CN116744615A - Power control device - Google Patents

Abstract

The present invention provides a power control device, comprising: a first switch substrate having a first wiring pattern and a plurality of first switch elements mounted on the first wiring pattern; a second switch substrate having a second wiring pattern and a plurality of second switching elements mounted on the second wiring pattern; a control board having a control unit for controlling an on state and an off state of the first switching element and the second switching element; and a device case accommodating the first switch substrate, the second switch substrate, and the control substrate, wherein the first switch substrate, the second switch substrate, and the control substrate are accommodated in the device case in a state in which the first switch substrate, the control substrate, and the second switch substrate are arranged in the order of the first switch substrate, the control substrate, and the second switch substrate at predetermined intervals in a height direction of the device case.

Description

Power control device

Technical Field

The present invention relates to an electric power control device.

Background

Japanese patent application laid-open No. 11-354956 discloses an electronic circuit device in which a device case is constituted by a single metal substrate having electronic components mounted on only one surface of the single metal substrate and the single metal substrate integrally formed with a heat sink.

In this electronic circuit device, the bottom surface of the device case is formed by one metal substrate on which electronic components are mounted, and the cover of the case is formed by the other metal substrate. The electronic component is disposed in the device case, and the case is filled with resin and sealed, whereby heat generated from the electronic component is released to the outside through the two metal substrates.

As a circuit element that generates heat by energization, a switching element such as a Metal-Oxide-semiconductor field effect transistor (MOSFET) or an Insulated Gate Bipolar Transistor (IGBT) is known. These switching elements are mounted on a switching substrate having high heat dissipation properties, which is made of a metal substrate or the like, in the case of a power control device or the like that controls power supply between a power source and a power supply target.

However, in the power control device having a large output voltage, the number of switching elements mounted increases, and the required area of the substrate increases. Therefore, if all the switching elements are to be mounted on one surface of the switching substrate, the device case accommodating the switching substrate also becomes large, and thus there is a problem that it is difficult to achieve miniaturization of the device.

Disclosure of Invention

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a power control device that can achieve both high output and downsizing of the device.

The power control device according to the first aspect of the present invention includes: a first switch substrate having a first wiring pattern and a plurality of first switch elements mounted on the first wiring pattern; a second switch substrate having a second wiring pattern and a plurality of second switching elements mounted on the second wiring pattern; a control board having a control unit for controlling an on state and an off state of the first switching element and the second switching element; and a device case accommodating the first switch substrate, the second switch substrate, and the control substrate, wherein the first switch substrate, the second switch substrate, and the control substrate are accommodated in the device case in a state in which the first switch substrate, the control substrate, and the second switch substrate are arranged in the order of the first switch substrate, the control substrate, and the second switch substrate at predetermined intervals in a height direction of the device case.

According to the power control device of the present invention, the plurality of switching elements controlled by the control board are separately mounted on the first switching board and the second switching board, so that the area of each switching board can be reduced. Such two switch substrates are accommodated in the device case so as to be spaced apart from each other by a predetermined interval in the height direction in the order of the first switch substrate, the control substrate, and the second switch substrate. Thus, the mounting area of the substrate portion in the device case is substantially equal to the mounting area of one substrate, and the device case is prevented from being enlarged, so that the device can be miniaturized while achieving high output.

Drawings

Exemplary embodiments of the present invention will be described in detail based on the following drawings, in which:

fig. 1 is a top view of an apparatus case of a power control apparatus according to an embodiment;

fig. 2 is an exploded perspective view of the power control device according to the embodiment;

FIG. 3 is a cross-sectional view of the device housing taken along line III-III of FIG. 1;

fig. 4 is a plan view of the first switch substrate viewed from the upper side;

fig. 5 is a plan view of the second switch substrate viewed from the upper side;

Fig. 6 is a perspective view showing a state in which the first substrate-side terminal and the second substrate-side terminal are connected via the first power-side terminal;

fig. 7 is a side cross-sectional view showing a state in which the first substrate-side terminal and the second substrate-side terminal are connected via the output terminal;

fig. 8 is a plan view of the control substrate viewed from the upper side;

fig. 9 is a partial side sectional view showing a connection structure of the control substrate and the switch substrate;

fig. 10 is an enlarged plan view showing a rogowski coil pattern formed on a control substrate in an enlarged manner;

FIG. 11 is an enlarged view of a cross-section taken along the line XI-XI of FIG. 10;

fig. 12 is a circuit diagram of the power control apparatus; and

fig. 13 is a block diagram showing the configuration of the detection processing section.

Detailed Description

An embodiment of the present invention will be described below with reference to fig. 1 to 13. In the present embodiment, for convenience of explanation, directions indicated by arrows in the drawings, which are appropriately indicated in the up-down, left-right, and front-rear directions, are defined as the up-down, left-right, and front-rear directions of the power control device, respectively.

In the present embodiment, as an example of the power control device according to the present invention, the power control device 1 is described, and the power control device 1 controls the power supply between the battery 2 (power source) mounted in the vehicle and the three-phase ac motor 4 (power supply target) (see fig. 12). As shown in fig. 2, the power control device 1 includes: a device case 10 formed in a rectangular box shape, two switch boards 50 (50A, 50B) accommodated in the device case 10, and one control board 60 provided with a coil for measuring current.

