JP2005192311A - Power supply system and automobile equipped with the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a power supply system reduced in the box of a power supply device, and an automobile equipped with such a power supply system. <P>SOLUTION: A PCU installed as the power supply device is housed in a box body 180. An output connector 200 is arranged so as to be adjacent to the box body 180 and is connected between the PCU 20 and a motor generator that is an electric load. The arrangement order of output terminals of the PCU differs from the arrangement order of output terminals of an output connector 200 that copes with the configuration of the electric load. A wiring disposition part 195#, that bends wiring or makes the wiring intersect for changing the arrangement order and a current sensor 190 are contained in the output connector 200, but is not arranged in the box body 180. The box body 180 of the power supply device is thereby reduced in size, whereby the layout arrangement of the power supply system, including the power supply device and the output connector, is facilitated. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a power supply system, and more particularly, to a power supply system including a power supply device and a connector for connecting the power supply device and an electric load, and an automobile equipped with the power supply system.

  In an electric vehicle including a hybrid vehicle, an AC motor (motor) that can drive wheels and a power supply device that drives and controls the AC motor are provided. At this time, in an automobile, the arrangement of the power supply device tends to be restricted in order to ensure comfort and loadability (storage capacity).

For this reason, in order to efficiently arrange the power supply device in a narrow space, a set of electric connection units for an electric vehicle in which a plurality of connectors arranged at the output terminal portion from the power supply device are connected by a bus bar on the same plate. An attached structure is disclosed (for example, Patent Document 1).
JP 2000-261936 A

  However, in the configuration disclosed in Patent Document 1, since the bus bar arrangement inside the power supply apparatus and the connector output arrangement that matches the form of the electric load (AC motor) are different, it is necessary to change the bus bar arrangement inside the power supply apparatus. Occurs. Such bus bar alignment requires a structure for bending and intersecting the bus bars, and therefore requires a gap for securing insulation between the bus bars. By providing such a bus bar alignment portion in the power supply device, the casing of the power supply device becomes large, and there arises a problem that layout arrangement in the automobile becomes difficult. In particular, in a configuration in which a plurality of AC motors are arranged, such a problem becomes remarkable because there are many bus bar wires to be aligned.

  Further, since a relatively large current flows through the bus bar, a magnetic flux detection type non-contact type current sensor needs to be arranged for detecting the passing current. By incorporating such a current sensor in the housing, there is a problem that a space for securing an insulation distance is required, and the housing of the power supply device becomes large.

  Accordingly, the present invention has been made to solve such a problem, and an object of the present invention is to provide a power supply system in which a casing of a power supply device is miniaturized and an automobile equipped with such a power supply system. is there.

  A power supply system according to the present invention is a power supply system for supplying electric power to an electric load, and includes a power supply device and an output connector. The power supply device has a power converter for supplying power to the electric load inside the casing, and further has a plurality of power supply output terminals for outputting power supplied from the power converter. The output connector is disposed adjacent to the housing and electrically connects between the power converter and the electric load. The output connector includes a plurality of input terminals that are sequentially connected to the plurality of power output terminals, and a plurality of output terminals that are sequentially connected to the terminals of the electrical load arranged in a predetermined order according to the form of the electrical load. The arrangement order of the plurality of power output terminals and the plurality of input terminals is different from the predetermined order, and the output connector electrically connects the plurality of input terminals and the plurality of output terminals according to the predetermined order, respectively. And a wiring alignment portion.

  Preferably, the output connector incorporates a current sensor for detecting a passing current of at least one of the plurality of input terminals, and the current sensor is not disposed inside the housing of the power supply device.

  Preferably, the wiring array portion includes a plurality of wirings that electrically connect the plurality of input terminals and the plurality of output terminals in a predetermined order, and an insulating member is provided in a gap between the plurality of wirings. Filled.

  More preferably, the plurality of wirings are sealed with a thermosetting or thermoplastic resin.

