DE102021209142A1 - Assembly module for connecting at least one phase output of an inverter device and inverter arrangement with the inverter device and the assembly module - Google Patents

Abstract

Inverters are required to convert DC voltage to AC voltage to supply drive motors in electric vehicles or hybrid vehicles.
An assembly module 3 for connecting at least one phase output of an inverter device 2 for a vehicle is proposed, with at least one rail device 5, the rail device 5 having an input connection 6 for making contact with the inverter device 2 and an output connection 7, with a plastic casing 8, wherein the plastic casing 8 encases the at least one rail device 5 in sections, with at least one sensor section for measuring a process variable of the assembly module 3, the plastic casing 8 encasing the at least one sensor section at least in sections and/or receiving it in a materially bonded manner.

Description

The invention relates to a mounting module for connecting at least one phase output of an inverter device for a vehicle. The invention also relates to an inverter arrangement with the inverter device and with the assembly module.

Inverters are required to convert DC voltage to AC voltage to supply drive motors in electric vehicles or hybrid vehicles. The inverters thus have inputs for supplying the DC voltage and outputs for outputting the AC voltage. The inverters and their connections must meet a large number of specifications with regard to electrical functionality and operational safety. The DC voltage used is referred to as high voltage (HV) in the vehicle sector and is usually more than 100 V, so that the entire structure must be designed for this voltage. In addition to the basic function of converting DC voltage to AC voltage, a large number of process signals must be provided in the inverter area in order to monitor the inverter. As a result, the inverter as a whole forms a complex arrangement with a large number of contact points for the various voltages, measurement signals, etc.

It is the object of the present invention to propose a contacting option for an inverter device that is suitable for assembly and production. This object is achieved by an assembly module with the features of claim 1 and by an inverter arrangement with the features of claim 13. Further features and advantages as well as effects of the invention are described in the dependent claims, the description with the figures.

The subject matter of the invention is an assembly module, the assembly module being suitable and/or designed for the connection of at least one phase output of an inverter device for a vehicle. The assembly module is designed in particular as a one-piece and/or one-piece and/or self-retaining assembly. The vehicle is designed in particular as an electric vehicle or as a hybrid vehicle. In any case, the vehicle has at least one traction motor for driving the vehicle, with the traction motor being designed as an electric motor.

The inverter device has the function of providing an AC voltage supply, in particular an AC supply for the electric motor, starting from a DC voltage supply, in particular a DC supply. The AC supply has the at least one phase output. Thus, the assembly module can also be referred to as an AC assembly module. For example, the inverter device has an intermediate circuit capacitor device and a plurality of switching devices. The switching devices are connected to the intermediate circuit capacitor device on the input side and to the at least one phase output on the output side.

The assembly module has at least one rail device, preferably a plurality of rail devices and in particular exactly three rail devices. The rail assemblies have an input port for contacting the inverter device and an output port for outputting the AC supply. The rail device can also be referred to as a busbar. In particular, the rail device is designed as an electrical conductor.

The assembly module has a plastic casing, the plastic casing partially encasing the at least one rail device. The plastic jacket is materially connected to the rail device. The plastic jacket is applied to the at least one rail device in particular in a primary form. The plastic jacket is cast, for example, so that the plastic jacket is designed as a cast jacket. Alternatively, the at least one rail device is overmoulded, so that the plastic jacket is designed as an overmoulded jacket. The integral connection between the plastic casing and the at least one rail device is produced by the casting and/or overmoulding.

The assembly module has at least one sensor section for measuring a process variable of the assembly module. The sensor section can in particular only form a part (section) of the sensor system. For example, the sensor system can be divided into a sensor as the sensor system section and an evaluation unit that matches the sensor as a further sensor system section.

In the context of the invention, it is proposed that the plastic casing at least partially encloses and/or cohesively accommodates the at least one sensory section. In particular, the plastic jacket is applied to the sensor section in a primary form. In particular, the at least one sensor section is cast in the cast jacket or encapsulated in the overmolding jacket.

It is a consideration of the invention that in the mounting module more functions than just contacting of the inverter device is introduced. Since the assembly module already comprises at least one sensor section as a one-piece and/or self-retaining assembly, this sensor section does not have to be additionally assembled during production of the inverter arrangement, but is already arranged in the inverter arrangement when the assembly module is assembled. This achieves a configuration of the inverter arrangement that is easy to assemble and manufacture.