As shown in fig. 1 and 2, the apparatus case 10 includes a box-shaped case main body 12 and a case cover (case cover) 14 attached to the case main body 12. The housing main body 12 is a rectangular box-like member made of metal having an opening portion 13 opening upward. The housing main body 12 includes a front wall portion 12A, a rear wall portion 12B, a left wall portion 12C, a right wall portion 12D, and a bottom wall portion 12E. A heat sink 12F for dissipating heat of the second switch board 50B, which will be described later, to the outside of the case main body 12 is provided on the outer surface of the bottom wall 12E.

The housing cover 14 is a rectangular plate-like member made of metal. The case cover 14 is fixed to the case body 12 by an adhesive applied to the upper ends of the front, rear, left, and right wall portions 12A to 12D of the case body 12 and fastening screws 24. Since the housing cover 14 is fixed to the housing main body 12, an accommodation space is formed inside the device housing 10. Further, a heat sink 14A for dissipating heat of the first switch board 50A, which will be described later, to the outside of the case main body 12 is provided on the outer surface of the case cover 14. Fig. 1 is a plan view of the interior of the housing main body 12 viewed from above, with the housing cover 14 omitted.

A connector mounting portion 16 is formed in the front wall portion 12A of the housing main body 12. The connector mounting portion 16 includes a through hole formed in the front wall portion 12A in the shape of a long hole. The sensor-side connector 30 is mounted on the connector mounting portion 16. The sensor-side connector 30 includes a housing attached to the connector attachment portion 16 and a plurality of connection terminals (not shown) provided in the housing. When the sensor-side connector 30 is mounted on the connector mounting portion 16, one end sides of the plurality of connection terminals protrude from the housing and extend inward of the device case 10, respectively, so as to be connected to the control board 60. A harness (cable) connected to electrical equipment such as various sensors mounted on the vehicle is connected to the sensor-side connector 30 via a connector (not shown).

The rear portion of the accommodation space in the device case 10 has an accommodation recess 18 provided so as to face the rear wall portion 12B of the case main body 12. The accommodation recess 18 is integrally formed with the rear wall portion 12B, the left wall portion 12C, the right wall portion 12D, and the bottom wall portion 12E, and protrudes downward from the rear bottom surface of the device case 10. The accommodating recess 18 accommodates a plurality of capacitors 3 and a terminal block 40 for holding the plurality of capacitors 3 in the case.

The terminal block 40 has five terminal members of a bus bar type arranged along the rear wall portion 12B of the housing main body 12. One end of each of the five terminal members extends from the terminal block 40 toward the inside of the device case 10, and the other end is exposed at the connection surface of the upper surface of the terminal block 40. The terminal member disposed at the left end is a first power supply side terminal 20P electrically connected to the positive electrode of the battery 2. The terminal member disposed at the right end is a second power supply side terminal 20N electrically connected to the negative electrode of the battery 2. The plurality of capacitors 3 are connected in parallel with the battery 2 by being connected to the first power supply side terminal on the positive electrode side and the second power supply side terminal 20N on the negative electrode side, and thereby function as elements for reducing noise generated in the inverter circuit 5 (see fig. 12) described later.

The three terminal members disposed between the first power supply side terminal 20P and the second power supply side terminal 20N are output terminals 26 that supply electric power to the three-phase ac motor 4. The output terminals 26 (26U, 26V, 26W) correspond to the phases (U-phase, V-phase, W-phase) of the three-phase ac motor 4, and each phase coil included in the stator of the three-phase ac motor 4 is electrically connected to wiring patterns 52 (52A, 52B) of a switch board 50 (50A, 50B) described later.

As shown in fig. 3, two switch substrates 50 each including a first switch substrate 50A and a second switch substrate 50B, and one control substrate 60 are accommodated in the accommodation space of the device case 10. These substrates are arranged in the order of the first switch substrate 50A, the control substrate 60, and the second switch substrate 50B from above at predetermined intervals in the height direction of the device case 10. Each substrate is formed in a rectangular plate shape having an equal size in a plan view with the vertical direction being the plate thickness direction. Therefore, three substrates are accommodated in the device case 10 in a mounting area of about one substrate.

As an example, the first switch substrate 50A and the second switch substrate 50B are constituted by insulating substrates for heat dissipation, which are formed by bonding wiring patterns 52 (52A, 52B) made of metal such as copper or aluminum to a substrate made of aluminum. The first switch board 50A disposed at the upper portion in the device case 10 is fixed to the case cover 14 by an adhesive applied to the inner surface (lower surface in fig. 3) of the case cover 14. Accordingly, the first switch substrate 50A is fixed to the housing cover 14 in a state where the upper surface side thereof is in contact with the inner surface of the housing cover 14, so that the heat of the first switch substrate 50A is radiated to the outside via the housing cover 14. The second switch board 50B disposed at the lower portion in the device case 10 is fixed to the case body 12 by an adhesive applied to the inner surface of the bottom wall portion 12E of the case body 12. Accordingly, the second switch substrate 50B is fixed to the case body 12 in a state where the lower surface side thereof is in contact with the inner surface of the case body 12, so that the heat of the second switch substrate 50B is radiated to the outside via the case body 12.

The control board 60 is supported by the plurality of interval holding members 46 in a state of being spaced apart from the second switch board 50B fixed to the housing main body 12 by a predetermined interval in the height direction of the device housing 10. The space holding member 46 is constituted by, for example, a cylindrical or polygonal column-shaped space nut (spacer nut), and the lower end of the space holding member 46 is joined (bonded) to the upper surface of the second switch substrate 50B. The spacer 46 and the control board 60 are fixed by screwing a screw 48 inserted into a through hole (reference numeral omitted) of the control board 60 into a screw hole at the upper end of the spacer 46.