  Alternatively, preferably, the plurality of output terminals of the output connector and the terminals of the electrical load are connected by a connector having a fitting structure.

  An automobile according to the present invention includes the power supply system according to any one of claims 1 to 5, a DC power supply, and a multi-phase AC motor. The DC power source is composed of a secondary battery. The multi-phase AC motor is provided as an electric load and can drive at least one wheel. The power converter performs power conversion between DC power supplied from a DC power source and AC power for driving and controlling the AC motor, and a plurality of output terminals of the output connector are connected to terminals of a plurality of phases of the AC motor, respectively. Is done.

  Preferably, a plurality of AC motors are provided, and the power supply apparatus has a plurality of inverters each provided corresponding to the plurality of AC motors as power converters.

  In the power supply system according to the present invention, since the wiring alignment portion that conventionally required a space is built in the output connector outside the casing, the casing of the power supply apparatus is downsized. By configuring the power supply system with the power supply device having a miniaturized casing and the output connector disposed adjacent thereto, the flexibility of the arrangement is improved, and the layout arrangement is facilitated.

  Furthermore, by incorporating a current sensor for detecting the passing current of the power supply output terminal in the output connector and not arranging it in the housing of the power supply device, the power supply device can be further downsized and its layout arrangement can be reduced. It becomes easier.

  Moreover, since the distance between the plurality of wires constituting the wiring alignment portion can be shortened by sealing the wiring alignment portion with a thermosetting or thermoplastic resin, the output connector itself can be miniaturized. As a result, the layout arrangement of the power supply system is further facilitated.

  Alternatively, the connection work can be facilitated and the reliability of the connection structure can be improved by connecting the power supply device and the electrical load to the output connector with a fitting connector.

  Since the automobile according to the present invention controls the drive of the AC motor for driving the wheels by the power supply system configured as described above, the power supply system is provided so as to ensure comfort and loadability (storage capacity). It can be arranged efficiently.

  In particular, when it is necessary to arrange a plurality of AC motors, the number of wirings to be aligned increases, which is effective in reducing the size of the power supply system as described above.

  Embodiments of the present invention will be described in detail with reference to the drawings. In addition, about the same or equivalent part in a figure, the same code | symbol is attached | subjected and the description is not repeated.

  FIG. 1 is a schematic block diagram showing the configuration of a hybrid vehicle shown as an example of a vehicle equipped with a power supply system according to the present invention.

  Referring to FIG. 1, a hybrid vehicle 100 according to an embodiment of the present invention includes a battery 10, a PCU (Power Control Unit) 20, a power output device 30, a differential gear (DG) 40, a front wheel. 50L, 50R, rear wheels 60L, 60R, front seats 70L, 70R, and a rear seat 80 are provided.

  The battery 10, which is a “DC power supply”, is composed of, for example, a secondary battery such as nickel hydride or lithium ion, and supplies a DC voltage to the PCU 20 and is charged by the DC voltage from the PCU 20. The battery 10 is disposed at the rear portion of the rear seat 80.

  The power output device 30 is disposed in the engine room in front of the dashboard 90. The PCU 20 is electrically connected to the power output device 30. The power output device 30 is connected to the DG 40.

  PCU 20 boosts the DC voltage from battery 10, converts the boosted DC voltage into an AC voltage, and drives and controls motor generators MG 1 and MG 2 included in power output device 30. PCU 20 charges battery 10 by converting the AC voltage generated by motor generators MG 1 and MG 2 included in power output device 30 into a DC voltage. In other words, PCU 20 includes a power converter that performs power conversion between DC power from battery 10 and AC power for driving and controlling motor generators MG1 and MG2 to supply power to motor generators MG1 and MG2. Corresponds to “power supply”.

