JP2015122884A - Electric power conversion system and arrangement structure of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric power conversion system which can be arranged between two large components even though a gap between the two large components is small.SOLUTION: An electric power conversion system 1 includes a case 4, a pair of pipes 6, and a plurality of connectors 7. The case 4 accommodates a device body of the electric power conversion system 1. The pair of pipes 6 are connected to a cooler within the case, and protrude from the case 4. The plurality of connectors 7 are mounted on the case 4 so as to protrude outside the case 4. The case 4 includes four wall parts 5 encompassing the device body within the case from four directions. Out of the four wall parts 5, a pipe projection wall part 5a from which the pair of pipes 6 protrude, and a connector mount wall part 5b on which the connectors 7 are mounted are provided to position the device body between them in a protrusion direction (X direction) of the pipes 6.

Description

  The present invention relates to a power conversion device having a case constituting an outer shell, a pair of pipes protruding from the case, and a plurality of connectors attached to the case, and an arrangement structure thereof.

  For example, a power conversion device that performs power conversion between direct current power and alternating current power is known that includes a device main body and a case that houses the device main body (see Patent Document 1 below). The apparatus main body includes a semiconductor module incorporating a semiconductor element, a cooler that cools the semiconductor module, and a control circuit board that controls the operation of the semiconductor module.

  A pair of pipes is attached to the cooler. The pair of pipes protrudes out of the case from the wall portion of the case. Of the pair of pipes, the refrigerant is introduced from one pipe into the cooler, and the refrigerant flowing through the cooler is led out from the other pipe. Thus, the semiconductor module is configured to be cooled.

  In addition, a plurality of connectors for electrically connecting the device main body to an external device are attached to the wall portion of the case. Each connector is attached to the wall portion so as to protrude to the outside of the case.

  In the power converter, the pipe and the connector are protruded from the case in directions orthogonal to each other. Further, the power conversion device itself is disposed in a vehicle, for example, together with large components such as an engine and a motor.

JP 2011-147261 A

  However, the power conversion device has a problem that it is difficult to arrange in a narrow space. That is, in the power conversion device (see FIGS. 12 and 13), the direction in which the pipe 96 protrudes from the case 94 and the direction in which the connector 97 protrudes are orthogonal to each other, so two large parts 92 (92a, 92b) When the power conversion device 91 is arranged between the pipe 96 and the connector 97, the pipe 96 or the connector 97 protrudes toward the adjacent large component 92. Therefore, there is a problem that the power conversion device 91 cannot be arranged unless the distance L between the two large components 92a is wide.

  The present invention has been made in view of such a background, and intends to provide a power conversion device that can be disposed between two large components even when the interval between the two large components is narrow, and an arrangement structure thereof. Is.

According to a first aspect of the present invention, there is provided a device body having a semiconductor module incorporating a semiconductor element, a cooler that cools the semiconductor module, and a control circuit board that is connected to the semiconductor module and controls the operation of the semiconductor module. And
A case for housing the apparatus main body,
A pair of pipes connected to the cooler, forming a flow path for the refrigerant flowing in the cooler and projecting from the case;
A plurality of connectors that are attached to the case so as to protrude to the outside of the case and electrically connect the device main body to external devices, respectively.
The case has four wall portions surrounding the device main body from four sides,
Of the four wall portions, a pipe protruding wall portion from which the pair of pipes protrudes and a connector mounting wall portion to which the plurality of connectors are attached sandwich the apparatus main body in the protruding direction of the pipe. It is in the power converter characterized by being provided in.

  Further, according to a second aspect of the present invention, the power conversion device is disposed between two large components so that the pipe is orthogonal to the arrangement direction of the two large components. In the arrangement structure of the power conversion device, the maximum distance between the large component and the case is narrower than any length in the protruding direction between the plurality of connectors and the pair of pipes.

In the power conversion device, of the four wall portions constituting the case, the pipe protruding wall portion and the connector mounting wall portion are provided at a position sandwiching the device main body portion in the protruding direction of the pipe.
Therefore, the pipe and the connector can be protruded from the case in opposite directions and in directions parallel to each other. Therefore, the power converter can be disposed between the two large components so that neither the pipe nor the connector protrudes toward the large component. Therefore, even if the interval between the two large components is narrow, the power conversion device can be disposed between the two large components.

Moreover, in the arrangement structure of the power converter, the maximum distance between the large component and the case is narrower than the length of any of the plurality of connectors and the pair of pipes in the protruding direction.
Therefore, a case and a large sized part can be brought closer. Therefore, even if the interval between the two large components is narrower, the power conversion device can be arranged between the two large components.