In this way, inside the apparatus case 10, the three substrates are stably held in a state of being spaced apart by a predetermined interval in the height direction. Therefore, it is not necessary to seal the space inside the device case 10 with potting resin (potting resin) to maintain the space between the substrates.

As shown in fig. 4, a first wiring pattern 52A is formed in a mounting region of the first switch substrate 50A on the lower surface side facing the control substrate 60. The first wiring pattern 52A electrically connects the battery 2 and the three-phase ac motor 4, and a plurality of switching elements 54 are mounted on the first wiring pattern 52A. In fig. 4, the outline of the first switch board 50A is shown by a two-dot chain line, and the member of the mounting region provided on the lower surface side is shown by a solid line.

As shown in fig. 5, a second wiring pattern 52B is formed in a mounting region of the second switch substrate 50B on the upper surface side facing the control substrate 60. The second wiring pattern 52B electrically connects the battery 2 and the three-phase ac motor 4, and a plurality of switching elements 54 are mounted on the second wiring pattern 52B.

The first wiring pattern 52A of the first switch substrate 50A, the second wiring pattern 52B of the second switch substrate 50B, the plurality of switching elements 54, and the like constitute a part of the inverter circuit 5 (see fig. 12) that converts the direct current on the battery 2 side into alternating current. The inverter circuit 5 has a high-side (high side) switching element electrically connected to the positive electrode side of the battery 2 with respect to the three-phase ac motor 4, and a low-side (low side) switching element electrically connected to the negative electrode side of the battery 2 with respect to the three-phase ac motor 4.

In the present embodiment, the plurality of switching elements 54 mounted on the first switching substrate 50A constitute a high-side switching element, and the plurality of switching elements 54 mounted on the second switching substrate 50B constitute a low-side switching element. As an example, each switching element 54 includes an n-type Metal-Oxide-Semiconductor Field-Effect Transistor (nMOSFET) that switches electric power supplied to each phase of the three-phase alternating current motor 4.

Specifically, six high-side switching elements 54UH, six high-side switching elements 54VH, and six high-side switching elements 54WH corresponding to the respective phases (U-phase, V-phase, and W-phase) of the three-phase ac motor 4 are mounted on the first wiring pattern 52A of the first switch substrate 50A. As shown in fig. 4, the high-side switching elements 54UH, 54VH, 54WH of the respective phases are arranged separately for each phase, and are arranged in a row in one direction (the front-rear direction in fig. 4).

The first wiring pattern 52A includes a drain connection pattern portion 521, a source connection pattern portion 522, and a connection pattern portion 523, and forms a current path having a high voltage level between the positive electrode of the battery 2 and the three-phase ac motor 4. The drain connection pattern portion 521 and the source connection pattern portion 522 are arranged on both sides of the arrangement formed by the high-side switching elements 54UH, 54VH, 54WH of each phase, and extend substantially in parallel in the arrangement direction (front-rear direction). The drain connection pattern 521 is connected to drain electrodes of the high-side switching elements 54UH, 54VH, and 54WH of the respective phases. The source connection pattern 522 is connected to source electrodes of the high-side switching elements 54UH, 54VH, and 54WH of the respective phases. Thereby, six high-side switching elements corresponding to each are connected in parallel with each other. The connection pattern portion 523 extends in the left-right direction on the front end side of the first switch substrate 50A, and connects the ends of the drain connection pattern portions 521 of the respective phases to each other. With such pattern arrangement, one end of the drain connection pattern portion 521 and one end of the source connection pattern portion 522 of each phase are arranged so as to avoid the connection pattern portion 523 at the rear end side of the first switch substrate 50A. Therefore, the five first substrate-side terminals 56A connected to the first wiring patterns 52A can be arranged on the rear end side of the first switch substrate 50A in a concentrated manner. The five first substrate-side terminals 56A include terminal members whose basic structures are set to be identical to each other in a bus bar type.

In the present embodiment, one first substrate-side terminal 56A connected to one end of the U-phase drain connection pattern portion 521, three first substrate-side terminals 56A connected to one end of each of the U-phase, V-phase, and W-phase source connection pattern portions 522, and one first substrate-side terminal 56A connected to one end of the noise removal pattern portion 524 are arranged in a row from the left end to the right end on the rear end side of the first switch substrate 50A, wherein the noise removal pattern portion 524 is connected to a ceramic capacitor (not shown) for noise removal.

The first substrate-side terminal 56A connected to one end of the U-phase drain connection pattern 521 is connected to the first power supply-side terminal 20P connected to the positive electrode of the battery 2. The first substrate-side terminals 56A connected to one ends of the source connection pattern portions 522 of the U-, V-, and W-phases are connected to three output terminals 26U, 26V, and 26W, respectively, which supply electric power to the respective phases of the three-phase ac motor 4. The first substrate-side terminal 56A connected to one end of the noise removal pattern portion 524 is connected to the second power-supply-side terminal 20N connected to the negative electrode of the battery 2.

As shown in fig. 5, six low-side switching elements 54UL, six low-side switching elements 54VL, and six low-side switching elements 54WL corresponding to each phase (U-phase, V-phase, and W-phase) of the three-phase ac motor 4 are mounted on the second wiring pattern 52B of the second switch substrate 50B. The low-side switching elements 54UL, 54VL, 54WL of each phase are arranged separately for each phase, and are arranged in a row in one direction (front-rear direction in fig. 5).

