DE112022000836T5 - POWER CONVERTER APPARATUS, ENGINE APPARATUS AND VEHICLE - Google Patents

Abstract

One form of the power converter device of the present invention is a power converter device having an inverter circuit and a converter circuit. The power converter device includes a power module that includes the inverter circuit, a reactor that smoothes a direct current supplied to the converter circuit, and a control board that controls at least one of the inverter circuit and the converter circuit. The control board is arranged on a side of a first direction with respect to the power module, with the first direction as a plate thickness direction. The reactor coil includes a coil element wound around a center axis line extending along the first direction, and is disposed on a side of a second direction orthogonal to the first direction with respect to the power module. The power module and the control board are positioned on the outside in the radial direction of the reactor when viewed from the first direction. The control board is positioned further than the choke coil on one side of the first direction.

Description

Technical area

The present invention relates to a power converter device, a motor device and a vehicle.

General state of the art

In recent years, the development of power conversion devices for motors and generators installed in electric vehicles or hybrid vehicles is being promoted. In such power converter devices, a converter circuit and an inverter circuit are formed. Therefore, it is necessary to prevent electromagnetic noise generated from a reactor of the converter circuit and the like from exerting influence on other components. In Patent Literature Example 1, a structure is disclosed in which a reactor case covering the entire reactor is formed, the reactor case covering the electromagnetic noise generated from the reactor.

Literature of precursor technology

Patent literature

Patent Literature Example 1: Patent Disclosure Publication 2020-089185

Disclosure of the invention

Task that the invention is intended to solve

Hitherto, in order to obtain a masking effect against electromagnetic noise generated from the choke coil, it was necessary to form a housing that covers the entire choke coil.

An object of the present invention, made in view of the above circumstances, is to provide a power conversion device in which electromagnetic noise generated from the reactor is difficult to influence other components even without covering the entire reactor with a housing, a motor device and provide a vehicle.

means of solving the task

One form of the power converter device of the present invention is a power converter device having an inverter circuit and a converter circuit. The power converter device includes a power module that includes the inverter circuit, a reactor that smoothes a direct current supplied to the converter circuit, and a control board that controls at least one of the inverter circuit and the converter circuit. The control board is arranged on a side of a first direction with respect to the power module, with the first direction as a plate thickness direction. The reactor coil includes a coil element wound around a center axis line extending along the first direction, and is disposed on a side of a second direction orthogonal to the first direction with respect to the power module. The power module and the control board are positioned on the outside in the radial direction of the reactor when viewed from the first direction. The control board is positioned further than the choke coil on one side of the first direction.

One form of the motor device of the present invention includes the power converter device described above.

One form of the vehicle of the present invention includes the above-mentioned engine device.

Result of the invention

According to one form of the present invention, a power conversion device in which electromagnetic noise generated from the reactor is difficult to influence other components, a motor device and a vehicle is provided.

Simple explanation of the drawings

• 1 : 1 is a circuit block diagram of a motor device of one embodiment.
• 2 : 2 is a schematic view showing a longitudinal section of a power conversion device of an embodiment.
• 3 : 3 is an oblique view of a choke coil of an embodiment.

Ways to carry out the invention

Referring to the drawings, a power conversion device 10, a motor device 1 and a vehicle 9 according to embodiments of the present invention will be described below. To facilitate understanding of each structure, the scale and number of structures in the drawings below may differ from the actual structures.

In the following explanation, the direction of gravity is defined based on the positional relationship when the power conversion device 10 was installed in a vehicle located on a horizontal road surface. The location of the power conversion device 10 in the present description is exemplary and does not constitute a limitation on the location in which the power conversion device 10 is actually mounted.

1 is a circuit block diagram of the motor device 1. The motor device 1 of the present embodiment is installed in a vehicle 9 that uses an internal combustion engine and a motor as power sources, such as a hybrid vehicle (HEV) or a plug-in hybrid vehicle (PHV). The motor device 1 can also be set up in an electric vehicle without an internal combustion engine (EV).

The vehicle 9 of the present embodiment includes the engine device 1 and an internal combustion engine (not shown). The motor device 1 has a generator 3 driven by the internal combustion engine, not shown, a battery 4 as a DC power source charged by the generator 3, and a motor 2 having at least one of the generator 3 and the battery 4 as a power source drives drive wheels, not shown.

The power conversion device 10 converts a DC voltage supplied from the battery 4 into an AC voltage after a voltage increase, supplies the converted AC voltage to the motor 2 and drives the motor 2, and also sets a voltage in a regeneration operation of the motor 2 after conversion into a DC voltage and supplies it to the battery 4. The power conversion device 10 reduces the voltage generated by the generator 3 after converting it into a DC voltage and supplies it to the battery 4 or drives the motor 3 with the voltage generated by the generator 3.

The individual structures of the power converter device 10 will be specifically explained below.