  Power output device 30 transmits power from engine and / or motor generators MG1, MG2 to front wheels 50L, 50R via DG 40 to drive front wheels 50L, 50R. The power output device 30 generates power by the rotational force of the motor generators MG1 and MG2 by the front wheels 50L and 50R, and supplies the generated power to the PCU 20. That is, motor generators MG1 and MG2 serve as “AC motors” capable of driving at least one wheel.

  Motor generators MG 1, MG 2 and PCU 20 are connected via output connector 200.

  The DG 40 transmits the power from the power output device 30 to the front wheels 50L and 50R, and transmits the rotational force of the front wheels 50L and 50R to the power output device 30.

  FIG. 2 is an electric circuit diagram showing a main part of the PCU 20 shown in FIG.

  Referring to FIG. 2, PCU 20 includes a converter 130 and an inverter unit 150. Inverter unit 150 includes inverters 151 and 152 corresponding to motor generators MG1 and MG2, respectively.

  Converter 130 includes a reactor 120, switching elements Q1, Q2, and diodes D1, D2. As the switching element in this embodiment, for example, an IGBT (Insulated Gate Bipolar Transistor) is applied.

  Reactor 120 has one end connected to power supply line 101 from battery 10 and the other end connected between switching element Q1 and switching element Q2, that is, between the emitter of switching element Q1 and the collector of switching element Q2. The

  Switching element Q1 and switching element Q2 are connected in series between power supply line 103 and earth line 102. Switching element Q1 has a collector connected to power supply line 103 and an emitter connected to the collector of switching element Q2.

  The emitter of the switching element Q2 is connected to the earth line 102. In addition, diodes D1 and D2 are connected between the collector and emitter of each switching element Q1 and Q2, respectively, so that a current flows from the emitter side to the collector side. Switching elements Q1 and Q2 are subjected to on / off control, that is, switching control, in response to a gate signal from a control device (not shown).

  Capacitor 140 is connected between power supply line 103 and ground line 102 in order to smooth the output voltage of converter 130, that is, the input voltage of inverters 151 and 152.

  Inverter 151 includes U-phase arm 153, V-phase arm 154, and W-phase arm 155. U-phase arm 153, V-phase arm 154, and W-phase arm 155 are connected in parallel between power supply line 103 and ground line 102. The U-phase arm 153 includes switching elements Q3 and Q4 connected in series, the V-phase arm 154 includes switching elements Q5 and Q6 connected in series, and the W-phase arm 155 includes switching elements connected in series. It consists of elements Q7 and Q8. Further, diodes D3 to D8 that flow current from the emitter side to the collector side are connected between the collectors and emitters of the switching elements Q3 to Q8, respectively. Switching elements Q3 to Q8 are subjected to on / off control, that is, switching control, in response to a gate signal from a control device (not shown).

  An intermediate point of each phase arm is connected to each phase end of each phase coil of motor generator MG1 through wirings 161 to 163 typically formed of bus bars. That is, motor generator MG1 is a three-phase permanent magnet motor, and is configured such that one end of three coils of U, V, and W phases are connected in common to the middle point, and the other end of the U-phase coil is connected via wiring 161. The other end of the V-phase coil is connected to the intermediate point of the switching elements Q5 and Q6 via the wiring 162 and the other end of the W-phase coil is connected to the switching elements Q7 and Q8 via the wiring 163. Is connected to the middle point of each.

  Inverter 152 has the same configuration as inverter 151. The intermediate point of each phase arm of inverter 151 is connected to each phase end of each phase coil of motor generator MG2. That is, motor generator MG2 is also a three-phase permanent magnet motor.

  Furthermore, the other end of the U-phase coil is connected to the intermediate point of switching elements Q3 and Q4 via wiring 171 and the other end of the V-phase coil is connected to the intermediate point of switching elements Q5 and Q6 via wiring 172. The other end of the W-phase coil is connected to an intermediate point between the switching elements Q7 and Q8 via the wiring 173.