Similarly to the first wiring pattern 52A, the second wiring pattern 52B includes a drain connection pattern portion 521, a source connection pattern portion 522, and a connection pattern portion 523. The second wiring pattern 52B forms a current path having a lower voltage level than the first wiring pattern 52A between the negative electrode of the battery 2 and the three-phase ac motor 4. The drain connection pattern portion 521 and the source connection pattern portion 522 of the second wiring pattern 52B are arranged on both sides of the arrangement formed by the low-side switching elements 54UL, 54VL, 54WL of each phase, and extend parallel to each other. Thereby, six low-side switching elements corresponding to each are connected in parallel with each other. The connection pattern portion 523 extends in the left-right direction on the front end side of the second switch substrate 50B, and connects the ends of the source connection pattern portions 522 of the respective phases to each other. With such a pattern arrangement, five second substrate-side terminals 56B connected to the second wiring patterns 52B are arranged in a concentrated manner on the rear end side of the second switch substrate 50B. The five second substrate-side terminals 56B include bus bar-type terminal members having the same basic structure as the first substrate-side terminals 56A.

Specifically, one second substrate-side terminal 56B connected to one end of the noise removal pattern 524, three second substrate-side terminals 56B connected to one end of each drain connection pattern 521 of the U-phase, V-phase, and W-phase, and one second substrate-side terminal 56B connected to one end of the source connection pattern 522 of the W-phase are arranged in a row from left to right at the rear end side of the second switch substrate 50B, wherein the noise removal pattern 524 is connected to a ceramic capacitor (not shown) for noise removal.

The second substrate-side terminal 56B connected to one end of the noise removal pattern portion 524 is connected to the first power-supply-side terminal 20P connected to the positive electrode of the battery 2. The second substrate-side terminals 56B connected to one ends of the drain connection pattern portions 521 of the U-, V-, and W-phases are connected to three output terminals 26U, 26V, and 26W, respectively, which supply electric power to the respective phases of the three-phase ac motor 4. The second substrate-side terminal 56B connected to one end of the W-phase source connection pattern 522 is connected to the second power supply-side terminal 20N connected to the negative electrode of the battery 2.

As shown in fig. 6 and 7, in the first switch board 50A and the second switch board 50B having the above-described configuration, five first board side terminals 56A and five second board side terminals 56B provided on the rear end sides of the respective boards are arranged so as to face each other in the height direction of the device case 10.

Here, the first substrate-side terminal 56A and the second substrate-side terminal 56B each have a connection portion 561, a vertical portion 562, a bent portion 563, and a horizontal portion 564, which are integrally provided. The connection portion 561 is mounted on and soldered to the mounting surface of the switch board 50 (50A, 50B) to connect with the wiring pattern 52 (52A, 52B). The vertical portion 562 is formed from an end of the connection portion 561 to be bent at a right angle and extends toward the control board 60. The bent portion 563 extends from the front end of the vertical portion 562 toward the outside of the substrate so as to be bent substantially in a crank shape. The horizontal portion 564 horizontally extends from the tip of the bent portion 563, and the tip of the horizontal portion 564 is welded or resistance welded in contact with the side surface of the one side of the first power supply side terminal 20P and the second power supply side terminal 20N or the output terminal 26 extending from the terminal block 40.

The first substrate-side terminal 56A and the second substrate-side terminal 56B have the same basic structure, and are arranged in the opposite direction in the height direction of the device case 10. Accordingly, in a state where the first substrate-side terminal 56A and the second substrate-side terminal 56B are mounted in the device case 10, the first substrate-side terminal 56A and the second substrate-side terminal 56B of the pair disposed opposite to each other are connected via the common terminal members (20P, 20N, 26) so as to be expected to sandwich the side surfaces thereof from both sides. In this way, the connection line between the first wiring pattern 52A of the first switch substrate 50A and the second wiring pattern 52B of the second switch substrate 50B is provided by using the space in the height direction of the device case 10, and the shortening of the connection line between the substrates is achieved.

The source electrodes of the high-side switching elements 54UH, 54VH, 54WH and the drain electrodes of the low-side switching elements 54UL, 54VL, 54WL of each phase of the three-phase ac motor 4 are connected by three first substrate-side terminals 56A and three second substrate-side terminals 56B. Further, the first substrate-side terminal 56A and the second substrate-side terminal 56B facing each other are connected via the common output terminal 26, and thus, a complicated wiring using a bus bar for connection is not required, and the wiring efficiency is improved (see fig. 7).

Here, three first substrate-side terminals 56A and three second substrate-side terminals 56B provided in correspondence with the respective three-phase ac motors 4 are inserted into and penetrate six current measuring coils provided on the control substrate 60, respectively.

As shown in fig. 8, the control board 60 is constituted by a rectangular plate-like printed wiring board. Six through-holes 62 are formed in the rear end side of the control board 60 so as to be aligned in the left-right direction. These through portions 62 are slit-shaped cuts formed at the rear end portion of the control substrate 60, and penetrate the control substrate 60 in the plate thickness direction. Around each of the six through-holes 62, a rogowski coil pattern 70 is formed as a current measuring coil constituting a part of the current detection sensor. The rogowski coil pattern 70 is formed as a wiring pattern on the control substrate 60, and is formed integrally with the control substrate 60. Hereinafter, these patterns 70 are referred to as the rogowski coils 70.