The motor 2 is mechanically connected to a reduction mechanism (not shown). The motor 2 drives the drive wheels of the vehicle 9 via the reduction mechanism. The generator 3 is mechanically connected to the reduction mechanism. The generator 3 acts as a regeneration brake with respect to the operation of the vehicle 9 and generates electricity based on the energy when decelerating. The motor 2 and the generator 3 of the present embodiment are a three-phase motor, but may also be a multi-phase motor with four or more phases. The motor 2 and the generator 3 are each connected to the power converter device 10. The battery 4 is, for example, a secondary battery or a double-layer capacitor. The battery 4 is connected to the power converter device 10. The battery 4 supplies the motor 2 via the power converter device 10 power. Or the battery 4 is supplied with power from the generator 3 via the power converter device 10.

The power converter device 10 includes a converter circuit 13, a motor inverter circuit (inverter circuit) 11 and a generator inverter circuit (inverter circuit) 12. The converter circuit 13 is a so-called DC-DC converter. The converter circuit 13 changes the voltage of the direct current supplied from the battery 4. The motor inverter 11 converts the direct current supplied from the converter circuit 13 into an alternating current and supplies it to the motor 2. The generator inverter circuit 12 converts the electricity generated in the generator 3 from an alternating current to a direct current and supplies it to the battery 4 .

In the explanation below, when no distinction is made between the motor inverter circuit 11 and the generator inverter circuit 12, they are simply referred to as inverter circuits 11, 12.

2 is a schematic view of a longitudinal section of the power converter device 10.

In 2 a first direction D1, a second direction D2 and a third direction D3 are indicated.

In the present embodiment, the first direction D1 is the vertical direction, one side of the first direction D1 being the top and the other side of the first direction D1 being the bottom.

The second direction D2 is a direction orthogonal to the first direction D1. In the present embodiment, the second direction D2 is a direction along the horizontal plane. One side of the second direction D2 is the right side in 2 , and the other side of the second direction D2 is the left side in 2 .

The third direction D3 is a direction along the horizontal plane that is orthogonal to the first direction D1 and the second direction D2. That is, the first direction D1, the second Direction D2 and the third direction D3 are directions that are orthogonal to each other.

The power converter device 10 includes an inverter control board (control board) 41, a converter control board (control board) 42, a power board 43, a first drive board 45, a second drive board 46, a motor power module 21, a generator power module 22, a choke coil 30, a choke coil base (second heat transfer plate) 35, a capacitor module 15, a cover plate 50, a heat transfer plate (first heat transfer plate) 55, a flow path forming body 60 and a housing 19. The flow path formation body 60 has a first cooling plate 61, a second cooling plate 62, a third cooling plate 63 and a connecting line 64.

The housing 19 houses the inverter control board 41, the converter control board 42, the power board 43, the first drive board 45, the second drive board 46, the motor power module 21, the generator power module 22, the choke coil 30, the choke coil base 35, the capacitor module 15, the cover plate 50, the heat transfer plate 55 and the flow path forming body 60.

As in 1 As shown, the motor power module 21 has the motor inverter circuit 11. On the other hand, the generator power module 22 has the generator inverter circuit 12. The motor inverter circuit 11 and the generator inverter circuit 12 convert a DC voltage into an AC voltage or an AC voltage into a DC voltage.

In the explanation below, when no distinction is made between the engine power module 21 and the generator power module 22, they are simply referred to as power modules 21, 22.

The engine power module 21 and the generator power module 22 each have six first switching elements (switching elements) 16. The first switching elements 16 in the present embodiment are insulated gate bipolar transistors (IGBT). That is, the power modules 21, 22 have insulated gate bipolar transistors. By using insulated gate bipolar transistors as first switching elements 16, the power modules 21, 22 can be formed relatively cheaply. The inverter circuits 11, 12 are PWM inverters based on pulse width modulation (PWM), which is provided with a bridge circuit in which the first switching elements 16 are connected in the form of a bridge.

As in 2 As shown, the engine power module 21 and the generator power module 22 are each arranged along the horizontal plane (the plane orthogonal to the first direction D1). The generator power module 22 is joined to the top of the engine power module 21 via the third cooling plate 63. That is, the third cooling plate 63 is inserted between the engine power module 21 and the generator power module 22. As will be discussed later, the third cooling plate 63 cools the engine power module 21 and the generator power module 22 via coolant L flowing inside.

The first drive board 45 is arranged on the underside of the motor power module 21. The second drive board 46 is arranged on the top of the generator power module 22. Board main bodies 45a, 46a of the first drive board 45 and the second drive board 46 are arranged along the horizontal plane (the plane orthogonal to the first direction D1).

The first drive board 45 is connected to the motor power module 21 and the inverter control board 41. Likewise, the second drive board 46 is connected to the generator power module 22 and the inverter control board 41. The first drive board 45 and the second drive board 46 each generate the drive current of the first switching elements 16 based on control signals for controlling the first switching elements 16 generated by the inverter control board 41.

As in 1 is shown, the power board 43 has a converter circuit 13. The converter circuit 13 increases the voltage supplied from the battery 4 or reduces the voltage supplied to the battery 4. The choke coil 30 is connected in series between the converter circuit 13 and the battery 4. The capacitor module 15 is connected in parallel to the downstream side of the converter circuit 13.