In a preferred embodiment of the invention, the rail device has a shunt sensor, the shunt sensor forming an embodiment for the at least one sensor section. The shunt sensor can measure a current flow as a process variable. In particular, the shunt sensor is arranged in a materially bonded manner in the plastic casing. For example, the shunt sensor can be designed as an intermediate piece in the rail device. This intermediate piece is arranged electrically in series in the rail device and has, for example, a higher resistance than the rest of the rail material. Furthermore, shunt connections can be provided so that the shunt signal can be routed away from the shunt sensor. Due to the fact that the shunt sensor is already implemented in the mounting module, no other current sensor has to be additionally placed on the mounting module and/or the inverter device.

In an alternative or development of the invention, the assembly module has a temperature sensor. The temperature sensor can measure a temperature as a process variable. In particular, the temperature sensor is designed as a PTC sensor. It can be provided that the temperature sensor forms an embodiment for the at least one sensor section. In particular, the temperature sensor is materially bonded to the plastic jacket at least in sections. Even if the temperature sensor is already integrated into the mounting module, the complexity for connecting the inverter device is reduced.

It is possible for a current sensor to be designed differently and for the temperature sensor to be integrated in the assembly module. However, it is preferred that both the shunt sensor and the temperature sensor are embedded in the assembly module in a materially bonded manner.

The temperature sensor is particularly preferably arranged so that it overlaps and/or is congruent with the shunt sensor. This configuration takes into account the fact that the shunt sensor forms a heat source in the mounting module and/or the rail device due to the slightly increased resistance. Due to the fact that the temperature sensor is arranged directly adjacent to the shunt sensor, the warmest point of the rail device is monitored by the temperature sensor. However, it is also possible for the temperature sensor to be arranged subsequently and not integrated in the plastic casing.

It is particularly preferred if the temperature sensor is arranged electrically insulated from the shunt sensor by an intermediate layer in order to avoid a voltage transfer and/or current flow from the rail device, in particular from the shunt sensor, to the temperature sensor. The intermediate layer can be made, for example, by the plastic mass of the plastic jacket if the temperature sensor is applied later. As an alternative to this, an insulating layer, in particular insulating film, for example a Kapton film, or a TIM layer can be arranged between the temperature sensor and the rail device if the temperature sensor is arranged in a materially bonded manner in the plastic casing.

In an alternative or development of the invention, the assembly module has an evaluation unit for evaluating the signals from the shunt sensor and/or from the temperature sensor. The evaluation unit forms a possible embodiment for the at least one sensor section. For example, the evaluation unit includes a printed circuit board, the printed circuit board being connected to the temperature sensor and/or to the shunt sensor in terms of signals. The evaluation unit can be integrally integrated into the plastic casing. As an alternative to this, the evaluation unit is subsequently placed on the plastic casing. In this alternative, bearing surfaces for a defined bearing and/or adhesive connection of the evaluation unit can be provided on the plastic casing.

In a preferred development of the invention, the assembly module has a plug-in socket for plugging in a lug connection of the inverter device. The tab connection forms the phase output. In particular, the plug-in socket has a rectangular cross section. In particular, the plug-in socket is designed as a plug-in slot. The assembly module can be plugged onto the inverter device in a plug-on direction, with the plug-in socket being pushed onto the tab connection.

The plug-in socket is formed internally on one side, in particular on a ceiling section, by the input connection of the rail device. Opposite the input port and/or on a bottom portion of the socket, the mounting module has a wedge portion. For example, the wedge section be formed by inserting a wedge element before the primary shaping of the plastic jacket. Alternatively, the wedge section is formed by the plastic jacket. The wedge section is designed to taper towards the input connection counter to the push-on direction and/or in a plug-in direction. The plug-in socket thus becomes increasingly narrower towards the course of the plug-on direction and/or inwards and/or in the plug-in direction. As a result, when the tab connector is inserted into the socket, the tab connector is pressed against the input connector. In this way, good electrical contact is established between the tab connection and the input connection. The contact can also be taken over by a correspondingly tolerated height of the lug and lug connection. In addition to or without the wedge effect, contact can be made here by a quasi-slight bending of the contact lug.