When the control board 60 is configured as the power control device 1, it is disposed between the first switch board 50A and the second switch board 50B in the accommodation space in the device case 10, and a predetermined interval is provided in the height direction between the switch boards 50A and 50B. In this state, the vertical portions 562 of the three first substrate-side terminals 56A and the vertical portions 562 of the three second substrate-side terminals 56B are inserted into and penetrate the six through portions 62 of the control substrate 60 in a state of being non-contact with the edges of the through portions 62. This results in the following structure: the current flowing through the three first substrate-side terminals 56A and the three second substrate-side terminals 56B provided corresponding to each of the three-phase alternating current motors 4 is sensed using the rogowski coil 70. These measurement currents are currents obtained by measuring currents flowing between the battery 2 and the three-phase ac motor 4 between the high-side source electrode and the low-side drain electrode. Therefore, the current on the input side and the current on the output side of the three-phase ac motor 4 can be detected at positions that are not affected by the loss due to the switching element 54, and the detection accuracy of the current can be improved. The three first substrate-side terminals 56A and the three second substrate-side terminals 56B are arranged parallel to each other, and the gradient and distance of the rogowski coil 70 with respect to these terminals are set to be the same.

Here, with reference to fig. 10 and 11, a rogowski coil 70 formed on a control board 60 will be described. The rogowski coil 70 is formed on the control board 60, and is disposed in a U-shaped annular region surrounding the through portion 62 with a space from the through portion 62. One end of the rogowski coil 70 is connected to the electrode connection piece 75, and a coil having a diameter equal to the plate thickness of the control board 60 is formed in a spiral shape (spiral shape rotating clockwise in the traveling direction) along the periphery of the through portion 62. The other end of the rogowski coil 70 is connected to the return line 71 at a position substantially one turn along the periphery of the through portion 62.

The rogowski coil 70 is formed by connecting a plurality of conductor films 72 and 73 formed on both surfaces of the control substrate 60 through a plurality of vias 74 formed through the control substrate 60 in the plate thickness direction (see the lower right diagram of fig. 10). Thus, the rogowski coil 70 has a small impedance and a small power loss in the current measurement because it is an air-core coil. The rogowski coil 70 can also handle measurement of a large current when the magnetic flux is not saturated.

One end of the return line 71 is connected to the rogowski coil 70, and is formed so as to surround the rogowski coil 70 when viewed in the axial direction of the through portion 62. The other end portion of the return line 71 is connected to an electrode tab 76 arranged side by side with the electrode tab 75. Therefore, the rogowski coil 70 is wound around the through portion 62 from the electrode connection piece 75 substantially once, and the return wire 71 is wound around the outer side of the rogowski coil 70 in the opposite direction so as to turn back from the through portion, and enters the inner side of the rogowski coil 70 at a position exceeding the outer side of the electrode connection piece 75, and is connected to the electrode connection piece 76. When a current flows through conductors (in the present embodiment, the first substrate-side terminal 56A and the second substrate-side terminal 56B) to be measured by the rogowski coil 70, an induced electromotive force is generated in the electrode connection pieces 75 and 76 at both ends of the coil. The induced electromotive force is output to a detection processing unit 7 described later as a signal output from the rogowski coil 70. The detection processing unit 7 calculates the value of the current flowing through the first substrate-side terminal 56A and the second substrate-side terminal 56B based on the signal output from the rogowski coil 70.

In the characteristic of the rogowski coil 70, an induced current corresponding to a magnetic flux passing through an area surrounded by the rogowski coil 70 is generated, but since an induced current of a reverse component is generated by the return line 71 and mutually offset, the induced current of the reverse component corresponds to a reverse magnetic flux passing through an area surrounded by the return line 71, it is possible to accurately detect a current flowing through the first substrate side terminal 56A and the second substrate side terminal 56B inserted into and passing through the penetration portion 62.

Further, since the current to be detected does not flow through the rogowski coil 70 itself, the amount of heat generated by the rogowski coil 70 does not increase due to energization. Suppressing the heat generation of the rogowski coil 70 contributes to improving the current detection accuracy of the rogowski coil 70 and a detection processing unit 7 (see fig. 12) described later.

Further, the correction value for correcting (calibrating) an error between a current value actually flowing through the conductor and a calculated value calculated by the operation varies depending on the gradient of the rogowski coil 70 with respect to the conductor in terms of the characteristics of the rogowski coil 70. Therefore, at the stage after the product is assembled, initial value correction for correcting errors caused by the above-described inclination of the rogowski coil 70 mounted on each of the power control apparatuses 1 is performed. This initial value correction is performed, for example, as follows: the inspection board having the diagnostic function is connected to the control board 60, and correction values stored in advance in a memory mounted on the control board 60 are initialized to restore correction values calculated based on the inspection current. Therefore, when a plurality of rogowski coils 70 are mounted on the power control apparatus 1, if the gradient of each rogowski coil 70 is varied, the initial value correction as described above needs to be performed for each single rogowski coil 70. Each single rogowski coil 70 requires a connection terminal for connecting to a board for inspection and a diagnostic circuit.

However, according to the present embodiment, a plurality of rogowski coils 70 are formed on one control substrate 60 by wiring patterns. Therefore, since the slope of each rogowski coil 70 does not deviate, initial value correction can be performed by using a common correction value for a plurality of rogowski coils 70. Therefore, man-hour associated with initial value correction is reduced.