The power board 43 has two second switching elements (switching elements) 17 and a board main body (in 1 omitted), on which the second switching elements 17 are set up. In the case of the present embodiment, the second switching elements 17 are transistors containing silicon carbide (SiC). That is, the power board 43 includes transistors containing silicon carbide. By using transistors containing silicon carbide as the second switching elements 17, the conversion rate of the voltage in the second switching elements 17 can be increased and heat generation of the power board 43 can be suppressed. The converter circuit 13 is provided with a chopper circuit to which the second switching elements 17 are connected.

As in 2 As shown, a board main body 43a of the power board 43 is arranged along the horizontal plane (the plane orthogonal to the first direction D1). That is, the power board 43 is arranged with the vertical direction (the first direction D1) as the board thickness direction. At the bottom (the other side of the first direction D1) of the power board 43, the first cooling plate 61 is arranged via a heat transfer plate 55.

The heat transfer plate 55 is formed of a metal material having high heat transfer ability. As the material constituting the heat transfer plate 55, for example, an aluminum alloy, a copper alloy, or the like can be cited. More preferably, for the material constituting the heat transfer plate 55, a material that shields magnetism (for example, aluminum alloy) is used.

The heat transfer plate 55 is arranged along the horizontal plane (the plane orthogonal to the first direction D1) and is plate-shaped. That is, the heat transfer plate 55 is arranged with the vertical direction (the first direction D1) as the plate thickness direction. In addition, the heat transfer plate 55 is stacked with the power board 43 along the vertical direction (the first direction D1).

The heat transfer plate 55 is in contact with the power board 43. Even more specifically, the heat transfer plate 55 is connected to the second switching elements 17 (in 2 not shown) in contact. The heat transfer plate 55 is cooled by the coolant L flowing inside the first cooling plate 61. The power board 43 is cooled by the coolant L via the heat transfer plate 55. The heat transfer plate 55 may also be designed to have heat radiation fins on the surface in contact with the coolant L.

As in 1 is shown, the capacitor module 15 is connected in parallel between the converter circuit 13 and the inverter circuits 11, 12. The capacitor module 15 smoothes the direct current supplied to the motor inverter circuit 11 by the converter circuit 13 in a capacitor element 15a.

As in 2 As shown, the capacitor module 15 has the capacitor element 15a and a capacitor housing 15b which accommodates the capacitor element 15a. The capacitor module 15 is on one side of the second direction D2 (the right side in.) with respect to the engine power module 21, the generator power module 22 and the third cooling plate 63 2 ) arranged. The capacitor module 15 is on the other side of the second direction D2 (the left side in.) with respect to the second cooling plate 62 2 ) arranged.

The capacitor module 15 is in contact with the second cooling plate 62 and the third cooling plate 63. The second cooling plate 62 and the third cooling plate 63 are cooled by a flow of the coolant L inside them. According to the present embodiment, the capacitor module 15 is efficiently cooled from both sides of the second direction D2 by contacting the second cooling plate 62 and the third cooling plate 63 disposed on one side and the other side of the second direction D2, respectively. This prevents the capacitor module 15 from reaching a high temperature and increases the reliability of the capacitor element 15a.

As in 1 As shown, the choke coil 30 is connected in series between the battery 4 and the converter circuit 13. The choke coil 30 smoothes the direct current supplied from the battery 4 to the converter circuit 13.

As in 2 As shown, the choke coil 30 is on one side of the second direction D2 (the right side in.) with respect to the power modules 21, 22 and the third cooling plate 63 2 ) arranged. The capacitor module 15, the third cooling plate 63 and the choke coil base 35 are arranged between the choke coil 30 and the power modules 21, 22 and the third cooling plate 63.

The choke coil 30 is held on the choke coil base 35. The reactor base 35 has a plate-shaped portion with the second direction D2 as the plate thickness direction. The reactor base 35 is formed of a metal material having high heat transfer capability. For the material constituting the reactor base 35, materials excellent in heat transferability such as aluminum alloy, copper alloy, or the like may be cited. More preferably, for the material constituting the reactor base 35, a material that shields magnetism (for example, aluminum alloy) is used.

The choke coil base 35 is in contact with the choke coil 30. The reactor base 35 is cooled by the coolant L flowing inside the second cooling plate 62. The choke coil 30 is cooled by the coolant L via the choke coil base 35. The choke coil base 35 may also have heat radiation fins on the contact surface with the coolant L.

3 is an oblique view of the choke coil 30

The choke coil 30 has three coil elements 30a and a choke coil housing 30b. The coil elements 30a are formed of a thin wire wound around a center axis line J extending along the vertical direction (the first direction D1). The reactor case 30b is formed of, for example, a resin material. The reactor housing 30b accommodates the three coil elements 30a. The coil elements 30a and the reactor housing 30b are on a side of the second direction D2 (the right side in 2 ) of the choke coil base 35 positioned. The three coil elements 30a are arranged side by side along the surface direction of the reactor coil base 35.

An embodiment is also possible in which a part of the reactor base 35 protrudes in the thickness direction and supports the periphery of the reactor housing 30b.

As in 2 As shown, the inverter control board 41 and the converter control board 42 are arranged at the top (one side of the second direction D1) with respect to the power modules 21, 22.

In the explanation below, when no distinction is made between the inverter control board 41 and the converter control board 42, they are simply referred to as control boards 41, 42.

