JP2016100943A - Electric power conversion system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric power conversion system capable of improving assemblability of a bus bar and a current sensor, securing mounting space inside a case, and reducing the number of components, while suppressing an influence of vibrations from an external device.SOLUTION: An electric power conversion system 1 includes a multilevel structure folded in multi-levels so that a bus bar 100 that electrically connects a power module 70 and an electric motor can freely be inserted into a through-hole 122 of a current sensor 120 while ascending from one end part thereof toward the other end part.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a power conversion device, and more particularly to a power conversion device that can be suitably applied to a vehicle that is a hybrid vehicle.

  In recent years, in vehicles such as four-wheeled vehicles, hybrid vehicles using an engine that is an internal combustion engine and an electric motor in cooperation with a drive system have become widespread.

  In such a hybrid vehicle, a power control device incorporating a power conversion device is used as one of electronic control devices that operate an engine and an electric motor in cooperation. Since such a power conversion apparatus inputs and outputs relatively large electric power, a plurality of flat bus bars made of a metal material are arranged as electric wiring.

  These multiple bus bars are arranged in a case containing a plurality of semiconductor elements that perform switching operations during power conversion, a current sensor that detects current, and the like, so the size of the power conversion device is not required Need to be arranged in the case so as not to increase.

  Under such circumstances, Patent Document 1 relates to a power control unit, and includes a power conversion module disposed on the upper surface of the heat sink, a first flat plate-like portion, a second flat plate-like portion, and a first flat plate-like portion and a first flat plate-like portion. A three-phase terminal formed by a bent portion provided between two planar plate-like portions, a current sensor through which the three-phase terminal is inserted, and a three-phase provided on the upper surface of the heat sink and supporting the second planar plate-like portion. A first flat plate-like portion that is fixed in contact with the contact surface of the three-phase output terminal of the power conversion module, and the second flat plate-like portion is fixed in contact with the fixed surface of the three-phase terminal block. A configuration in which a predetermined gap is formed between the first plane plate-like portion and the contact surface when the first plane plate-like portion is fixed while the second plane plate-like portion is fixed. Is disclosed.

JP 2013-115958 A

  However, according to the inventor's study, in the configuration of Patent Document 1, a bus bar-shaped three-phase terminal having a single step is inserted through a through hole of a current sensor that detects a current flowing therethrough. Considering that the step length (distance between the steps) is large, a part of the three-phase terminal that passes through the through-hole is configured as a bent portion with a spring property, so that the penetration in the current sensor The insertion work when inserting the three-phase terminal into the hole tends to be complicated, and there is room for improvement in the assembling property of the three-phase terminal.

  Further, according to the further examination of the present inventor, in the configuration of Patent Document 1, since the three-phase terminal is fixed so as to sandwich the current sensor, a space for the fixing portion for this is required, and Since the number of fastening points also increases, the number of parts tends to increase and there is room for improvement.

  Further, according to a further study by the present inventor, in the configuration of Patent Document 1, since the bent portion of the three-phase terminal is brought into contact with the current sensor and fixed together, the vibration from the electric motor that is the output destination is fixed. Is transmitted from the three-phase terminal to the current sensor, and there is a room for improvement in consideration of the tendency to affect the circuit board to which the current sensor is connected and the solder part and terminal of the electronic component mounted on the circuit board.

  The present invention has been made through the above-described studies. While suppressing the influence of vibration from an external device, the assembly of the bus bar and the current sensor is improved, and the mounting space in the case is ensured. It aims at providing the power converter device which can reduce a score.

  In order to achieve the above object, the present invention provides a power module that exhibits a power conversion function for converting power supplied to an electric motor, a bus bar that electrically connects the power module and the electric motor, and a flow through the bus bar. In the power conversion device including a current sensor for detecting current, and a case for housing the power module, the bus bar, and the current sensor, the bus bar is raised from one end thereof toward the other end. However, the first aspect is to have a multistage structure that is bent in multiple stages so as to be freely inserted into the through hole of the current sensor.