  As described above, according to the present invention, it is possible to provide a power conversion device that can be disposed between two large components even when the interval between the two large components is narrow, and an arrangement structure thereof.

  The “large component” means a component having a size that cannot be disposed between the pair of pipes or between two connectors. For example, an air cleaner box, an engine, a wall of a vehicle body, and the like correspond to this.

  In addition, irregularities may be formed on the surface of a large component or case. In this case, the distance between these large parts and the case is not constant. Therefore, the widest interval between them is defined as the “maximum interval”.

The perspective view of the power converter device in Example 1. FIG. The conceptual diagram of the vehicle which provided the power converter device in Example 1. FIG. The principal part enlarged view of FIG. IV-IV sectional drawing of FIG. VV sectional drawing of FIG. The top view of the power converter device in Example 1 immediately after fixing to the vehicle body. VII arrow line view of FIG. It is sectional drawing of the power converter device in Example 1, Comprising: It is VIII-VIII sectional drawing of FIG. IX-IX sectional drawing of FIG. XX sectional drawing of FIG. XI-XI sectional drawing of FIG. The conceptual diagram of the vehicle which provided the power converter device in the comparative example 1. FIG. The conceptual diagram of the vehicle which provided the power converter device in the comparative example 2. FIG.

  The power conversion device can be a vehicle-mounted power conversion device to be mounted on a vehicle such as an electric vehicle or a hybrid vehicle.

Example 1
The said power converter device and the Example which concerns on the arrangement structure are described using FIGS. As shown in FIG. 1, the power converter 1 of this example includes a case 4, a pair of pipes 6 (6a, 6b), and a plurality of connectors 7 (7a, 7b, 7c). As shown in FIGS. 8 and 9, the case 4 houses the device main body 11 of the power conversion device 1. The apparatus main body 11 includes a semiconductor module 2, a cooler 3 that cools the semiconductor module 2, and a control circuit board 12. The semiconductor module 2 includes a semiconductor element (not shown) such as an IGBT element. The control circuit board 12 is connected to the semiconductor module 2 and controls the operation of the semiconductor module 2.

  The pair of pipes 6 are connected to the cooler 3 and form a flow path for the refrigerant 30 flowing in the cooler 3. As shown in FIGS. 1 and 3, the pair of pipes 6 protrude from the case 4. The plurality of connectors 7 are attached to the case 4 so as to protrude outward from the case 4. Each connector 7 is provided to electrically connect the apparatus main body 11 to the external device 8.

  As shown in FIG. 8, the case 4 has four wall portions 5 (5a to 5d) surrounding the device main body 11 from four directions. Of these four wall portions 5, the pipe protruding wall portion 5 a from which the pair of pipes 6 protrudes and the connector mounting wall portion 5 b to which a plurality of connectors 7 (see FIG. 3) are attached are the protruding direction of the pipe 6. It is provided at a position sandwiching the apparatus main body 11 in the (X direction).

  As shown in FIG. 1, the power conversion device 1 of this example includes three connectors 7. The connector 7 includes a DC connector 7a, an AC connector 7b, and a control connector 7c. The DC connector 7a is provided to electrically connect the above-described apparatus main body 11 and the DC power source 8a (see FIG. 2). The AC connector 7b electrically connects the apparatus main body 11 and the AC motor 8b (see FIG. 2). The control connector 7c is provided for connecting the control circuit board 12 to an ECU (not shown). Cables 70 extend from the individual connectors 7. The control connector 7 c includes two parts: a case side part 71 fixed in advance to the case 4 and a cable side part 72 connected to the case side part 71.

  As shown in FIG. 1, the case 4 of this example includes two connecting wall portions 5c and 5d that connect the pipe protruding wall portion 5a and the connector mounting wall portion 5b. The case 4 includes an upper wall plate 46 connected to each of the four wall portions 5 (5a to 5d). A connector connection opening 41 and a main body opening 47 which will be described later are formed in the upper wall plate 46. The connector connection opening 41 is closed by a connector cover 42. The main body opening 47 is closed by the main body cover 44. Further, as shown in FIGS. 9 and 10, the case 4 of this example includes bottom wall plates 49 respectively connected to the four wall portions 5.

  On the other hand, as shown in FIG. 2, the power conversion device 1 of this example is a vehicle-mounted power conversion device to be mounted on a vehicle 81 such as an electric vehicle or a hybrid vehicle. The power converter 1 is disposed between two large components 13 (13a, 13b). In addition to the power conversion device 1, the vehicle 81 includes devices such as an engine 82, a DC power supply 8 a, an AC motor 8 b, a light 83, a brake 85, and a gear 86. One large component 13a of the two large components 13 described above is an air cleaner that cleans the air sent to the engine 82, and the other large component 13b is a general component box that houses an ECU, a fuse box, and the like. .

