和所述副箱体连接的电缆连接于所述副箱体的后侧面。
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