  In addition to the first aspect, the second aspect of the present invention is that the step length of the multi-stage structure is set to become longer toward the connection end side of the bus bar with respect to the electric motor. And

  In addition to the second aspect, the present invention provides the multistage structure when the bus bar is inserted into the through hole of the current sensor by relatively moving the bus bar and the current sensor while being relatively inclined. It is a third aspect that the insertion height of the step length that is closest to the connection end portion is set larger than the diameter of the through hole.

  Moreover, this invention makes it the 4th aspect that the said bus-bar is fitted by the positioning part provided in the said case in addition to any 1st to 3rd aspect.

  According to the power conversion device according to the first aspect of the present invention described above, the bus bar is multistage so that the bus bar can be inserted into the through hole of the current sensor while rising from the one end to the other end. Because it has a multi-stage structure that is bent into two parts, the assembly of the bus bar and current sensor is improved while suppressing the influence of vibration from external devices, and the mounting space in the case is secured to reduce the number of parts. can do. In particular, by bending the bus bar in multiple stages so that it can be inserted into the through hole of the current sensor, the height of the bus bar between its input end and output end can be divided to reduce the individual step length. Therefore, even if the hole diameter of the through hole of the current sensor is relatively small, the bus bar can be inserted through the through hole while relatively penetrating the through hole, and the assembling property can be improved. In addition, when the bus bar is fixed, since the insertion portion of the bus bar with respect to the through hole of the current sensor is not in contact with the current sensor, the influence of the vibration from the electric motor on the terminals and the solder portion of the current sensor can be significantly reduced. it can. In addition, by giving the bus bar a multi-stage structure, its strength and rigidity, and shape accuracy during press molding can be improved, and after the bus bar is assembled, unnecessary contact of the bus bar with the through hole of the current sensor is suppressed. can do. In addition, since the flat portion can be provided by bending in multiple stages in this way, the mounting portion occupation area can be secured widely at a uniform height.

  Further, according to the power conversion device according to the second aspect of the present invention, the step length of the multi-stage structure is set so as to become longer toward the connection end side of the bus bar with respect to the electric motor, It is possible to fix the bus bar on the power module side at a position away from the current sensor while suppressing the individual step length of the bus bar and increasing the portion through which the through hole of the current sensor can be inserted. As a result, it becomes possible to make a space around the fixed portion of the bus bar on the power module side, and the size of the case can be correspondingly reduced.

  Further, according to the power conversion device of the third aspect of the present invention, when the bus bar and the current sensor are relatively moved while being relatively inclined and the bus bar is inserted into the through hole of the current sensor, Since the insertion height of the step length existing on the connection end portion side of the bus bar with respect to the electric motor is set larger than the diameter of the through hole, the position of the connection end portion of the bus bar with respect to the electric motor, Even when the difference between the position of the through hole of the current sensor is large, the bus bar can be electrically connected to the electric motor in a state where the bus bar is inserted into the through hole of the current sensor.

  Moreover, according to the power converter device concerning the 4th aspect of this invention, since a bus-bar is fitted by the positioning part provided in the case, it is in positioning parts, such as the positioning pin provided in the case. Since the bus bar can be positioned by aligning and fitting a part of the bus bar (the part drilled in the flat part provided by bending in multiple stages), there is no need for a fastening member such as a bolt, The number of parts and assembly man-hours can be reduced.

FIG. 1 is a perspective view showing a configuration of a power conversion device according to an embodiment of the present invention. FIG. 2 is a partially enlarged perspective view showing the configuration of the power conversion device according to the present embodiment with the upper case removed. 3A is an AA enlarged partial cross-sectional view of FIG. 1, and FIG. 3B is a cross-sectional view showing FIG. 3A in more detail. FIG. 4 is a schematic diagram illustrating a dimensional configuration for inserting the output bus bar of the power conversion device according to the present embodiment into the through hole of the power sensor.