  In this embodiment, motor generators MG1 and MG2 that are three-phase motors are shown as representative examples of AC motors serving as electric loads of the power supply system according to the present invention. However, the power supply system of the present invention can be applied without particularly depending on the number of phases of the AC motor. As will be apparent from the following description, the power supply system according to the present invention is effective in a power supply system that uses a plurality of AC motors as electrical loads and that has a large number of wires.

  Converter 130 receives a DC voltage supplied from battery 10 between power supply line 101 and earth line 102, and switching elements Q1 and Q2 are subjected to switching control in accordance with a gate signal, thereby boosting the DC voltage to a capacitor. 140. Capacitor 140 smoothes the DC voltage from converter 130 and supplies it to inverters 151 and 152.

  Inverter 151 converts the DC voltage from capacitor 140 into an AC voltage to drive motor generator MG1. Similarly, inverter 152 converts the DC voltage from capacitor 140 into an AC voltage to drive motor generator MG2.

Inverter 151 converts the AC voltage generated by motor generator MG1 into a DC voltage and supplies it to capacitor 140 by switching control of switching elements Q3 to Q8 in response to the gate signal. Similarly, inverter 152 includes motor generator M.
The AC voltage generated by G2 is converted to a DC voltage and supplied to the capacitor 140.

  In this way, inverters 151 and 152 operate as “power converters” for supplying power to motor generators MG1 and MG2.

  Capacitor 140 smoothes the DC voltage from motor generator MG <b> 1 or MG <b> 2 and supplies it to converter 130. Converter 130 steps down the DC voltage from capacitor 140 and supplies it to battery 10 or a DC / DC converter (not shown) for auxiliary power.

  3 and 4 are diagrams illustrating a configuration of a power supply unit (PCU) provided with a bus bar alignment unit in a casing, which is shown as a comparative example.

  Referring to FIG. 3, the bus bars in inverters 151 and 152 shown in FIG. 2 are arranged in U1 phase (U phase of MG1), U2 phase (U phase of MG2), V1 phase (V phase of MG1), V2 The order is the phase (the V phase of MG2), the W1 phase (the W phase of MG1), and the W2 phase (the W phase of MG2). Such an arrangement order is caused by arranging switching elements having the same reference numerals in FIG. 2 having the same connection form in parallel so as to be efficient in layout arrangement.

  On the other hand, on the motor generator side, since a connection terminal is provided for each motor generator, the arrangement order thereof is the order of U1, V1, W1, U2, V2, and W2. For this reason, it is necessary to provide a bus bar alignment portion 195 as shown in FIG.

  Referring to FIG. 4, bus bar aligning section 195 flexes bus bars 161-163, 171-173 as appropriate in order to obtain an arrangement order that matches the form of the motor generator (that is, the order in which the connection terminals are arranged). , It is necessary to cross. At this time, since it is necessary to secure a sufficient insulation distance between the bus bars, the bus bar aligning portion 195 has a certain amount of space.

  Referring to FIG. 3 again, in the control of the three-phase motor, it is necessary to detect the phase current for two phases, so that the bus bar that is the detection target (corresponding to the U phase and the W phase as an example in FIG. 3). A current sensor 190 is further arranged for the bus bars 161, 171, 163, 173).

  In the power supply device shown in FIG. 3, the current sensor 190 and the bus bar aligning portion 195 are built in the housing 180 in the same manner as the electric circuit portion shown in FIG. As a result, if layout restrictions are severe, it becomes difficult to arrange the PCU 20 in the automobile 100.

  Next, the configuration of the power supply system according to the embodiment of the present invention will be described.

  Referring to FIG. 5, the power supply system according to the present invention includes PCU (that is, power supply unit) 20 housed in housing 180, and input connector 95 and output connector 200 arranged adjacent to housing 180. .