The inverter control board 41 is electrically connected to the motor power module 21 and the generator power module 22 via the first drive board 45 and the second drive board 46. The inverter control board 41 controls the inverter circuits 11, 12. The inverter control board 41 generates control signals for controlling the first switching elements 16 of the motor power module 21 and the first switching elements 16 of the generator power module 22.

The converter control board 42 is electrically connected to the power board 43. The converter control board 42 controls the converter circuit 13 of the power board 43. The converter control board 42 generates control signals for controlling the second switching elements 17 of the power board 43.

The board main bodies 45a, 46a of the control boards 41, 42 are arranged along the horizontal plane (the plane orthogonal to the first direction D1). That is, the control boards 41, 42 are arranged with the vertical direction (the first direction D1) as the thickness direction. The inverter control board 41 is arranged at the top (on one side of the direction D1) with respect to the converter control board 42.

The control boards 41, 42 are comparatively easily influenced by electromagnetic noise with a high frequency. The inventors of the present invention have found that the electromagnetic noise generated from the reactor 30 propagates outward at a high frequency in the radial direction of the center axis lines J of the reactor 30. According to the present embodiment, the control boards 41, 42 are positioned on the outside in the radial direction of the reactor 30 with respect to the reactor 30 when viewed from the vertical direction (the first direction D1). In addition, the control boards 41, 42 are positioned further up (on one side of the first direction D1) than the choke coil 30. Therefore, the high frequency electromagnetic noise propagating outward from the reactor 30 in the radial direction hardly reaches the control boards 41, 42 in the present embodiment. As a result, the control boards 41, 42 are hardly affected by electromagnetic noise with a high frequency, and the reliability of the control boards 41, 42 can be increased.

In the present embodiment, a case where the inverter control board 41 and the converter control board 42 both have the above-described arrangement with respect to the reactor 30 has been explained. However, when one of the inverter control board 41 and the converter control board 42 is arranged as described above, the effect of being difficult to be affected by electromagnetic noise can be obtained for the control board concerned. That is, when a control board that controls at least one of the inverter circuit 11 and the converter circuit 13 is arranged as described above, the specific effect can be obtained for that control board.

According to the present embodiment, the reactor base 35 is arranged between the reactor 30 and the control boards 41, 42 and the power modules 21, 22 as viewed from the vertical direction (the first direction D1). And preferably, for the material constituting the reactor base 35, a material that shields magnetism (for example, aluminum alloy) is used. In this case, the reactor base 35 covers the electromagnetic noise radiating from the reactor 30 outward toward the control boards 41, 42 and the power modules 21, 22 in the radial direction of the center axis lines J. The effect of shielding electromagnetic waves through the choke coil base 35 is only below supportive. Therefore, it is not necessary to make the reactor base 35 thick to increase the shielding effect.

In the present embodiment, the second cooling plate 62 extending along the vertical direction (the first direction D1) is arranged between the power modules 21, 22 and the reactor 30. For the material constituting the second cooling plate 62, a material that shields magnetism (for example, aluminum alloy) is preferably used. In this case, the second cooling plate 62 covers the electromagnetic noise radiating from the choke coil 30 outward toward the control boards 41, 42 and the power modules 21, 22 in the radial direction of the center axis lines J.

In the present embodiment, the capacitor module 15 is arranged between the power modules 21, 22 and the second cooling plate 62. Therefore, the capacitor module 15 covers the electromagnetic noise radiating from the reactor 30 in the radial direction of the center axis lines J outward toward the control boards 41, 42 and the power modules 21, 22.

Further, the power modules 21, 22 according to the present embodiment are positioned on the outside in the radial direction of the reactor 30 as viewed from the vertical direction (the first direction D1). The power modules 21, 22 are comparatively large-sized elements among the elements constituting the power conversion device 10. According to the present embodiment, the space inside the case 19 is effectively utilized by arranging the power modules 21, 22 as described above, and can be aimed at making the power conversion device 10 small in size.

In the present embodiment, the center axis lines J of the coil elements 30a extend along the first direction D1. Here, the “running of the center axis lines J along the first direction D1” includes not only a course of the center axis lines J that is strictly parallel to the first direction D1, but also an inclination in a range of ± 45 ° with respect to the first direction D1 in at least one from the second direction D2 and the third direction D3. According to the present embodiment, the above-described specific effect can also be obtained when the center axis lines J of the coil elements 30a are arranged in a position in which they are inclined with respect to the first direction D1 in a range of ±45°.

In the present embodiment, the control boards 41, 42 and the power board 43 are stacked along the vertical direction (the first direction D1). That is, the power board 43 is arranged in layers with the control boards 41, 42. According to the present embodiment, it becomes easy to arrange the control boards 41, 42 and the power board 43 close to each other, and a cable set (not shown) connecting the boards can be shortened. This can reduce the electromagnetic noise generated by the cable set.