Structurally, it is preferable for the rail device to be L-shaped, with the lying leg forming the input connection. Preferably, the entry terminal and the tab terminal have the same width perpendicular to the direction of insertion. Alternatively or additionally, the standing leg has the shunt sensor.

It is preferred that the assembly module has at least one assembly sleeve. The mounting sleeve is cohesively arranged in the plastic casing. A fastening direction of the mounting sleeve is aligned perpendicular to the push-on direction and/or to the surface extension of the input connection and/or the tab connection. In particular, the at least one mounting sleeve has a through-opening for receiving a screw element. For example, it can be provided that the inverter device and the mounting module are plugged into one another and are subsequently fixed to one another by the screw element in the mounting sleeve. In the fastening direction, the input connection and the lug connection are preferably arranged in an overlapping manner and also one after the other such that the input connection is pressed onto the lug connection by fastening the mounting sleeve (addition above).

Provision is particularly preferably made for the plastic jacket to be in the form of a thermally conductive plastic, with the heat conduction being greater than 4 W/m*K or greater. This improves the cooling and increases the heat capacity and the outer surface, so that any heat that occurs can be better absorbed.

It is particularly preferred that the assembly module has three of the rail devices. A three-phase AC output can thus be represented with a single mounting module. The rail devices are preferably arranged in parallel and/or in a row.

• 1 eine schematische, dreidimensionale Darstellung einer Inverteranordnung als ein Ausführungsbeispiel der Erfindung;
• 2 eine schematische, dreidimensionale Darstellung von Einlegerteilen für das Montagemodul in der 1 ;
• 3 eine schematische, dreidimensionale und teilweise durchsichtig gestaltete Darstellung von einem Montagemodul für die Invertervorrichtung der vorhergehenden Figuren als ein Ausführungsbeispiel der Erfindung;
• 4 in gleicher Darstellung wie in der 3 das vollständig bestückte Montagemodul;
• 5 a, b eine Detailansicht des Montagemoduls der vorhergehenden Figuren im Bereich einer Einsteckbuchse.

A further object of the invention is an inverter arrangement, which comprises the inverter device described above and the assembly module, the inverter device and the assembly module being plugged into one another.

• 1 a schematic, three-dimensional representation of an inverter arrangement as an embodiment of the invention;
• 2 a schematic, three-dimensional representation of insert parts for the assembly module in the 1 ;
• 3 a schematic, three-dimensional and partially transparent representation of a mounting module for the inverter device of the preceding figures as an embodiment of the invention;
• 4 in the same representation as in the 3 the fully assembled assembly module;
• 5a, b a detailed view of the assembly module of the preceding figures in the area of a socket.

The 1 shows a schematic, three-dimensional representation of an inverter arrangement 1 with an inverter device 2 and with a mounting module 3. The inverter device 2, which is only partially shown, has the function of an applied direct voltage (DC supply) on the output side of an alternating voltage (AC supply) to provide. As an interface, the inverter arrangement 2 has three lug connections 4, which are rectangular in plan view, lie next to one another in a common plane and are aligned parallel to one another. For example, the DC voltage is greater than 100 V.

The mounting module 3 can be plugged onto the lug connections 4 in a plug-on direction A in order to make electrical contact with them. The assembly module 3 thus forms a connection for three phase outputs and/or a three-phase AC supply.

The assembly module 3 has three rail devices 5, each of which has an input connection 6, which is shown here only covered, for making contact with the inverter device 2, in particular with its strap connections 4. Furthermore, the rail devices 5 each have an output terminal 7 so that the AC supply can be routed. The rail devices 5 are offset in a row in parallel, spaced apart from one another and, in particular, arranged in an electrically insulated manner from one another.

The assembly module 3 has a plastic casing 8, the plastic casing 8 enclosing and/or accommodating the rail devices in a materially bonded manner. The plastic jacket 8 is produced by molding and can be produced, for example, by casting, overmolding or injection molding in general. (Possibly also possible as a two-part clip connection with filler (e.g. prototype area via 3D printing)

The mounting module 3 has three plug-in sockets 9, with the mounting module 3 being mounted in the insertion direction A in such a way that the tab connections 4 reach the plug-in sockets 9, so that the input connections 6 are contacted. The assembly module 3 has four assembly sleeves 10 , screws 11 being able to be inserted through the assembly sleeve 10 in a direction perpendicular to the plug-on direction A in order to fasten the assembly module 3 to the inverter device 2 . The mounting sleeves 10 are made, for example, from the material EN AW 6082 (optionally T6).