  Hereinafter, the power converter according to the embodiment of the present invention will be described in detail with reference to FIGS. 1 to 3 as appropriate. In the figure, the x-axis, y-axis, and z-axis constitute a three-axis orthogonal coordinate system, the z-axis direction corresponds to the vertical direction, and the xz plane is the horizontal plane.

  FIG. 1 is a perspective view illustrating a configuration of a power conversion device according to the present embodiment. FIG. 2 is a partially enlarged perspective view showing the configuration of the power conversion device according to the present embodiment with the upper case removed. 3A is an AA enlarged partial cross-sectional view of FIG. 1, and FIG. 3B is a cross-sectional view showing FIG. 3A in more detail. FIG. 4 is a schematic diagram showing a dimensional configuration for inserting the output bus bar of the power conversion device according to the present embodiment into the through hole of the power sensor.

  As shown in FIGS. 1 to 4, the power conversion device 1 is mounted on a lower case 10 that is a main case and an upper portion of the lower case 10 via a fitting structure (not shown) and the like. An upper case 40 that closes the upper part, a heat sink 60 that is disposed at the lower part of the lower case 10 via a fastening member (not shown), the lower case 10 and the upper case 40 are defined in cooperation. And a power module 70 housed in the interior housing space, and is mounted on a vehicle such as a hybrid vehicle (not shown). The power conversion device 1 is typically mounted on a vehicle and is not shown in the figure, but a direct current supplied from a battery as a secondary battery to a driving electric motor is converted into an alternating current (three-phase current). It has a DC (Direct Current) / AC (Alternate Current) conversion function for conversion. In addition, the power converter device 1 may have an AC / DC conversion function for converting an alternating current supplied to the battery from the electric motor or a regenerative mechanism (not shown) into a direct current as necessary.

  Both the lower case 10 and the upper case 40 are typically molded products made of non-conductive resin (synthetic resin), and the heat sink 60 is typically a cast product made of metal such as an aluminum material. is there. The power module 70, the circuit board 80, the output bus bar 100, and the current sensor 120 are accommodated in an internal housing space defined by the lower case 10 and the upper case 40 in cooperation.

  Specifically, the lower case 10 mainly includes a side peripheral wall 12 that circulates around a vertical axis on a plane parallel to the xy plane, and a bottom wall 13 that closes the bottom of the side peripheral wall 12.

  A part of the bottom wall 13 is provided with an inner terminal block 14 projecting downward, and disposed on the positive side of the x-axis with respect to the inner terminal block 14 and projecting upward. A positioning pin 18 and an opening 19 that is disposed on the negative side of the x-axis with respect to the inner terminal block 14 and that opens the interior of the lower case 10 are provided. The inner terminal block 14 and the positioning pins 18 are provided in such a manner that three inner terminal blocks 14 and three positioning pins 18 are juxtaposed in the y-axis direction, and are typically formed integrally with the bottom wall 13 when the lower case 10 is formed. Each of the inner terminal blocks 14 is fitted with a collar 16 made of metal or the like. Typically, the upper ends of the collars 16 are set flush with the upper surface of the inner terminal block 14. In the opening 19, the bottom of the power module 70 is exposed to the outside from the internal housing space defined by the lower case 10 and the upper case 40 in cooperation. A fastening portion that fastens the bottom wall 13 to the heat sink 60 via a fastening member is provided on the remaining portion of the bottom wall 13 other than the inner terminal block 14, the positioning pins 18, and the opening 19. Illustration of such fastening members and fastening portions is omitted.