  The PCU 20 has a structure in which the converter 130, the capacitor 140, the inverters 151 and 152, and the cooler 160 of the switching elements Q1 to Q8 shown in FIG. 2 are stacked. The cooler 160 is provided with a refrigerant passage (not shown) inside. The cooler 160 is in close contact with the switching elements Q1 to Q8, and dissipates heat generated by the switching operation to the refrigerant.

  Input connector 95 electrically connects between battery 10 and PCU 20 shown in FIG. 1, and output connector 200 electrically connects inverters 151 and 152 in PCU 20 and motor generators MG1 and MG2. To do. The output connector 200 is provided on the side surface of the housing 180 at a position corresponding to the inverters 151 and 152. Output terminal group of output connector 200 is connected to each phase terminal of motor generators MG 1, MG 2 by output cable 210.

  FIG. 6 is a diagram illustrating the structure of the output connector. 6A shows a view of the output connector 200 as viewed from the top in FIG. 5, and FIG. 6B shows a view of the output connector 200 as viewed from the side in FIG.

  As shown in FIG. 6A, the output connector 200 has input terminals 161 # to 163 #, 171 # to 173 #. Input terminals 161 # to 163 # and 171 # to 173 # are sequentially connected to bus bars 161 to 163 and 171 to 173 corresponding to “power output terminals” from PCU 20 in the power supply system according to the present invention. That is, bus bars 161-163, 171-173 and input terminals 161 # -163 #, 171 # -173 # are connected to U1 phase, U2 phase, V1 phase, V2 phase, W1 phase and W2 as shown in FIG. Arranged in phase order.

  Output connector 200 incorporates current sensor 190 and wiring alignment portion 195 #. By measuring the passing currents of the input terminals 161 # to 163 # and 171 # to 173 # with the current sensor 190 built in the output connector 200, the power supply output can be achieved without arranging the current sensor inside the casing of the PCU 20. The passing currents of the bus bars 161 to 163 and 171 to 173 corresponding to “terminals” can be measured. Wiring alignment portion 195 # is sealed (molded) with thermoplastic resin 196.

  Referring to FIG. 7, wiring alignment unit 195 # corresponds to bus bar arrangement unit 195 shown in FIG. 4, and is connected in sequence to bus bars 161-163, 171-173 corresponding to power output terminals from PCU 20. Wirings 281 to 286 connecting input terminals 161 # to 163 # and 171 # to 173 # and their own output terminals 261 to 263 and 271 to 273 are included. The arrangement structure of the wirings 281 to 286 is the same as the arrangement structure of the bus bars in the bus bar arrangement portion 195 shown in FIG. That is, wires 281 to 286 are electrically connected between input terminals 161 # to 163 # and 171 # to 173 # and output terminals 261 to 263, 271 to 273 in accordance with the arrangement order of connection terminals of motor generators MG1 and MG2. Connect.

  Further, in wiring alignment portion 195 #, since wirings 281 to 286 are sealed (molded) with a thermosetting or thermoplastic resin, a gap between the wirings is filled with an insulator. As a result, the distance between the wirings necessary for securing the insulation between the wirings can be shortened, so that the wiring alignment portion 195 # can be reduced in size.

  As shown in FIG. 8, wiring arrangement unit 195 # causes output terminals 261 to 263 and 271 to 273 of output connector 200 to be arranged in the U1 phase in accordance with the arrangement of connection terminals of motor generators MG1 and MG2. The order is V1, W1, U2, V2, and W2.

  As shown in FIG. 6B, the output terminal of the output connector 200 is taken out by the output cable 210 and connected to the connection terminal of each phase of the motor generators MG1, MG2.

  At this time, as shown in FIG. 9, if the connection portion between the output cable 210 and the motor generators MG1 and MG2 has a concave and convex fitting structure by the fitting connectors 240 and 250, the connection work can be facilitated, and The reliability of the connection structure can be improved. A similar fitting structure can also be applied to a connection structure between the PCU 20 and the output connector 200, a connection structure of another part between the input connector 95 and the PCU 20, and the like. Thereby, assembly property can be improved.

