JP2010183749A - Power conversion apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve a further reduction in size of a power conversion apparatus. <P>SOLUTION: The power conversion apparatus includes: a power module converting alternately a DC current and an AC current and supplying the AC current to an AC drive motor, a plurality of circuit boards controlling the drive of the power modules, a current detector for detecting a current value of the AC current, and a plurality of connectors provided respectively on the plurality of circuit boards to allow the plurality of circuit boards and the current detector to mutually exchange signals through a signal line. The plurality of circuit boards are stacked on the power modules, the current detector is arranged on one prescribed side of the circuit board, and the plurality of connectors are aligned and arranged on one prescribed side of the circuit board. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a power conversion device used for a vehicle drive motor.

  For pure electric vehicles that are driven by the output of the motor without using an engine, or hybrid-type vehicles that are used in combination with the engine, it is hoped that the ratio of the room to the total volume of the vehicle will be as large as possible to improve comfort. It is rare. For this reason, it is desired to further reduce the size of the power conversion device for motor control so that it can be mounted in as small a space as possible.

  The power conversion device described in Patent Document 1 includes a power module for mutually converting a direct current and an alternating current, a plurality of control circuit boards that control the power module, and a plurality of control circuit boards that are connected to each other. Signal lines are provided.

  However, further downsizing of the power conversion device including these components is required.

JP 2006-121834 A

  The problem to be solved by the present invention is further miniaturization of the power converter.

  In order to solve the above-described problem, a power conversion device according to the present invention is provided on each of a plurality of circuit boards arranged to be superimposed on an upper part of a power module, and the plurality of circuit boards and A plurality of connectors for exchanging signals with each other, and the current detector is disposed on a side of a predetermined side of the circuit board, and the plurality of connectors are arranged on the circuit board. Are arranged on the predetermined one side.

  Thereby, since the wiring of a signal line can be shortened and the wiring of the signal line of a power converter device can be made small, the further size reduction of a power converter device is attained.

  Preferably, the power conversion device according to the present invention includes a DC side wiring for supplying DC power to the power module, and the DC side wiring is opposite to the plurality of connectors via the power module. Placed on the side.

  Thereby, a communication line can be kept away from the DC side wiring used as a noise source, and the noise mixed in a communication line can be reduced.

  According to the present invention, the power converter can be further downsized.

It is an external appearance perspective view which shows one Example of the power converter device by this embodiment. It is the figure which looked at one Example of the power converter device by this embodiment from the side surface side. It is the figure which looked at one Example of the power converter device by this embodiment from the front side. It is the figure which looked at one Example of the power converter device by this embodiment from the upper surface side. It is an external appearance perspective view which shows one Example of the signal harness by this embodiment. It is an external appearance perspective view which shows one Example of the signal harness fixing method by this embodiment.

  Hereinafter, embodiments of a power converter according to the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic perspective view of the power conversion apparatus 200 according to the present embodiment with the upper lid (not shown) removed. FIG. 2 is a view seen from the side of the power conversion device 200 with the housing 400 removed. 3 is a cross-sectional view taken along the line AA of FIG.

  As shown in FIG. 3, the power conversion device 200 controls a capacitor module 300 having a plurality of smoothing capacitors that suppresses voltage fluctuations of a DC power supply, a power module 100 incorporating a plurality of power semiconductors, and a switching operation of the power module 100. And a control circuit board 110a having a motor control circuit for generating a PWM signal for controlling a pulse width modulation signal for determining a time width of the switching operation. . In the present embodiment, two power modules 100 are provided. Since each power module includes three-phase AC terminals OT of U, V, and W phases, a total of six AC terminals OT are provided.

  The power module 100 includes an inverter circuit composed of a plurality of power semiconductor elements. A signal for controlling the plurality of power semiconductor elements is generated by the control board 110a and sent to the driver circuit board 110b. The driver circuit board 110b generates a gate drive signal to be supplied to the gate of each power semiconductor, the gate drive signal is sent to the gate of each power semiconductor element, and each power semiconductor element performs a switching operation based on the gate drive signal. Do.

  Next, the detailed configuration of each component of the power conversion device 200 illustrated in FIG. 3 will be sequentially described.

  The power module 100 is disposed in a substantially central portion in the height direction inside the power conversion device 200. As shown in FIG. 3, the DC terminal IT connected to the power module 100 is arranged at a substantially central portion in the width direction in the power conversion device 200. The DC terminal IT includes a plate-like positive electrode terminal, a plate-like negative electrode terminal, and an insulating sheet interposed between the positive electrode terminal and the negative electrode terminal.

  The capacitor module 300 includes a DC terminal (not shown) to which DC power is supplied from a DC power supply. Capacitor module 300 also includes a DC side bus bar 140 extending to DC terminal IT. The DC-side bus bar 140 includes a plate-like positive electrode terminal, a plate-like negative electrode terminal, and an insulating sheet interposed between the positive electrode terminal and the negative electrode terminal, and is electrically connected to the DC terminal IT. The

  The AC terminal OT is arranged on one side of the power module 100 and is provided in the vicinity of the inner wall of the housing 400 provided with the current sensor. In addition, the AC terminal OT of the power module 100 is electrically connected to the AC bus bar 150 that protrudes outward from the power converter 200. The current sensor 130 has a through hole for allowing the AC terminal OT and the AC bus bar 150 to pass through, and detects an AC current value based on a change in magnetic flux in the through hole.