  A part of the side peripheral wall 12 is provided with a configuration in which three outer terminal blocks 20 each projecting in the positive direction of the x-axis are juxtaposed in the direction of the y-axis. Each of the outer terminal blocks 20 is typically formed integrally with the side peripheral wall 12 when the lower case 10 is formed. The outer terminal blocks 20 are each formed with a recess 22 that is recessed downward from the upper surface thereof. Each of the recesses 22 is fitted with a collar 24 made of metal or the like, and each of the collars 24 is typically set to be flush with the upper surface of the corresponding outer terminal block 20. The outer end portions of the corresponding output bus bars 100 are respectively placed on the upper surfaces of the outer terminal blocks 20, and the outer end portions of the output bus bars 100 are respectively connected to the electric motor side through the fastening members 26 and omitted from the reference numerals. It is fastened to the screw hole of the collar 24 together with the end of the bus bar. The side peripheral wall 12 is formed with notches 28 and 30 that are recessed downward from the upper end thereof. The notches 28 are provided corresponding to the three external terminal blocks 20 arranged side by side, and the corresponding output bus bars 100 are formed outside the internal housing space in which the lower case 10 and the upper case 40 define the cooperation. To each of them. Instead of each notch 28, a through-hole penetrating the side peripheral wall 12 may be provided.

  The upper case 40 mainly includes a side peripheral wall 42 that circulates around a vertical axis on a plane parallel to the xy plane, and an upper wall 43 that closes the upper portion thereof.

  A part of the side peripheral wall 42 is formed with notches 44 and 46 that are recessed upward from the lower end thereof. The cutout portions 44 are provided corresponding to the cutout portions 28 of the lower case 10 and extend the corresponding output bus bars 100. However, the notch portion 44 is provided when the corresponding output bus bar 100 is extended only by the notch portion 28 of the lower case 10 or when a through hole penetrating the side peripheral wall 12 is provided instead of the notch portion 28. Is omitted. The notch portion 46 is provided corresponding to the notch portion 30 of the lower case 10, and in cooperation with the notch portion 30, the illustration of which is omitted is omitted, but an electric control ECU (Electronic Control) is omitted. A receiving portion for receiving an input / output signal connector electrically connected to (Unit).

  A part of the upper wall 43 forms a protruding wall 47 whose shape changes so as to protrude upward. Below the protruding wall 47, a high-profile component such as a smoothing capacitor mounted on the upper surface of the circuit board 80 is disposed.

  The heat sink 60 mainly includes a rectangular main body 62 and a plurality of fins 64 that protrude downward from the lower surface of the main body 62.

  A recess 66 is formed in the end region of the peripheral edge of the main body 62 on the positive side of the x-axis so as to be recessed downward from the upper surface thereof. In the recess 66, the inner terminal block 14 of the lower case 10 is correspondingly accommodated in a position-aligned manner. The upper surface position of the inner terminal block 14 is typically set in the recess 66. In the main body 62, the vertical thickness of the portion where the concave portion 66 is not formed is thicker than the vertical thickness of the portion where the concave portion 66 is formed. That is, in the main body 62, the portion where the concave portion 66 is not formed is a thick portion having a large vertical thickness, and the portion where the concave portion 66 is formed is a thin portion having a thin vertical thickness. is there.

  The power module 70 is typically a molded product made of a plurality of power semiconductor elements for power conversion such as an IGBT (Insulated Gate Bipolar Transistor) (not shown) and a non-conductive resin (synthetic resin). A module case 72 for housing a plurality of power semiconductor elements, and a conductive plate typically connected at one end to the plurality of power semiconductor elements and at the other end extending from the module case 72 And a power module side bus bar 74 made of a member.

  The bottom of the module case 72 is opened toward the upper surface of the heat sink 60. The plurality of power semiconductor elements are attached to the module case 72 and abut on the upper surface of the heat sink 60 through the opened bottom of the module case 72 and the opening 19 of the lower case 10. Between the plurality of power semiconductor elements and the upper surface of the heat sink 60, the heat conductivity typically equal to or higher than that of the heat sink 60 is exhibited in order to improve the heat conductivity at the bottom of the plurality of power semiconductor elements. May be provided with a metal heat spreader 76. A fastening portion for fastening the module case 72 to the heat sink 60 via a fastening member is provided on the remaining portion other than the opened bottom portion of the module case 72 and the extending portion of the power module side bus bar 74. Illustration of such fastening members and fastening portions is omitted. The module case 72 may have a structure in which the bottom thereof is not opened as necessary. In such a case, a plurality of power semiconductor elements are connected to the heat sink 60 via the module case 72. Thermally contacts the top surface.