  As described above, in the power supply system according to the present invention, since the wiring alignment portion (bus bar array portion), which has conventionally required a space, is built in the output connector outside the housing, the power supply unit (PCU) is downsized. . The power supply system is configured by the miniaturized power supply device and the connector disposed adjacent thereto, thereby facilitating the layout arrangement.

  Furthermore, by incorporating the current sensor in the output connector and not arranging it in the casing of the power supply unit (PCU), the power supply unit (PCU) can be further miniaturized and the layout arrangement can be further facilitated.

  Moreover, the output connector itself can be reduced in size by molding the wiring alignment portion with a thermoplastic resin.

  The embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

1 is a schematic block diagram showing a configuration of a hybrid vehicle shown as an example of a vehicle equipped with a power supply system according to the present invention. It is an electric circuit diagram which shows the principal part of PCU20 shown by FIG. It is a figure explaining the structure of the power supply device shown as a comparative example. It is a figure which shows the structure of the bus-bar alignment part shown by FIG. It is a figure which shows the structure of the power supply system according to this invention. It is the upper side figure and side view of an output connector. It is a figure which shows the structure of the wiring alignment part incorporated in the output connector. It is a figure which shows the output terminal of an output connector. It is a figure which illustrates the structure of the connection part of an output connector and another apparatus.

Explanation of symbols

  10 battery, 30 power output device, 50L, 50R front wheel, 60L, 60R rear wheel, 95 input connector, 100 hybrid vehicle, 120 reactor, 130 converter, 140 capacitor, 160 cooler, 161-163, 171-173 wiring, 180 Enclosure (PCU), 190 Current sensor, 195 Busbar array section, 195 # Wiring alignment section, 196 Thermoplastic resin, 200 output connector, 210 output cable, 240, 250 Mating connector, 261 to 263, 271 to 273 Output terminal (Output connector), 281-286 Wiring (wiring alignment section), MG1, MG2 motor generator, Q1-Q8 switching element.

Claims (7)

A power supply system for supplying power to an electric load,
A power supply device having a power converter for supplying power to the electric load inside the housing;
An output connector disposed adjacent to the housing and electrically connected between the power converter and the electrical load;
The power supply device further includes a plurality of power supply output terminals for outputting supply power from the power converter,
The output connector is
A plurality of input terminals connected in sequence with the plurality of power output terminals;
A plurality of output terminals connected in order with the terminals of the electric load arranged in a predetermined order according to the form of the electric load;
The arrangement order of the plurality of power output terminals and the plurality of input terminals is different from the predetermined order,
The output connector further includes a wiring alignment unit for electrically connecting the plurality of input terminals and the plurality of output terminals according to the predetermined order. The output connector includes a current sensor for detecting a passing current of at least one of the plurality of input terminals,
The power supply system according to claim 1, wherein the current sensor is not arranged inside a housing of the power supply device. The wiring array unit has a plurality of wirings that electrically connect the plurality of input terminals and the plurality of output terminals according to the predetermined order, respectively.
The power supply system according to claim 1, wherein a gap between the plurality of wirings is filled with an insulating member.   The power supply system according to claim 3, wherein the plurality of wirings are sealed with a thermosetting or thermoplastic resin.   The power supply system according to claim 1, wherein the plurality of output terminals of the output connector and the terminals of the electric load are connected by a connector having a fitting structure. The power supply system according to any one of claims 1 to 5,
A DC power source composed of a secondary battery;
A plurality of AC motors capable of driving at least one wheel provided as the electric load;
The power converter performs power conversion between DC power supplied by the DC power source and AC power for driving and controlling the AC motor,
The plurality of output terminals of the output connector are respectively connected to the plurality of phase terminals of the AC motor. A plurality of the AC motors are provided,
The automobile according to claim 6, wherein the power supply device includes a plurality of inverters each provided corresponding to the plurality of AC motors as the power converter.

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