  The control board 110a is disposed at the top of the power conversion apparatus 200. The control board 110a includes a plurality of microcomputers 115, and various signals such as input signals from the outside of the power converter 200, such as signals from a motor rotational position sensor and temperature sensor, engine rotational speed and accelerator opening signals, and the like. It has the role which determines an operation mode based on the information of this, and the role which controls a motor based on the determination result.

  Here, the driving mode refers to, for example, each mode when the vehicle starts or when traveling at a low speed, when traveling normally (medium speed, when traveling at high speed), when accelerating, decelerating, or braking. One of the plurality of microcomputers 115 determines the operation mode, transmits a determination result to the other microcomputers 115, and controls the motor based on the result.

  For example, when the vehicle starts or runs at a low speed, the control content corresponding to the operation mode mainly operates the vehicle using the motor as power. During normal driving of the vehicle, the engine and the motor are used in combination, and the vehicle runs with both torques. When the vehicle is decelerated or braked, the motor is operated as a generator, and the three-phase AC power obtained thereby is converted into DC power by the power converter 200 and supplied to the battery for charging.

  The other microcomputers 115 that have received the operation mode information from one microcomputer 115 obtain the operation timing of the power semiconductor elements constituting the power conversion device 200 by arithmetic processing. A timing signal based on the calculation result of the microcomputer 115 is sent to the driver circuit board 110b through the interface circuit.

  Note that the output of the current sensor 130 that detects the current value flowing through each phase of the stator winding of the motor and the output of the temperature sensor incorporated in the power module 100 are taken into the microcomputer 115 via the interface circuit. The microcomputer 115 uses the output of the acquired current sensor 130 to perform operation control of the operation timing of the power semiconductor element and perform feedback control so that control based on the operation mode determination is performed. The output of the temperature sensor is used to diagnose abnormal operation.

  The driver circuit board 110b is disposed between the control board 110a and the power module 100 described above. A switching timing signal generated by the microcomputer 115 is input to the driver circuit board 110b via the interface circuit of the control board 110a. These timing signals are respectively input to the driver circuit of each phase of the three-phase AC output via an insulating circuit composed of, for example, a photocoupler. Each output from these driver circuits is used as a drive signal for controlling the switching operation of each power semiconductor element in the power module 100.

  The driver circuit board 110b is provided with a voltage sensor circuit that detects a voltage in the driver circuit. The output of the voltage sensor circuit is sent to the microcomputer 115 via the interface circuit of the control circuit 110a.

  The control board 110a and the driver circuit board 110b described above include a plurality of connectors 120a to 120d for communicating various signals between the respective boards and with the current sensor 130, and between the plurality of connectors. A signal harness 125 is used as a means for connection.

  In the power conversion device that is miniaturized, the component mounting density in the housing 400 is very high, and the control board 110a, the driver circuit board 110b, and the current sensor 130 are arranged in the housing of the power conversion apparatus with a space therebetween. In such a case, there is a problem that it is difficult to assemble the electrical connection of each component.

  Therefore, in the power conversion device of this embodiment, the plurality of connectors 120a to 120c provided on the control board 110a are arranged side by side on a predetermined one side of the control board 110a. The plurality of connectors 120d provided on the driver circuit board 110b are arranged near one side of the driver circuit board 110b on the side close to the plurality of connectors 120a to 120c. Further, the plurality of connectors 120a to 120d are provided on the side close to the inner wall of the housing 400 in which the current sensor 130 is provided.

  Thereby, the length of the signal harness 125 can be shortened. Furthermore, since the signal harness 125 is intensively arranged on one surface of the inner wall of the housing 400, the harness that connects the control board 110a and the driver circuit board 110b and between the control board 110a and the current sensor 130 can be bundled. As a result, the assembly workability of the power converter is improved.

  In addition, in order to satisfy the function of detecting an alternating current, the current sensor 130 needs to be disposed on the alternating current output side in the power converter 200, and is formed integrally with the alternating current bus bar 150, for example. Sometimes it is.

  FIG. 5 shows an enlarged view of the signal harness 125. The signal harness 125 has a shape in which a plurality of communication lines 125b to 125f connected to each other are bundled using a molding member 125a in order to exchange electrical signals between the plurality of connectors 120a to 120c described above. . As the forming member 125a, there are various methods such as using a tube-shaped member, winding a tape, or using a band-shaped member.

  FIG. 6 is a diagram illustrating a method for fixing the signal harness 125. The signal harness 125 described above can be fixed to the inner wall of the housing 400 using the fixing member HD. The fixing location of the fixing member HD may be the current sensor 130, the substrate holding bracket 410, or the like in addition to the side wall of the housing 400.