  The power module side bus bars 74 are typically provided in a manner in which three power module side bus bars 74 are juxtaposed in the y-axis direction corresponding to the U-phase, V-phase, and W-phase of the three-phase current. It consists of a single plate-like member made of metal bent in the vertical direction while being horizontally arranged in a posture along the direction of the y-axis. Each of the power module side bus bars 74 extends from the module case 72 and extends in the positive direction of the x-axis, and terminates on the upper surface of the inner terminal block 14 of the lower case 10. It is mounted on the upper surface of the inner terminal block 14 and is fastened to the screw hole of the collar 16 together with the inner end portion of the corresponding output bus bar 100 via the fastening member 102. The upper surface of the terminal portion of the power module side bus bar 74, the upper surface of the inner end portion of the output bus bar 100, and the vertical position of the top of the fastening member 102 are the depth of the recess 66 formed in the main body portion 62 of the heat sink 60, and By adjusting the accommodation depth of the inner terminal block 14 with respect to the recess 66, the inner volume can be adjusted so as to increase the effective volume of the internal accommodation space defined by the lower case 10 and the upper case 40 in cooperation.

  The circuit board 80 is typically arranged in parallel to the xy plane and is a flat circuit board such as a PCB (Printed Circuit Board), and is mounted on the lower case 10 or the upper case 40.

  Mounted on the circuit board 80 are high-profile components such as a smoothing capacitor, a CPU (Central Processing Unit) for driving control of a plurality of power semiconductor elements, and low-profile components such as a resistance element and a memory. A region where the space around the circuit board 80 is occupied by components is shown as a mounting component occupation region 82. Since the depth of the concave portion 66 formed in the main body portion 62 of the heat sink 60 and the accommodation depth of the inner terminal block 14 with respect to the concave portion 66 are ensured, the position of the top portion of the fastening member 102 in the vertical direction is lowered, As a result, the volume of the mounting component occupation area 82 on the lower side of the circuit board 80 is ensured equally large at a position where the position in the vertical direction is lowered to the vicinity of the upper surface of the module case 72 of the power module 70.

  The output bus bar 100 is typically an electrical wiring provided in a manner arranged in parallel in the y-axis direction corresponding to the U-phase, V-phase, and W-phase of the three-phase current. It consists of a single plate-like member made of metal that is bent in the vertical direction while being horizontally arranged in a posture in which the width direction is along the y-axis direction.

  The current sensor 120 is typically attached to the lower case 10 that is the main case, and in order to detect the current of the three-phase currents of the U-phase, V-phase, and W-phase flowing through the output bus bar 100, the y-axis A case 121 which is a molded product made of a magnetically permeable resin (synthetic resin), a current element such as a Hall element which is included in the case 121 and is not shown, and a case And a through hole 122 that penetrates 121 in the x-axis direction. The corresponding output bus bar 100 is inserted through each of the through holes 122, and the current sensor 120 detects the current flowing through the corresponding output bus bar 100. The position of the through hole 122 in the vertical direction (the position of the central axis of the through hole 122 in the x-axis direction) is higher than the position of the upper surface of each inner terminal block 14 of the lower case 10 and each outer terminal of the lower case 10. It is set lower than the position of the upper surface of the table 20. The diameter of the through hole 122 (the diameter of the narrowest part) is naturally larger than the plate width of the corresponding output bus bar 100, but on the power module side on the inner terminal block 14 of the lower case 10 accommodated in the recess 66 of the heat sink 60. More than the difference between the vertical height position of the portion attached corresponding to the terminal portion of the bus bar 74 and the vertical height position of the portion attached corresponding to the outer terminal block 20 of the lower case 10 Very small.