  As shown in FIG. 3, in this example, the power conversion device 1 is placed between two large components 13 so that the pipe 6 is orthogonal to the arrangement direction (Y direction) of the two large components 13. It is arranged. Further, in this example, the power conversion device 1 is arranged in a direction in which the bolt 43 and the case fixing bolt 400 can be inserted from an orthogonal direction (Z direction) orthogonal to both the X direction and the Y direction. .

  Further, as shown in FIGS. 3 to 5, fixing portions 40 for fixing the case 4 to the mounting portion 45 are formed on the pipe protruding wall portion 5 a and the connector mounting wall portion 5 b so as to protrude in the X direction. It is. The fixing portion 40 is formed only on the pipe protruding wall portion 5a and the connector mounting wall portion 5b, and is not formed on the connecting wall portions 5c and 5d.

  Moreover, in this example, as shown in FIG. 3, the large-sized component 13 and the case 4 and the individual connectors 7 (7a, 7b, 7c) and the pair of pipes 6 (6a, 6b) are longer than any length in the X direction. The maximum gap G between the two is narrower. In this example, among the plurality of connectors 7 (7a to 7c) and the pair of pipes (6a, 6b), the component having the shortest length in the X direction is the input connector 7a. The maximum gap G is narrower than the length L1 of the input connector 7a in the X direction.

  Further, the X-direction length L2 of the fixed portion 40 is shorter than the X-direction length L1 of the input connector 7a. In this example, the maximum gap G is narrower than the length L2 of the fixed portion 40 in the X direction.

  As shown in FIG. 4, the power conversion device 1 of this example is arranged at a position sandwiched between the body 84 of the vehicle 81 and the engine 82 from the X direction. The pipe 6 protrudes outside the vehicle. A hose 60 attached to the pipe 6 extends to the lower side of the vehicle 81. The hose 60 is connected to a cooling device (not shown).

  Next, the process of attaching the power conversion device 1 to the vehicle 81 will be described. When performing the attaching process, as shown in FIGS. 6 and 7, first, the power conversion device 1 to which the connector cover 42 and the connector 7 are not attached is prepared and disposed between the two large components 13. . At this time, the direction of the pipe 6 is orthogonal to the arrangement direction (Y direction) of the two large components 13. Moreover, the power converter device 1 is arrange | positioned so that the opening part 41 for connector connection may open in a Z direction. Then, the case fixing bolt 400 is inserted into the fixing portion 40 to fix the case 4 to the mounting portion 45 of the vehicle 81.

  As described above, since the power conversion device 1 is disposed without the connector cover 42 attached, in the state immediately after the placement, the connector input opening 41 and the DC input terminal 15 of the device main body 11 are connected to the alternating current. The output terminal 16 can be visually recognized. Further, as shown in FIG. 7, the connector mounting wall 5b of the power conversion device 1 has an input connector insertion hole 51 for inserting the input connector 7a, and an output connector insertion hole 52 for inserting the output connector 7b. The terminals 15 and 15 inside the case can be visually recognized from these insertion holes 51 and 52. Moreover, the case side part 71 of the control connector 7c is previously attached to the connector attachment wall part 5b.

  After fixing the power converter 1 to the vehicle 81, the input connector 7 a is inserted into the input connector insertion hole 51, and the output connector 7 b is further inserted into the output connector insertion hole 52. Then, the terminals (not shown) of the individual connectors 7a and 7b are superimposed on the DC input terminal 15 or the AC output terminal 16, and a terminal fastening bolt (not shown) is inserted from the connector connection opening 41 (see FIG. 6). Conclude these. Thereafter, the connector connecting opening 42 is closed using the connector cover 42 (see FIG. 1). Then, the connector cover 42 is fixed to the case 4 using bolts 43 (see FIG. 3).

  Moreover, the cable side part 72 (refer FIG. 1) is connected to the case side part 71 of the control connector 7c, and the hose 60 (refer FIG. 4) is connected to each pipe 6a, 6b. The power conversion device 1 is attached to the vehicle 81 by performing the operations described above.