The cover plate 50 is arranged between the inverter control board 41 and the converter control board 42. The cover plate 50 is arranged along the horizontal plane (the plane orthogonal to the first direction D1) and is plate-shaped. That is, the cover plate 50 is arranged with the vertical direction (the first direction D1) as the plate thickness direction. The cover plate 50 holds the control boards 41, 42. That is, the inverter control board 41 is fixed to the upper surface of the cover plate 50, while the converter control board 42 is fixed to the lower surface of the cover plate 50. In addition, the cover plate 50 is fixed to the inner side surface of the housing 19.

The cover plate 50 provides shielding from magnetism between the inverter control board 41 and the converter control board 42. Consequently, the cover plate 50 prevents electromagnetic noise generated by one of the inverter control board 41 and the converter control board 42 from reaching and affecting the other of these elements. The shield plate 50 is formed of, for example, an aluminum alloy. However, it is also possible to use a shield plate 50 formed of an iron-based alloy with the intention of increasing the magnetic shielding effect.

In the converter control board 42 of the present embodiment, both a high voltage region in which a high voltage current flows and a low voltage region in which a low voltage current flows are formed. In the inverter control board 41, on the other hand, only a low voltage region in which a low voltage current flows is formed. According to the present embodiment, an influence of the electromagnetic noise generated by the high voltage portion of the converter control board 42 on the inverter control board 41 can be suppressed.

In the present embodiment, the cover plate 50 covers the entire lower surface of the inverter control board 41. That is, the cover plate 50 overlaps from the vertical direction (the first direction D1) views the entire inverter control board 41. Thereby, the cover plate 50 effectively suppresses electromagnetic noise from reaching the inverter control board 41 from the bottom.

According to the present embodiment, the inverter control board 41 is disposed above (on one side of the first direction D1) of the cover plate 50 and the converter control board 42 is disposed below the cover plate 50. The inverter control board 41 is more easily affected by the high frequency electromagnetic noise from the reactor 30 compared to the converter control board 42. According to the present embodiment, since the inverter control board 41 is disposed at the top of the cover plate 50, the electromagnetic noise of the reactor 30 disposed further below the cover plate 50 can be prevented from reaching the inverter control board 41, and the reliability of the power conversion device 10 increase.

The coolant L flows inside the flow path formation body 60. The flow path formation body 60 is a separate element from the housing 19. The flow path forming body 60 forms a flow path for the coolant L inside the housing 19. The coolant L flowing in the flow path of the flow path forming body 60 cools the components disposed inside the housing 19.

The flow path forming body 60 has a first flow path forming member 60A and a second flow path forming member 60B that are separable from each other. The first flow path forming member 60A includes the first cooling plate 61 and the second cooling plate 62. The second flow path forming member 60B includes the third cooling plate 63 and the connecting pipe 64. The second flow path forming member 60B is connected to the first flow path forming member 60A by connecting the connection line 64 to the first cooling plate 61. That is, the first flow path forming member 60A and the second flow path forming member 60B are connected to each other.

In the power conversion device 10 of the present embodiment, a plurality of cooling plates 61, 62, 63 are formed inside the housing 19, and these cooling plates 61, 62, 63 are in contact with each other. Therefore, the plurality of cooling plates 61, 62, 63 inside the case 19 can be arranged complexly, and the structural components inside the case 19 can be cooled efficiently.

The first flow path forming member 60A and the second flow path forming member 60B are formed of a material having high heat transferability. For the material constituting the first flow path forming member 60A and the second flow path forming member 60B, for example, an aluminum alloy, a copper alloy, or the like may be cited. More preferably, a material that shields magnetism (for example, aluminum alloy) is used for the material constituting the first flow path forming member 60A and the second flow path forming member 60B.

The coolant L sequentially flows through the interior of the flow path forming body 60 via the third cooling plate 63, the connecting pipe 64, the first cooling plate 61 and the second cooling plate 62. Below, the individual portions of the flow path forming body 60 following the flow of the coolant L will be explained.

The third cooling plate 63 is arranged along the horizontal plane (the plane orthogonal to the first direction D1) and is plate-shaped. That is, the third cooling plate 63 is arranged with the vertical direction (the first direction D1) as the plate thickness direction.

The third cooling plate 63 is arranged between the engine power module 21 and the generator power module 22. The third cooling plate 63 cools the engine power module 21 and the generator power module 22 through the coolant L flowing inside.

In the third cooling plate 63, a first connection opening 63c and a third recess 63a and a first connection opening 63d and a fourth recess 63b are formed. The coolant L flows into the interior of the flow path forming body 60 at the first connection opening 63c.

The first connection opening 63c opens in the second direction D2. An inflow opening 69 for the coolant L is connected to the opening of the first connection opening 63c. The first connection hole 63c opens in the inner side surface of the third recess 63a.

The third recess 63a is formed on the lower surface of the third cooling plate 63. The third recess 63a opens to the bottom. That is, the third recess 63a opens to the engine power module 21 side. The third recess 63a is covered by the engine power module 21. Heat radiation fins 21p are directed toward the upper surface of the engine power module 21. The heat radiation fins 21p are inside the third recess 63a arranged. In the third recess 63a, the coolant 21p flows between the heat radiation fins 21p.

The first communication hole 63d extends in the vertical direction (the first direction D1) through the third cooling plate 63. The first communication hole 63d opens in the bottom surface of the third recess 63a and the bottom surface of the fourth recess 63b. The first connection opening 63d connects the third recess 63a and the fourth recess 63b with each other.