  Here, while the output bus bars 100 are respectively inserted through the through holes 122 of the corresponding current sensors 120, between the upper surface of the corresponding inner terminal block 14 of the lower case 10 and the upper surface of the corresponding outer terminal block 20 of the lower case 10. The output bus bar 100 has a multi-stage structure that extends in the x-axis direction while bending between the inner end portion and the outer end portion in a multi-stage (a plurality of stages) in the vertical direction. Have

  That is, the output bus bar 100 includes, for example, as shown in FIG. 3, the first flat plate portion 106 having the inner end portion, the first step connection portion 107, the second step portion, in order from the inner end portion to the outer end portion. The flat plate portion 108, the second step connecting portion 109, the third flat plate portion 110, the third step connecting portion 111, the fourth flat plate portion 112, the fourth step connecting portion 113, and the fifth flat plate portion 114 having the outer end portion. . Note that the first flat plate portion 106, the second flat plate portion 108, the third flat plate portion 110, the fourth flat plate portion 112, and the fifth flat plate portion 114 are typically flat portions each parallel to the xy plane. is there. The first step connection portion 107, the second step connection portion 109, the third step connection portion 111, and the fourth step connection portion 113 typically include the first flat plate portion 106, the second flat plate portion 108, respectively. Although it is a flat plate part like the 3rd flat plate part 110, the 4th flat plate part 112, and the 5th flat plate part 114, it may be not only a vertical wall but an inclined wall.

  The first flat plate portions 106 having the inner end portions of the output bus bars 100 are respectively placed on the upper surfaces of the corresponding inner terminal blocks 14 of the lower case 10 and corresponding power module side bus bars 74 via the fastening members 102. Are fastened to the screw holes and the like of the collar 16 together with the terminal portions of the collar 16. The fifth flat plate portions 114 having the outer end portions of the output bus bar 100 are respectively placed on the upper surface of the corresponding outer terminal block 20 of the lower case 10, and the corresponding electric motor-side bus bar via the fastening member 26. It is fastened to the screw hole or the like of the collar 24 together with the end portion. Each of the second flat plate portions 108 positioned on the negative side of the x-axis by about one step from the third flat plate portion 110 that is the central portion in the x-axis direction of the output bus bar 100 has a corresponding positioning pin 18 of the lower case 10. It is inserted and fitted with positioning pins 18 for positioning. The fourth flat plate portions 112 located on the positive side of the x-axis by about one step from the third flat plate portion 110 that is the central portion of the output bus bar 100 are respectively through holes formed in the case 121 of the corresponding current sensor 120. 121 is inserted in the direction of the x-axis. In addition, the shield plate 104 extending from the intermediate portion on the negative side of the x-axis to the inner end portion of the output bus bar 100 from the central portion of the output bus bar 100 extends from the third flat plate portion 110 to the fastening member 102. Fastening members using a free space on the layout between the upper surface of the third flat plate part 110, the upper ends of the positioning pins 18 and the tops of the fastening members 102, and the mounting component occupation region 82 on the lower side of the circuit board 80 It is arranged to penetrate above the top of 102.

  In particular, as shown in FIG. 4, in the multistage structure of the output bus bar 100, the plate-like multistage structure increases the free space on the layout in the internal housing space defined by the lower case 10 and the upper case 40 in cooperation. In order to facilitate the workability of inserting the output bus bar 100 having a structure corresponding to the through hole 121 of the current sensor 120, the step length between adjacent flat plate portions (the lower surface of the flat plate portion positioned below and the flat plate positioned above the flat plate portion) The vertical distance between the upper surfaces of the first and second portions is set to become longer in order from the first flat plate portion 106 having the inner end portion of the output bus bar 100 toward the fifth flat plate portion 114 having the outer end portion of the output bus bar 100. It is preferable. Further, by providing a multi-stage structure to each of the output bus bars 100 in this way, in addition to being able to improve their strength and rigidity, it is possible to improve the shape accuracy when they are formed by press molding. it can.