  Next, the internal structure of the power converter 1 will be described. As shown in FIGS. 8 and 9, the power conversion device 1 of this example includes a stacked body 110 in which a plurality of semiconductor modules 2 and a plurality of cooling pipes 31 are stacked. Each of the semiconductor modules 2 includes a main body portion 21 containing a semiconductor element such as an IGBT element, a control terminal 22 protruding from the main body portion 21, and a power terminal 23. The control terminal 22 is connected to the control circuit board 12. As shown in FIG. 10, the power terminal 23 includes a positive electrode terminal 23 a and a negative electrode terminal 23 b to which a DC voltage is applied, and an AC terminal 23 c connected to the AC output terminal 16. The control circuit board 12 controls the switching operation of the semiconductor module 2 to convert the DC voltage applied between the positive terminal 23a and the negative terminal 23b into an AC voltage and output it from the AC terminal 23c. Thus, the AC motor 8b is configured to be driven.

  Further, as shown in FIG. 8, a pressure member 17 (plate spring) is provided between the inner wall 410 of the case 4 and the laminated body 110. The pressurizing member 17 pressurizes the laminated body 110 in the X direction, and presses the laminated body 110 against the pipe protruding wall portion 5 a of the case 4. Thereby, the laminated body 110 is fixed in the case 4 while ensuring a contact pressure between the cooling pipe 31 and the semiconductor module 2.

  Further, the two cooling pipes 31 adjacent in the X direction are connected by connecting pipes 32 at both ends in the Y direction. A plurality of cooling pipes 31 and connecting pipes 32 constitute the cooler 3 of this example. The pair of pipes 60a and 60b described above are connected to the cooling pipe 31a closest to the pipe protruding wall portion 5a among the plurality of cooling pipes 31. When the refrigerant 30 is introduced from one pipe 60a, the refrigerant 30 flows through all the cooling pipes 31 through the connecting pipe 32 and is led out from the other pipe 60b. Thereby, the semiconductor module 2 is configured to be cooled.

  Further, the case 4 accommodates a capacitor 14 for smoothing the DC voltage. As shown in FIG. 8, the capacitor 14 includes a plurality of capacitor elements 141, a capacitor case 142 that houses the capacitor elements 141, and a sealing member 143 that seals the capacitor elements 141 in the capacitor case 142. The capacitor element 141 is a so-called film capacitor. As shown in FIG. 10, both end surfaces 144 and 145 in the Z direction of the capacitor element 141 are electrode surfaces. Bus bars 146 and 147 are connected to both end faces 144 and 145, respectively. Terminals 148 and 149 of these bus bars 146 and 147 protrude to the laminated body 11 side. The terminals 148 and 149 are connected to the positive terminal 23a and the negative terminal 23b of the semiconductor module 2 by a conductive plate (not shown). The bus bars 146 and 147 are each connected to the DC input terminal 15 (see FIG. 8) by a conductive member (not shown).

  As shown in FIG. 11, the AC bus bar 18 is connected to the AC terminal 23 c of the semiconductor module 2. The power conversion apparatus 1 of this example includes three AC bus bars 18 (18u, 18v, 18w). These three AC bus bars 18u, 18v, 18w are sealed with a sealing resin 19 and integrated to form a bus bar module 161. One end of each AC bus bar 18 is connected to the AC terminal 23c of the semiconductor module 2, and the other end is connected to the AC output terminal 16 described above.

The effect of this example will be described. As shown in FIG. 8, in the power conversion device 1 of the present example, among the four wall portions 5 constituting the case 4, the pipe protruding wall portion 5 a and the connector mounting wall portion 5 b are connected to the device main body portion in the X direction. 11 is provided at a position sandwiching 11.
Therefore, the pipe 6 and the connector 7 can be protruded from the case 4 in opposite directions in parallel directions. Therefore, as shown in FIG. 3, the power converter 1 can be arranged between the two large components 13 a and 13 b so that neither the pipe 6 nor the connector 7 protrudes toward the large component 13. Therefore, even if the space | interval L3 of the two large components 13a and 13b is narrow, it becomes possible to arrange | position the power converter device 1 between these two large components 13a and 13b.

  That is, as shown in FIGS. 12 and 13, assuming that the pipe projecting wall portion 95a and the connector projecting wall portion 95b of the case 94 are orthogonal to each other, the electric power is generated between the two large components 92 (92a, 92b). When the conversion device 91 is arranged, one of the pipe 96 and the connector 97 always protrudes toward the large component 92. Therefore, the power conversion device 91 cannot be arranged unless the distance L between the two large components 92 is increased.