The fourth recess 63b is formed on the upper surface of the third cooling plate 63. The fourth recess 63b opens to the top. That is, the fourth recess 63b opens to the generator power module 22 side. The fourth recess 63b is covered by the generator power module 22. Heat radiation fins 22p are directed toward the lower surface of the generator power module 22. The heat radiation fins 22p are arranged inside the fourth recess 63b. In the fourth recess 63b, the coolant L flows between the heat radiation fins 22p.

In the present embodiment, the coolant L sequentially passes through the first connection hole 63c, the third recess 63a, the first communication hole 63d, and the fourth recess 63b. The coolant L cools the engine power module 21 as it passes through the third recess 63a and the generator power module 22 as it passes through the fourth recess 63b.

According to the present embodiment, by forming the heat radiation fins 21p, 22p on the power modules 21, 22, the contact area between the power modules 21, 22 and the coolant L can be ensured, and the power modules 21, 22 can be efficiently cooled by the coolant L.

The surface of the third cooling plate 63 facing one side of the second direction D2 (the right side in 2 ) is facing, is in contact with the capacitor module 15. As a result, the third cooling plate 63 cools the capacitor module 15.

The connection line 64 runs along the vertical direction (the first direction D1). The connecting line 64 connects the third cooling plate 63 and the first cooling plate 61, and the coolant L moves from the inside of the third cooling plate 63 to the inside of the first cooling plate 61 via the connecting line 64.

The first cooling plate 61 is arranged along the horizontal plane (the plane orthogonal to the first direction D1). That is, the first cooling plate 61 is arranged with the vertical direction (the first direction D1) as the plate thickness direction.

The first cooling plate 61 is arranged along the lower surface of the power board 43. The heat transfer plate 55 is arranged between the first cooling plate 61 and the power board 43. The first cooling plate 61 cools the power board 43 by the coolant L flowing inside it. That is, the power board 43 is disposed on a surface side of the first cooling plate 61 and is cooled by the coolant L.

In the first cooling plate 61, a second connection opening 61b and a first recess 61a and a second connection opening 61c are formed. The coolant L sequentially passes through the second connection opening 61b, the first recess 61a and the second connection opening 61c.

The second connection hole 61b extends in the vertical direction (the first direction D1). The second connection opening 61b opens to the bottom. The connecting line 64 is connected to the opening of the second connection opening 61b. In addition, the second connection opening 61b opens toward the bottom surface 61f of the first recess 61a.

The first recess 61a is formed in the lower surface of the first cooling plate 61. The first depression 61a opens to the top. That is, the first recess 61a opens to the power board 43 side. The coolant L flows in the first recess 61a. In addition, the first recess 61a is covered by the heat transfer plate 55. The coolant L in the first recess 61a cools the power board 43 via the heat transfer plate 55.

The first recess 61a has a bottom surface 61f facing the opening side. The bottom surface 61f has an inclined surface 61s. The slanted surface 61s makes the opening depth deeper toward the downstream side of the coolant L. Thereby, the pressure loss of the coolant L flowing in the first recess 61a can be reduced. Consequently, the power consumption of a pump that supplies the refrigerant L under pressure can be reduced. In the present embodiment, the inclined surface 61s is formed on a part of the bottom surface 61f. However, it is also possible that the entire bottom surface 61f is an inclined surface that makes the opening depth deeper toward the downstream side of the coolant L.

The second connection opening 61c extends along the second direction D2. The second connection hole 61c opens in the bottom surface 61f of the first recess 61a. In addition, the second connection opening 61c opens in a bottom surface 62f of a second recess 62a. The second connection opening 61c connects the first recess 61a and the second recess 62a with each other.

The second cooling plate 62 is arranged along the vertical direction (the first direction D1) and is plate-shaped. In addition, the second cooling plate 62 is arranged with the second direction D2 as the plate thickness direction.

The second cooling plate 62 is arranged along the choke coil 30. The choke coil base 35 is formed between the second cooling plate 62 and the choke coil 30. The second cooling plate 62 cools the reactor coil 30 by the coolant L flowing inside it. That is, the reactor coil 30 is disposed on the side of a surface of the second cooling plate 62 and is cooled by the coolant L.

In the second cooling plate 62, the second recess 62a and a discharge opening 62b are formed. The coolant L sequentially passes through the second recess 62a and the discharge port 62b.

The second recess 62a is on the surface of the second cooling plate 62 facing one side of the second direction D2 (the right side in 2 ) is skilled, trained. The second recess 62a opens on one side of the second direction D2. That is, the second recess 62a opens to the reactor 30 side. The second recess 62a has the bottom surface 62f facing the opening side. The second connection opening 61c extending from the first cooling plate 61 is opened in the bottom surface 62f. The coolant L flows into the second recess 62a via the second connection opening 61c. The coolant L flows in the second depression 62a. In addition, the second recess 62a is covered by the reactor base 35. The coolant L in the second recess 62a cools the power board 43 via the choke coil base 35.