  In FIG. 4, specifically, the diameter of the through hole 121 of the current sensor 120 is indicated by H1. Also, in the figure, the step length between the first flat plate portion 106 and the second flat plate portion 108 is h1, the step length between the second flat plate portion 108 and the third flat plate portion 110 is h2, and the third flat plate portion 110 and The step length between the fourth flat plate portions 112 is indicated by h3, and these are set in a relationship of h1 <h2 <h3. Also, in the figure, the output bus bar 100 is inserted into the through-hole 121 of the current sensor 120 by moving the current sensor 120 relative to the output bus bar 100 in a zigzag manner while being relatively inclined along the arrow. In this case, the insertion height obtained by inclining the step length h2 between the second flat plate portion 108 and the third flat plate portion 110 is denoted by H2, and these are set in a relationship of H2 <H1. Further, in FIG. 4, if it is considered that the fourth flat plate portion 112 has the outer end portion of the output bus bar 100, the insertion height of the step length h <b> 3 between the third flat plate portion 110 and the fourth flat plate portion 112. May be set larger than the diameter H1 of the through hole 121 of the current sensor 120. Accordingly, the step length h3 between the third flat plate portion 110 and the fourth flat plate portion 112 can be set relatively large, and the position of the through hole 122 and the position of the upper surface of the corresponding outer terminal block 20 of the lower case 10 The output bus bar 100 inserted through the through hole 121 can reach the outer terminal block 20 even when the vertical difference in the vertical direction is large.

  Also, under such conditions, while securing the necessary strength and rigidity of the plate-shaped output bus bar 100, the output bus bar 100 is inserted in correspondence with the through hole 121 of the current sensor 120 and the positioning pin of the lower case 10 is inserted. 18, in addition to the portion attached correspondingly on the terminal portion of the power module side bus bar 74 and the portion attached correspondingly on the outer terminal block 20 of the lower case 10, the current sensor 120. In consideration of the necessity of a portion inserted corresponding to the through hole 121 and a portion positioned corresponding to the positioning pin 18 of the lower case 10, the output bus bar 100 is connected to the end of the power module side bus bar 74. It is preferable that at least three steps are set with reference to a portion attached corresponding to the portion.

  As is clear from the above description, in the power conversion device 1 according to the present embodiment, the bus bar 100 that electrically connects the power module 70 and the electric motor rises from one end portion toward the other end portion. However, since it has a multi-stage structure that is bent in multiple stages so that it can be inserted into the through hole 122 of the current sensor 120, the assembly of the bus bar 100 and the current sensor 120 while suppressing the influence of vibration from an external device. In addition, the mounting space in the case 10 can be secured and the number of parts can be reduced. In particular, by bending the bus bar 100 in multiple stages so that the bus bar 100 can be inserted into the through hole 122 of the current sensor 120, the height dimension of the bus bar between its input end and output end is divided to reduce individual step lengths. Therefore, even when the hole diameter of the through hole 122 of the current sensor 120 is relatively small, the bus bar 100 can be inserted through the through hole 122 while relatively intruding into the through hole 122, and its assembly property Can be improved. Further, when the bus bar 100 is fixed, the insertion portion of the bus bar 100 with respect to the through hole 122 of the current sensor 120 is not in contact with the current sensor 120, and therefore, the influence of the vibration from the electric motor on the terminals and solder portions of the current sensor 120 It can be remarkably reduced. In addition, by providing the bus bar 100 with a multi-stage structure, the strength and rigidity of the bus bar 100 and the shape accuracy at the time of press molding can be improved, and after the bus bar 100 is assembled, the bus bar 100 is inserted into the through hole 122 of the current sensor 120. Unnecessary contact can be suppressed.