Referring back to fig. 8, a plurality of through holes 68 penetrating the control board 60 in the board thickness direction are formed on the front end side of the control board 60. The distal ends of the plurality of connection terminals of the sensor-side connector 30 are inserted from below, pass through the through holes 68, and are soldered to be connected to the control board 60. Signals detected by various sensors mounted on the vehicle are output to the control board 60 via the sensor-side connector 30, and are output to the central processing unit (Central Processing Unit, CPU) 64 via a wiring pattern formed on the control board 60.

Further, a circuit constituting the control unit 6 and the detection processing unit 7 shown in fig. 12 is mounted on the mounting region of the control board 60. The control unit 6 has a Central Processing Unit (CPU) 64 (see fig. 8) as a control IC, and controls the on state and the off state of the plurality of switching elements 54. As shown in fig. 9, the control board 60 and the first switch board 50A and the control board 60 and the second switch board 50B are connected to each other in the height direction by a floating connector 90 having a plurality of conductor pins 92. The conductor pins 92 are connected to the male connectors 94 connected to the respective switch boards 50A and 50B, and the signal lines of the control unit 6 are electrically connected to the first wiring pattern 52A of the first switch board 50A and the second wiring pattern 52B (gate electrode of the switching element 54) of the second switch board 50B.

In the device configuration, the second switch board 50B and the control board 60, which are positioned at the lower layer, are assembled, and then the first switch board 50A, which is disposed at the upper portion in the device case 10, is assembled to the control board 60. Therefore, since a tolerance due to assembly is easily generated, the tip of the male connector 94 is connected to the female connector 96 disposed on the opposite surface of the control board 60. The second switch board 50B disposed at the lower portion in the device case 10 is not likely to have a tolerance due to assembly for the above-described reasons, and therefore the male connector 94 connected to the second switch board 50B is directly connected to the control board 60. However, the present invention is not limited to this, and the second switch board 50B may be configured to connect the male connector 94 to the female connector 96 disposed on the opposite surface of the control board 60, similarly to the first switch board 50A.

In the present embodiment, the current detection sensor is constituted by the rogowski coil 70 and the detection processing unit 7. The control unit 6 calculates a current value based on the signal input from the detection processing unit 7, and switches the on state and the off state of the plurality of switching elements 54 to control the electric power supplied to each phase of the three-phase ac motor 4.

As shown in fig. 12, the power control device 1 includes an inverter circuit 5 mounted on two switch boards 50A and 50B. The inverter circuit 5 converts the direct current on the battery 2 side into alternating current, and supplies the alternating current to each phase of the three-phase alternating current motor 4. The drain electrodes of the switching elements 54UH, 54VH, 54WH on the side (high side) with higher voltage levels corresponding to the U-phase, V-phase, and W are connected to the positive electrode side of the battery 2. The source electrodes of the switching elements 54UL, 54VL, 54WL on the lower side (low side) of the voltage levels corresponding to the respective switching elements are connected to the negative electrode side of the battery 2. The gate electrodes of all the switching elements 54 are connected to signal lines of control signals outputted from the control unit 6, respectively.

The six rogowski coils 70 include: three rogowski coils 70U1, 70V1, 70W1 and three rogowski coils 70U2, 70V2, 70W2, wherein the three rogowski coils 70U1, 70V1, 70W1 measure currents flowing between source electrodes of the high side switching elements 54UH, 54VH, 54WH of the inverter circuit 5 and the three phase ac motor 4, respectively, and the three rogowski coils 70U2, 70V2, 70W2 measure currents flowing between the three phase ac motor 4 and drain electrodes of the low side switching elements 54UL, 54VL, 54WL, respectively. In these six rogowski coils 70, the current value at the moment when the on state and the off state are switched to the switching element 54 corresponding to each of the three-phase ac motors 4 is measured. The output signals (induced electromotive forces) output from the respective rogowski coils 70 are input to the detection processing unit 7 mounted on the control board 60.

As shown in fig. 13, the detection processing unit 7 is configured to include six integrator circuits 80A to 80F corresponding to the six rogowski coils 70 and three adders 82U to 82W corresponding to the three-phase ac motors 4. In the detection processing unit 7, the output signals of the six rogowski coils 70 are input to the six integrating circuits 80A to 80F, respectively. Each integrating circuit 80 is configured to have an operational amplifier, a resistor, and a capacitor, for example. The integrating circuit 80 integrates the output signal from the rogowski coil 70 and outputs a signal corresponding to a voltage waveform proportional to the measured current at each point.

The adder 82 includes an adder 82U corresponding to U of the three-phase ac motor 4, an adder 82V corresponding to V, and an adder 82W corresponding to W. The adder 82U adds the voltage waveforms obtained by integrating the output signals of the two rogowski coils 70U1, 70U2 corresponding to U. By this, the detected value on the positive electrode side of the battery 2 and the detected value on the negative electrode side are added, and an output signal UC proportional to the direct current output from the battery 2 to the U phase can be obtained. Similarly, the adder 82V can obtain an output signal UV proportional to the direct current output from the battery 2 to the V phase. In addition, the adder 82W can obtain an output signal UW proportional to the direct current output from the battery 2 to the W phase. The signals output from the adders 82U, 82V, 82W are input to the control unit 6, and the control unit 6 performs arithmetic processing to obtain output currents of the respective phases output from the battery 2 to the three-phase ac motor 4.