The one to the other side of the second direction D2 (the left side in 2 ) facing surface of the second cooling plate 62 is in contact with the capacitor module 15. As a result, the second cooling plate 62 cools the capacitor module 15.

The ejection port 62b extends from the inner wall surface of the second recess 62a in the vertical direction (the first direction D1). That is, the ejection port 62b opens in the inner wall surface of the second recess 62a. In addition, the discharge port 62b opens in the lower end of the second cooling plate 62. The discharge port 62b is disposed on the most downstream side of the flow path formation body 60 and discharges the coolant L inside the flow path formation body 60. Another flow path forming member may be disposed downstream of the discharge port 62b.

The first flow path forming member 60A of the present embodiment has the first cooling plate 61 and the second cooling plate 62 crossing each other. That is, the second cooling plate 62 is connected to the first cooling plate 61 so that it crosses the first cooling plate 61. Here, this “crossing” of the first cooling plate 61 and the second cooling plate 62 means that they are arranged along surfaces that are not parallel to each other and are connected to each other.

According to the present embodiment, in the housing 19, the first cooling plate 61 and the second cooling plate 62 crossing each other are arranged. This increases the degree of freedom for arranging the individual structural elements in the housing 19 compared to the case in which flow paths are formed in the housing itself and the heat-generating components are cooled by placing them along the housing. As a result, the individual elements are arranged efficiently in the housing and a completely small-format implementation is possible. Specifically, in the present embodiment, since the first cooling plate 61 and the second cooling plate 62 are arranged to cross each other, the flow path forming body 60 can be efficiently disposed in the gaps between the individual structural members of the power conversion device 10.

Of the two crossing angles that form the first cooling plate 61 and the second cooling plate 62, the larger one is set as the obtuse angle α and the smaller other is set as the smaller angle β. The superobtuse angle α is an angle that exceeds 180°. β is an angle that is less than 180°. According to the present embodiment, the first cooling plate 61 and the second cooling plate 62 meet each other at right angles. Therefore, the obtuse angle α is 270 ° and the smaller angle β is 90 °.

According to the present embodiment, the choke coil 30 and the power board 43 are arranged on the side where the first cooling plate 61 and the second cooling plate 62 form the obtuse angle α. The power modules 21, 22 and the capacitor module 15 are arranged on the side on which the first cooling plate 61 and the second cooling plate 62 form the smaller angle β. According to the present embodiment, the power conversion device 10 can be made small in size by arranging the reactor 30 and the power board 43, which have a comparatively small thickness dimension among the heat generating bodies, on the side of the first flow path forming member 60A on which the obtuse angle α is located. And according to the present embodiment, the space surrounded by the first cooling plate 61 and the second cooling plate 62 can be made larger by arranging the power modules 21, 22 and the capacitor module 15, which are comparatively large in size among the heat generating bodies, on the side of the first flow path forming member 60A the smaller angle β can be used efficiently and the power converter device 10 can be made small. According to the present embodiment, the reactor 30, the power board 43, the power modules 21, 22 and the capacitor module 15 can be cooled efficiently. According to the present embodiment, the area where the reactor 30 and the power module 30 are arranged and the area where the power modules 21, 22 and the capacitor module 15 are arranged can be separated by the flow path forming body 60. This allows the interior of the housing 19 to be used efficiently.

According to the present embodiment, the first cooling plate 91 is arranged between the power board 43 and the power modules 21, 22. Thereby, the first cooling plate 61 divides the arrangement space of the power board 41 and the arrangement space of the power modules 21, 22 from each other and suppresses heat exchange therebetween. Thereby, one of the power board 43 and the power modules 21, 22 can be prevented from being heated by the other, and the reliability of the power board 43 and the power modules 21, 22 can be increased.

According to the present embodiment, the second cooling plate 62 is arranged between the choke coil 30 and the capacitor module 15. As a result, the second cooling plate 62 efficiently cools the choke coil 30 and the capacitor module 15 on its two surfaces. In addition, the second cooling plate divides the arrangement space of the reactor 30 and the arrangement space of the capacitor module 15 from each other and suppresses heat exchange between these spaces. Thereby, one of the reactor 30 and the capacitor module 15 can be prevented from being heated by the other, and the reliability of the reactor 30 and the capacitor module 15 can be increased.

According to the present embodiment, the engine power module 21, the third cooling plate 63, the generator power module 2, the first cooling plate 61 and the power board 43 form a layer structure. Therefore, a high-density arrangement of these components is easy, the internal space of the housing 19 can be efficiently used, and the power conversion device 10 as a whole can be made small in size. The power modules 21, 22 and the power board 43, which are heat generating bodies, can be efficiently cooled using the first cooling plate 61 and the third cooling plate 63. In addition, the first cooling plate 61 and the third cooling plate 63 are respectively disposed between the power modules 21, 22 and the power board 43, which are heat generating bodies. Therefore, overheating of the heat-generating bodies with each other can be suppressed even though the heat-generating bodies are arranged close to each other, and the reliability of the power modules 21, 22 and the power board 43, which are heat-generating bodies, can be increased.