The 2 shows in a schematic, three-dimensional representation the three rail devices 5 and the three mounting sleeves 10 as insert parts for the plastic casing 8.

The rail devices 5 are L-shaped, with the upper end of the standing limb forming the outlet connection 7 and the lying limb forming the inlet connection 6 . The rail devices 5 have an intermediate piece in the middle part, the intermediate piece forming a shunt sensor 13 . In particular, the sections with the input connection 6 and the output connection 7 are made of copper and the shunt sensor is made of a CuMn compound. The busbar devices each have two signal pins 14 for tapping a voltage drop at the shunt sensor 13 . The signal pins 14 are arranged along a center line in front of and behind the shunt sensor 13 and extend perpendicularly to the surface extent of the rail device 5.

The mounting sleeves 10 are designed as straight hollow cylinders and have widenings on the upper side, so that when the screws 11 are screwed in, they have a sufficient contact surface on or in the plastic casing 8 .

The 3 shows the assembly module 3 with the rail devices 5 in a schematic, three-dimensional and partially transparent representation, with the rail device 5 being cut off in the area of the output connection 7 for graphic reasons.

The plastic casing 8 is formed as a continuous block in a lower area with the plug-in sockets 9 , in the upper area there are shoulders which enclose the rail devices 5 . The plug-in sockets 9 into which the lug connections 4 are inserted can be seen again from this illustration. The plastic casing 8 has a window-like recess in the area of the shunt sensor 13, so that access to the shunt sensor 13 through the plastic casing 8 for contacting the shunt sensor 13 is possible from the outside. Circular bearing surfaces 15 are applied to the plastic jacket 8, which enable a defined positioning of further components, as will be explained below. The bearing surfaces 15 are arranged, for example, in a common plane. It can also be seen that the signal pins 14 are fed through the plastic casing 8 so that the shunt sensor 13 can be contacted despite the plastic casing 8 .

The 4 shows the assembly module 3 in the same representation, but which is fully equipped, in a slightly modified embodiment. In an intermediate step that is not shown, the temperature sensors 12 have been applied to the shunt sensors 13 . The temperature sensors 12 are designed as a PT 100, for example. On the one hand, it is possible for an intermediate layer made of the plastic compound of the plastic casing 8 to be applied between the temperature sensor 12 and the shunt sensor 13 in order to achieve electrical insulation. As an alternative to this, an insulating film, such as a Kapton film, or a TIM layer is arranged between the shunt sensor 13 and the temperature sensor 12 . In the case of the last-mentioned possible embodiment, it is also conceivable to first equip the rail devices 5 with the temperature sensors 12 and the insulating layer placed between them and then to enclose them with the plastic during primary shaping in order to form the plastic jacket 8 .

An evaluation unit 16 was placed on each of the bearing surfaces 15 of a rail device 5, with the evaluation unit 16 in each case comprising a circuit board or being formed by it. On the one hand, the protruding signal pins 14 are contacted with the evaluation unit 16, in particular via the circuit board. On the other hand, the temperature sensors 12 are connected to the evaluation unit 16 via additional electrical lines. For this purpose, the evaluation unit 16, in particular the circuit board, has a window-like passage, the window-like passage being congruent is arranged to the window-like recess in the plastic jacket 8. The evaluation unit 16, in particular the circuit board, rests on the bearing surfaces 15 and is thus defined in position. In further exemplary embodiments, it is also conceivable that the evaluation unit 16 is also mounted on the rail devices 5 and is subsequently encased in the plastic jacket 8 in the primary forming process, so that all three sensor sections, namely the temperature sensor 12, the shunt sensor 13 and the evaluation unit 16, are integrally bonded by the plastic of the plastic jacket 8 are wrapped. To contact the evaluation units 16, they can have plugs or sockets.

In the 5a a partially sectioned illustration of the assembly module 3 in the area of the input connection 6 or the plug-in socket 9 is shown. In the 5b This area is shown in a schematic cross section. It can be seen from these illustrations that the strap connection 4 is arranged under the input connection 6 in the fastening direction of the screws 11, so that when the assembly module 3 is screwed tight, the input connection 6 is pressed onto the strap connection 4.