  On the other hand, as shown in FIG. 3, the pipe protruding wall portion 5a and the connector protruding wall portion 5b are not orthogonal to each other as in this example, and the pipe protruding wall portion 5a and the connector protruding wall portion 5b are If it arrange | positions in the position which pinches | interposes the apparatus main body part 11 (refer FIG. 8), since the pipe 6 and the connector 7 can be made parallel, respectively, neither the pipe 6 nor the connector 7 protrudes toward the large sized component 13. Thus, the power converter device 1 can be arrange | positioned between the two large sized components 13. FIG. Therefore, even if the space | interval L3 of the two large components 13 is narrow, it becomes possible to arrange | position the power converter device 91. FIG.

As shown in FIG. 3, the case 4 of this example includes a fixing unit 40 for fixing the power conversion device 1 to the mounting unit 45. The fixing portion 40 is formed so as to protrude in the X direction from the pipe protruding wall portion 5a and the connector mounting wall portion 5b.
If it does in this way, it is not necessary to make the fixing | fixed part 40 protrude in a Y direction. Therefore, the space | interval of the large sized component 13 and the case 4 can be made narrower.

Further, as shown in FIG. 3, in the power converter arrangement structure 10 in this example, the power converter 1 is arranged between two large components 13 so that the pipe 6 is orthogonal to the Y direction. It is. Then, the maximum distance G between the large component 13 and the case 4 is longer than any length in the protruding direction between the plurality of connectors 7 (7a, 7b, 7c) and the pair of pipes 6 (6a, 6b). It is narrow.
Therefore, the connecting wall portions 5c, 5d of the case 4 and the large component 13 can be brought closer to each other. Therefore, even if the space | interval L3 of the two large components 13 is narrower, the power converter device 1 can be arrange | positioned between these two large components 13. FIG.

Further, as shown in FIG. 6, in the power converter arrangement structure 10 in this example, the connector connection opening that opens in the case 4 toward the terminals 15 and 16 for connecting the device main body 11 to the connector 7. 41 is formed. The connector connection opening 41 is open in the Z direction.
Therefore, the connector connection opening 41 is not hidden by the large component 13 or the like. Therefore, it is possible to arrange the power conversion device 1 in a narrow space between the two large components 13 while facilitating the fastening operation between the terminals of the connector 7 and the terminals 15 and 16 of the device main body 11. It becomes possible.

  As described above, according to this example, it is possible to provide a power conversion device that can be disposed between two large components even when the interval between the two large components is narrow, and an arrangement structure thereof.

DESCRIPTION OF SYMBOLS 1 Power converter 10 Arrangement structure 11 Apparatus main-body part 12 Control circuit board 2 Semiconductor module 3 Cooler 30 Refrigerant 4 Case 5 Wall part 5a Pipe protrusion wall part 5b Connector mounting wall part 6 Pipe 7 Connector 8 External apparatus

Claims (4)

A semiconductor module (2) incorporating a semiconductor element, a cooler (3) for cooling the semiconductor module (2), and a control circuit connected to the semiconductor module (2) to control the operation of the semiconductor module (2) An apparatus body (11) having a substrate (12);
A case (4) for housing the apparatus main body (11);
A pair of pipes (6) projecting from the case (4), connected to the cooler (3), forming a flow path for the refrigerant (30) flowing through the cooler (3);
A plurality of connectors (7) attached to the case (4) so as to protrude outward from the case and electrically connecting the device main body (11) to the external device (8),
The case (4) has four wall portions (5) surrounding the device main body (11) from four directions,
Of the four wall portions (5), a pipe protruding wall portion (5a) from which the pair of pipes (6) protrudes, and a connector mounting wall portion (5b) to which the plurality of connectors (7) are attached. Is provided at a position sandwiching the device main body (11) in the projecting direction of the pipe.   The case (4) includes a fixing portion (40) for fixing the power converter (1) to the mounting portion (45), the pipe protruding wall portion (5a), the connector mounting wall portion (5b), and the like. The power conversion device (1) according to claim 1, wherein each of the power conversion devices (1) is formed so as to protrude in the protruding direction.   In the power conversion device (1) according to claim 1 or 2, the pipe (6) is orthogonal to the arrangement direction of the two large components between the two large components (13). Between the large component (13) and the case (4) rather than any length in the protruding direction between the plurality of connectors (7) and the pair of pipes (6a, 6b). The arrangement (10) of the power converter is characterized in that the maximum gap (G) is narrower.   The case (4) includes a connector connection opening (41) opened toward the terminals (15, 16) for connecting the apparatus main body (11) to the connector, and the connector connection opening ( 41), and the connector connection opening (41) opens in an orthogonal direction orthogonal to both the projecting direction and the arrangement direction. The arrangement structure (10) of the power converter device according to claim 3.

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