In the flow path formation body 60 of the present embodiment, the coolant L cools the power modules 21, 22, the power board 43 and the reactor 30 from the upstream side to the downstream side in this order. In general, the temperature of the heat-generating bodies of the power converting device 10 in the order of power modules 21, 22, power board 43, and choke coil 30 easily occurs. According to the present embodiment, heat-generating bodies requiring more cooling may occur due to the cooling by the coolant L therein Order can be supplied with cooler coolant so that the reliability of the power converter device can be increased.

In general, the frequency of use of the engine power module 21 is higher than that of the generator power module 22 and it easily becomes hot. According to the present embodiment, the coolant L cools the engine power module 21 and the generator power module 22 in this order. Therefore, the engine power module 21, which easily becomes hot, can be prevented from reaching a high temperature, and the reliability of the power conversion device 10 can be increased.

In the foregoing, an embodiment of the present invention has been explained, but the individual structures, their combination and the like in the present embodiment are exemplary and may be subject to additions, deletions, substitutions within a scope not departing from the content of the present invention modifications of superstructures or other changes can be made. The present invention is not limited by the embodiment.

For example, in the embodiment described above, a power conversion device 10 each provided with an engine power module 21 connected to the engine 2 and a generator power module 22 connected to the generator 3 was explained. However, the power converter device 10 may also have only one of the engine power module 21 and the generator power module 22.

In the embodiment described above, a case in which the inclined surface 61e is formed on the bottom surface of the first recess 61a has been explained. However, it is also possible to form an inclined surface on the bottom surface of the second recess 62a. That is, it is sufficient if at least one of the bottom surfaces of the first recess 61a and the second recess 62a has an inclined surface.

Further, in the embodiment described above, a case in which heat radiation fins are formed on the power modules and the reactor base has been explained, but as long as the heat radiation area can be increased, there is no limitation on the shape of the fins. For example, they can also be pin fins or plate-shaped ribs.

Explanation of reference symbols

1 motor device; 2 engine; 3 generators; 9 vehicle; 10 power converter device; 11 motor inverter circuit (inverter circuit); 12 generator inverter circuit (inverter circuit); 13 converter circuit; 15 capacitor module; 19 housing; 21 power module; 21 engine power module; 22 generator power module; 30 choke coil; 30a coil element; 35 choke coil base (second heat transfer plate); 41 inverter control board (control board); 42 converter control board (control board); 43 power board; 50 cover plate; 55 heat transfer plate (first heat transfer plate); 60 flow path formation bodies; 60A first flow path forming element; 60B second flow path forming element; 61 first cooling plate; 61a first depression; 61f, 62f floor area; 61a inclined surface; 62 second cooling plate; 62a second recess; 63 third cooling plate; D1 first direction; D2 second direction; J central axis line; L coolant; α obtuse angle; β smaller angle.

Claims (12)

Power converter device, which is a Inverter circuit and a converter circuit a power module that has the inverter circuit, a choke coil that smoothes a direct current supplied to the converter circuit, and a control board that controls at least one of the inverter circuit and the converter circuit, the control board being arranged on a side of a first direction with the first direction as a plate thickness direction with respect to the power module, wherein the choke coil includes a coil element wound around a center axis line extending along the first direction and disposed on a side of a second direction orthogonal to the first direction with respect to the power module, wherein the power module and the control board are positioned on the outside in the radial direction of the choke coil as viewed from the first direction, wherein the control board is positioned further than the choke coil on one side of the first direction. Power converter device according to Claim 1 , which further has, as a control board, an inverter control board that controls the inverter circuit, and a converter control board that controls the converter circuit, a cover plate being formed between the inverter control board and the converter control board, which is arranged with the first direction as the plate thickness direction, the cover plate shields magnetism between the inverter control board and the converter control board. Power converter device according to Claim 2 , wherein the inverter control board is arranged further than the cover plate on one side in the first direction. Power converter device according to one of the Claims 1 until 3 , comprising a power board having the converter circuit, the power board being stacked with the control board with the first direction as the board thickness direction along the first direction. Power converter device according to one of the Claims 1 until 4 , comprising a cooling plate disposed between the power module and the choke coil and extending along the first direction. Power converter device according to Claim 5 , comprising a capacitor module that supplies a direct current to the inverter circuit is smoothed, with the capacitor module being arranged between the power module and the cooling plate. Power converter device according to one of the Claims 1 until 6 , comprising a power board having the converter circuit, and a flow path formation body inside which a coolant flows, the coolant cooling the power module, the power board and the reactor from the upstream side to the downstream side in this order. Power converter device according to one of the Claims 1 until 7 , whereby a motor power module, which is connected to a motor, and a generator power module, which is connected to a generator, are designed as a power module. Power converter device according to one of the Claims 1 until 8th , comprising a power board comprising the converter circuit, the power board comprising a transistor containing silicon carbide, the power module comprising an insulated gate bipolar transistor. Power converter device according to one of the Claims 1 until 9 , comprising a plate-shaped reactor base with the second direction as a plate thickness direction, the reactor being positioned on the one side of the second direction of the reactor base and having three coil elements which are arranged side by side along the surface direction of the reactor base. Motor device, comprising a power converter device according to one of Claims 1 until 10 . Vehicle, having a motor device according to Claim 11 .

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