In order to further improve the electrical contact, a wedge section 17 is introduced into the plastic jacket 8, which in the 5b can be seen. The wedge section 17 is arranged in such a way that a distance between a bottom of the plug-in socket 9 and the input terminal 6 against the plug-on direction A becomes smaller. Thus, the lug connection 4 can initially penetrate into the plug-in sockets 9 with almost no force. If the assembly module 3 is pushed on further, the lug connection 4 is pressed against the input connection 6 due to the wedge section 17 . With this additional measure, the electrical contact is further improved.

In particular, the following advantages can be achieved with the assembly module 3: A reduced installation space requirement is achieved due to the compact design. Air creepage distances are minimized by encasing the rail devices 5 with the plastic jacket 8 . Easy assembly and disassembly. The HV contact is made via terminals (plug contact). Reduction of screw connections. In particular, the HV dielectric strength is greater than 24/kV/mm (for 0.2mm). The plastic mass of the plastic jacket 8 is thermally conductive with more than 4W/m*K.

Reference List

1

inverter arrangement

2

inverter device

3

assembly module

4

tab connection

5

rail facility

6

input port

7

output port

8th

plastic jacket

9

sockets

10

Assembly sleeve

11

screws

12

temperature sensor

13

shunt sensor

14

signal pins

15

bearing surfaces

16

evaluation unit

17

wedge section

A

mounting direction

Claims (13)

Mounting module (3) for connecting at least one phase output of an inverter device (2) for a vehicle, with at least one rail device (5), the rail device (5) having an input connection (6) for contacting the inverter device (2) and an output connection ( 7), with a plastic casing (8), the plastic casing (8) encasing the at least one rail device (5) in sections, with at least one sensor section for measuring a process variable of the assembly module (3), characterized in that the plastic casing (8) the at least one sensor section is at least partially encased and/or cohesively accommodated. Mounting module (3) according to claim 1 , characterized in that the rail device (5) has a shunt sensor (13), wherein the shunt sensor (13) forms an embodiment for the at least one sensor section. Mounting module (3) according to claim 2 , characterized in that the shunt sensor (13) is designed as an intermediate piece in the rail device (5), the intermediate piece being bonded to the plastic casing (8) at least in sections. Mounting module (3) according to any one of the preceding claims, characterized in that this has a temperature sensor (12), wherein the temperature sensor (12) forms an embodiment for the at least one sensor section. Mounting module (3) according to claim 4 , characterized in that the temperature sensor (12) is arranged to overlap with the shunt sensor (13). Mounting module (3) according to claim 5 , characterized in that the temperature sensor (12) is arranged electrically insulated from the shunt sensor (13) by an intermediate layer. Mounting module (3) according to one of the preceding claims, characterized in that it has an evaluation unit (16) for evaluating the signals from the shunt sensor (13) and/or from the temperature sensor (12), the evaluation unit (16) being designed for forms the at least one sensor section. Assembly module (3) according to one of the preceding claims, characterized in that the assembly module (3) has a plug-in socket (9) for plugging in a lug connection (4) of the inverter device (2) against a plug-in direction (A), the plug-in socket (9 ) is formed by the input connection (6) of the rail device (5) and opposite by a wedge section (17) of the assembly module (3), wherein the wedge section (17) is designed to run towards the input connection (6) against the plug-on direction (A), so that when the tab connector (4) is inserted into the socket (9), the tab connector (4) is pressed against the input connector (6). Assembly module (3) according to one of the preceding claims, characterized in that the rail device (5) is L-shaped, with the lying leg forming the input connection (6) and/or the standing leg having the shunt sensor (13). Assembly module (3) according to one of the preceding claims, characterized in that it has at least one assembly sleeve (10), the assembly sleeve (10) being integrally accommodated in the plastic casing and wherein a fastening direction of the assembly sleeve (10) is perpendicular to the push-on direction (A ) and/or to the surface extent of the input connection (6) and/or the tab connection (4). Assembly module (3) according to one of the preceding claims, characterized in that the plastic material for the plastic jacket (8) is designed as a thermally conductive plastic. Assembly module (3) according to one of the preceding claims, characterized in that the assembly module (3) has three of the rail devices (5) and/or is designed as a three-phase AC output. Inverter arrangement (1) with the inverter device (2) and the mounting module (3) according to one of the preceding claims.

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