(action and Effect)

As described above, according to the power control device 1 according to the above embodiment, the plurality of switching elements 54 controlled by the control board 60 are separately mounted on the first switching board 50A and the second switching board 50B, so that the area of each switching board can be reduced. The two switch substrates 50A and 50B are accommodated in the device case 10 at predetermined intervals in the height direction in the order of the first switch substrate 50A, the control substrate 60, and the second switch substrate 50B. Accordingly, the mounting area of the substrate portion in the device case 10 is substantially equal to the mounting area of one substrate, and the device case 10 is miniaturized, so that the miniaturization of the device can be achieved while achieving a high output.

According to the power control device 1, the high-side switching elements 54UH, 54VH, 54WH of the inverter circuit 5 are mounted on the first switching substrate 50A, and the low-side switching elements 54UL, 54VL, 54WL are mounted on the second switching substrate 50B. Therefore, since independence of the wiring patterns can be ensured on the high side and the low side of the inverter circuit 5, wiring efficiency can be improved.

According to the power control device 1, the source electrodes of the high-side switching elements 54UH, 54VH, 54WH corresponding to the respective three-phase ac motors 4 are electrically connected to the drain electrodes of the low-side switching elements 54UL, 54VL, 54WL by the three first substrate-side terminals 56A connected to the first wiring pattern 52A and the three second substrate-side terminals 56B connected to the second wiring pattern 52B. Since the first substrate-side terminal 56A and the second substrate-side terminal 56B are arranged to face each other in the height direction of the device case 10, a connection line between the high-side source electrode and the low-side drain electrode can be shortened, and transmission loss can be reduced.

According to the power control device 1, bus bar type output terminals 26U, 26V, 26W are provided, which are connected between the source electrodes of the high side switching elements 54UH, 54VH, 54WH and the drain electrodes of the low side switching elements 54UL, 54VL, 54 WL. Similarly, the source electrode and the drain electrode are connected by sandwiching the side surfaces of the output terminals 26 from both sides by the first substrate-side terminal 56A and the second substrate-side terminal 56B which are constituted by bus bar-type terminals. Therefore, since the first substrate-side terminal 56A and the second substrate-side terminal 56B can be directly connected to the common output terminal 26, a complicated connection using a bus bar for connection is not required, and wiring can be easily realized.

According to the power control device 1, the current flowing through the first substrate-side terminal 56A and the second substrate-side terminal 56B can be measured in each phase of the three-phase ac motor 4 using the current measuring coil constituted by the two rogowski coils 70. Such a measurement current is a current obtained by measuring a current flowing between the battery 2 and the three-phase ac motor 4 between the high-side source electrode and the low-side drain electrode. Therefore, since the current on the input side and the current on the output side of the three-phase ac motor 4 can be detected at positions that are not affected by the loss due to the switching element 54, the detection accuracy of the current can be improved.

Further, since the current flowing between the battery 2 and the three-phase ac motor 4 is measured using the rogowski coil 70, the measurement current does not flow through the rogowski coil 70 itself. Therefore, even when a large current flows between the battery 2 and the three-phase ac motor 4, for example, the large current can be detected with high accuracy using the rogowski coil 70 without increasing the heat generation amount of the rogowski coil 70 due to the measurement current. Further, since the control board 60 on which the pattern of the rogowski coil 70 is formed is disposed at a predetermined interval with respect to the first and second switch boards 50A and 50B having the plurality of switch elements 54, the rogowski coil 70 is not susceptible to heat generation of the switch elements 54. This can further improve the accuracy of detecting the current.

According to the power control device 1, the first switch board 50A and the control board 60 and the second switch board 50B and the control board 60 are connected in the height direction of the device case 10 by the plurality of conductor pins 92 provided in the floating connector 90. The plurality of conductor pins 92 electrically connect the first wiring pattern 52A with the signal lines of the control section 6, and the plurality of conductor pins 92 electrically connect the second wiring pattern 52B with the signal lines of the control section 6, thereby transmitting the control signal from the control section 6 to the plurality of switching elements 54. In such a configuration, the connection line between the wiring patterns 52A and 52B of the respective switch boards 50A and 50B and the signal line of the control unit 6 can be shortened, and thus the transmission loss can be reduced.

In addition, according to the above embodiment, the male connector 94 of the floating connector 90 connected to the first switch board 50A is connected to the female connector 96 disposed on the opposite surface of the control board 60, so that the boards are connected to each other. This allows the substrates to be connected to each other by absorbing the tolerance such as the position of the connector, and thus the assembly can be easily performed.

According to the power control device 1, the first switch substrate 50A and the second switch substrate 50B are fixed in a state of being in contact with the bottom surface of the housing main body 12 and the inner surface of the housing cover 14, respectively, whereby the interval between the two substrates can be maintained in the height direction of the device housing 10. In addition, since the control board 60 is supported at a predetermined interval from the second switch board 50B fixed to the housing main body 12 in the height direction of the device housing 10, the interval between the switch boards 50A, 50B can be maintained in the height direction of the device housing 10. As described above, since the space between the three substrates can be stably maintained, damage to the welded portion due to thermal deformation during use can be reduced, and it is not necessary to use a potting resin in the device case 10 for maintenance, and thus weight reduction can be achieved.

Further, a plurality of heat radiating fins 12F, 14A are formed on the outer surfaces of the case main body 12 and the case cover 14, respectively. This allows heat from the plurality of switching elements 54 to be efficiently dissipated to the outside.

Supplementary explanation

In the above embodiment, the power source in the present invention is the battery 2, and the power supply object in the present invention is the three-phase ac motor 4, but the present invention is not limited to this. The power source and the power supply object can be set appropriately. For example, the power source may also be a power source selected from a generator or an outlet. The electric power supply target may be appropriately a single-phase ac motor, an ac motor of three or more phases such as four-phase ac and five-phase ac, various electric devices, or the like.