  Thereby, even if a vibration is transmitted to the power converter device 200 in the vehicle, the signal harness 125 can be firmly fixed, and the connection reliability with the connector can be improved. Further, when the signal harness 125 and the plurality of connectors 120a to 120d are connected in a state where the signal harness 125 is attached to the inner wall of the housing 400, the signal harness 125 is not accidentally dropped into the housing 400, and assembly is performed. Can be improved.

  Next, noise countermeasures of the power conversion device 200 according to this embodiment will be described.

  In order to prevent electromagnetic noise from being mixed into the signal harness 125 that electrically connects each component, the signal harness 125 is desirably as short as possible. In addition, a DC bus bar 140 for electrically connecting the power module 100 and the capacitor module 300 is present inside the casing of the power conversion device, which is a component that itself becomes a large noise source. How to arrange the signal harness 125 with respect to such a noise source is important for noise countermeasures.

  The DC side bus bar 140 is arranged on the opposite side of the AC side bus bar 150 via the power module 100. As described above, since the current sensor 130 is disposed on the AC bus bar 150 side, the signal harness 125 is connected to the noise source from the DC bus bar 140 by disposing the signal harness 125 in the vicinity of the current sensor 130. It is possible to keep away.

  Further, as shown in FIG. 4, the plurality of connectors 120 a to 120 d arranged on the substrate are arranged so as not to overlap each other in the height direction of the power conversion device 200. That is, the plurality of connectors 120a to 120d are arranged so as to be displaced in the depth direction of the power conversion device 200 (the direction in which the AC bus bars are arranged).

  Further, the connector 120d mounted on the driver circuit board 110b protrudes closer to the current sensor 130 than the connectors 120a to 120c mounted on the control board 110a. That is, even after the control board 110a is mounted on the housing 400, the connector 120d is arranged so that it can be seen by the assembly operator.

  As a result, workability at the time of connector connection is improved, and connector connection work can be performed after the substrate and the current sensor are assembled.

  As shown in FIG. 3, the signal harness 125 is provided above the AC terminal OT and the current sensor 130. That is, the signal harness 125 is disposed between the work opening of the housing 400 and the current sensor 130. Furthermore, the connector provided in the current sensor 130 protrudes toward the work opening of the housing 400. Thereby, the signal harness 125 can be accommodated in the internal space of the housing 400 formed by the control board 110a, the driver circuit board 110b, and the current sensor 130, and the power converter 200 can be downsized. Further, the signal harness 125 and the current sensor 130 can be easily assembled.

  The configurations according to the above-described embodiments may be used alone or in combination. The effects of the configuration according to each embodiment can be achieved independently or synergistically.

DESCRIPTION OF SYMBOLS 100 Power module 110a Control board 110b Driver circuit board 115 Microcomputer 120a-120d Connector 125 Signal harness 130 Current sensor 140 DC side bus bar 150 AC side bus bar 200 Power conversion device 300 Capacitor module 400 Case 410 Board holding bracket IT DC terminal OT AC terminal HD fixing member

Claims (8)

A power module that mutually converts direct current and alternating current and supplies the alternating current to an alternating current drive motor;
A plurality of circuit boards for controlling driving of the power module;
A current detector for detecting a current value of the alternating current;
A plurality of connectors that are provided on each of the plurality of circuit boards and that allow the plurality of circuit boards and the current detector to exchange signals with each other via signal lines;
The plurality of circuit boards are arranged so as to overlap the power module,
The current detector is disposed on a side of a predetermined side of the circuit board,
The plurality of connectors are power converters arranged on the predetermined one side of the circuit board. The power conversion device according to claim 1,
DC side wiring for supplying DC power to the power module,
The direct current side wiring is a power conversion device arranged on the opposite side to the plurality of connectors via the power module. The power conversion device according to claim 1,
A plurality of the signal lines are provided,
A power converter comprising a holding member for bundling and holding the plurality of signal lines. The power conversion device according to any one of claims 1 and 3,
A housing for housing the power module and the plurality of circuit boards;
A power conversion device comprising: a fixing member for fixing the inner wall of the housing on the side close to the current detector and the signal line. The power conversion device according to claim 1,
The plurality of circuit boards includes a driver circuit board for driving the power module and a control board for outputting a control signal for controlling the power module to the driver circuit board.
The driver circuit board is a power conversion device disposed between the control board and the power module. The power conversion device according to claim 1,
A housing for housing the power module, the plurality of circuit boards, and the current detector;
The current detector is installed on the inner wall of the housing,
The connector mounted on the driver circuit board is disposed closer to the current detector than the connector mounted on the control board. The power conversion device according to claim 1,
A housing that houses the power module and the plurality of circuit boards and has an opening for housing the power module and the plurality of circuit boards in an upper part thereof,
An AC output terminal connected to the power module and extending to the outside of the housing through a through hole provided in the current detector,
The communication line is a power conversion device arranged between the AC output terminal and the opening. The power conversion device according to claim 1, wherein:
The plurality of connectors are power conversion devices that are arranged so as not to face each other in a direction in which the plurality of circuit boards are arranged to overlap each other.

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