In the above embodiment, the case where the electric power is supplied from the battery 2 to the three-phase ac motor 4 has been described, but the present invention can also be used for controlling the electric power supplied (charged) from the motor to the battery as in the case of the regenerative electric power.

In the above embodiment, the configuration was adopted in which the currents flowing through the three first substrate-side terminals 56A and the three second substrate-side terminals 56B corresponding to the respective phases (U, V, W) of the three-phase ac motor 4 were measured, but the present invention is not limited to this. For example, if the currents corresponding to two phases of the three-phase ac motor can be measured, the electric power supplied to the remaining one phase can be calculated and controlled using the detected value of the currents. In this case, any configuration may be used as long as the current flowing through the two first substrate-side terminals 56A and the two second substrate-side terminals 56B corresponding to any two of the phases of the three-phase ac motor is measured. In this case, four rogowski coils 70 are formed on the control substrate 60.

In the power control device 1 of the above embodiment, the plurality of capacitors 3 are connected in parallel with the battery 2, but a configuration without the capacitor 3 may be adopted.

In the above embodiment, the example was described in which the conductor connecting between the first switch substrate 50A and the control substrate 60 and the conductor connecting between the second switch substrate 50B and the control substrate 60 are constituted by the conductor pins 92 of the floating connector 90, but the present invention is not limited to this. The "conductor" according to the present invention may be constituted by a plate-like terminal member, a wire, a cable, or the like.

Description of the reference numerals

1 electric power control device

2 batteries (Power)

4 three-phase AC motor (electric power supply object)

6. Control unit

10. Device housing

12. Casing body

12F radiating fin

14. Shell cover

14A radiating fin

26 output terminal (26U, 26V, 26W)

50A first switch substrate

50B second switch substrate

54 switch element (first switch element, second switch element)

52A first wiring pattern

52B second wiring pattern

56A first substrate side terminal

56B second substrate side terminal

60 control substrate (coil substrate, substrate for detecting current)

62. Through part

90 floating connector

92 conductor pin (conductor)

94. Male connector

96. Female connector

70 Rogowski coil (coil for measuring current, pattern of Rogowski coil)

Claims (8)

1. An electric power control device is provided with:

a first switch substrate having a first wiring pattern and a plurality of first switch elements mounted on the first wiring pattern;

a second switch substrate having a second wiring pattern and a plurality of second switching elements mounted on the second wiring pattern;

a control board having a control unit for controlling an on state and an off state of the first switching element and the second switching element; and

a device housing accommodating the first switch substrate, the second switch substrate, and the control substrate, wherein,

the first switch substrate, the second switch substrate, and the control substrate are housed in the device case in a state of being arranged in the order of the first switch substrate, the control substrate, and the second switch substrate at predetermined intervals in the height direction of the device case.

2. The power control device according to claim 1, wherein,

The first wiring pattern and the second wiring pattern are formed so as to electrically connect a power source and a power supply object,

the first switching element is constituted by a high-side switching element electrically connected to a positive side of the power supply with respect to the power supply object,

the second switching element is configured by a low-side switching element electrically connected to a negative side of the power supply with respect to the power supply object.

3. The power control device according to claim 2, having:

a first substrate-side terminal connected to the first wiring pattern; and

a second substrate-side terminal connected to the second wiring pattern, wherein,

the first substrate-side terminal and the second substrate-side terminal are disposed to face each other in a height direction of the device case, and electrically connect a source electrode of the first switching element and a drain electrode of the second switching element.

4. The power control device according to claim 3, having:

an output terminal electrically connected between a source electrode of the first switching element and a drain electrode of the second switching element and supplying electric power to the electric power supply target,

The first substrate-side terminal, the second substrate-side terminal, and the output terminal include bus bar-type terminals,

the first substrate-side terminal and the second substrate-side terminal are connected via the output terminal so as to sandwich the side surfaces of the output terminal from both sides.

5. The power control device according to claim 3 or 4, wherein,

the control substrate is provided with a slit-shaped penetration portion penetrating the control substrate in the plate thickness direction,

the first substrate-side terminal is inserted into and penetrates a Rogowski coil pattern formed around one penetration portion of the control substrate, and the second substrate-side terminal is inserted into and penetrates a Rogowski coil pattern formed around the other penetration portion of the control substrate.

6. The power control apparatus according to any one of claims 1 to 4, wherein,

each of the first switch substrate and the control substrate and the second switch substrate and the control substrate is connected in the height direction of the device case by a plurality of conductors,

the plurality of conductors electrically connect the first wiring pattern with the signal lines of the control section, and the plurality of conductors electrically connect the second wiring pattern with the signal lines of the control section.

7. The power control apparatus according to any one of claims 1 to 4, wherein,

the device housing has: a housing main body, and a housing cover mounted to the housing main body,

one of the first switch substrate and the second switch substrate is fixed to the case body in a state of being in contact with the bottom surface of the case body,

the control board is fixed to a switch board fixed to the housing main body in a state of being supported at a predetermined interval from the switch board in a height direction of the device housing,

the other of the first switch substrate and the second switch substrate is fixed to the housing cover in a state of being in contact with an inner surface of the housing cover.

8. The power control device according to claim 7, wherein,

a plurality of heat radiating fins are formed on each of the outer surface of the housing main body and the outer surface of the housing cover.