  Moreover, in the power converter device 1 in this embodiment, the step length of the multistage structure is set so as to become longer toward the connection end portion side of the bus bar 100 with respect to the electric motor. The bus bar 74 on the power module 70 side can be fixed at a position away from the current sensor 120 while suppressing the step length of the current sensor 120 and increasing the portion through which the through hole 122 of the current sensor 120 can be inserted. As a result, a space around the fixed portion of the bus bar 74 on the power module 70 side can be made, and the size of the case 10 can be correspondingly reduced.

  Further, in the power conversion device 1 in the present embodiment, when the bus bar 100 and the current sensor 120 are relatively moved while being relatively inclined and the bus bar 100 is inserted into the through hole 122 of the current sensor 120, the multi-stage structure is included. Since the insertion height of the step length existing on the connection end portion side of the bus bar with respect to the electric motor is set to be larger than the diameter of the through hole 122, the position of the connection end portion of the bus bar 100 with respect to the electric motor is determined. Even when the difference between the position of the through hole 122 of the current sensor 120 is large, the bus bar 100 is electrically connected to the electric motor in a state where the bus bar 100 is inserted into the through hole 122 of the current sensor 120. can do.

  Moreover, in the power converter 1 in this embodiment, since the bus bar 100 is fitted to the positioning portion 18 provided in the case 10, the positioning portion 18 such as a positioning pin provided in the case 10 is used. Since the bus bar 100 can be positioned by aligning and fitting a part of the bus bar 100, there is no need for a fastening member such as a bolt, and the number of parts and assembly man-hours can be reduced.

  In the present invention, the type, shape, arrangement, number, and the like of the members are not limited to the above-described embodiment, and the gist of the invention is appropriately replaced such that the constituent elements are appropriately replaced with those having the same operational effects. Of course, it can be changed as appropriate without departing from the scope.

  As described above, the present invention improves the assembly of the bus bar and the current sensor while suppressing the influence of vibration from the external device, and secures the mounting space in the case to reduce the number of parts. It is expected that the power conversion device can be widely applied to power conversion devices for vehicles such as hybrid vehicles because of its universal universal character.

1 ... Power converter 10 ... Lower case (main case)
12 ... side wall 13 ... bottom wall 16 ... collar 18 ... positioning pin 19 ... opening 20 ... outer terminal block 22 ... recess 24 ... collar 26 ... fastening member 28 ... notch 30 ... notch 40 ... upper case 42 ... Side wall 43 ... Upper wall 44 ... Notch 46 ... Notch 47 ... Projection wall 60 ... Heat sink 62 ... Main body 64 ... Fin 66 ... Recess 70 ... Power module 72 ... Module case 74 ... Power module side bus bar 76 ... Heat spreader 80 ... circuit board 82 ... mounting component occupation area 100 ... output bus bar 102 ... fastening member 104 ... shield plate 106 ... first flat plate portion 107 ... first step connecting portion 108 ... second flat plate portion 109 ... second step connecting portion 110 ... 3rd flat plate part 111 ... 3rd level | step difference connection part 112 ... 4th flat plate part 113 ... 4th level | step difference connection part 114 ... 5th flat plate part 113 ... 4th level | step difference Connection portion 114 ... fifth flat plate portion 120 ... current sensor 121 ... Case 122 ... through hole

Claims (4)

A power module that exhibits a power conversion function that converts power supplied to the electric motor; a bus bar that electrically connects the power module and the electric motor; a current sensor that detects a current flowing through the bus bar; and the power module; In a power converter comprising a case for housing the bus bar and the current sensor,
The bus bar has a multi-stage structure in which the bus bar is bent in multiple stages so that the bus bar can be inserted into the through hole of the current sensor while rising from one end to the other end.   2. The power converter according to claim 1, wherein a step length of the multistage structure is set so as to become longer toward a connection end side of the bus bar with respect to the electric motor.   When the bus bar is inserted into the through hole of the current sensor by relatively moving the bus bar and the current sensor while being relatively inclined, the step length that is present on the connection end side most in the multi-stage structure The power conversion device according to claim 2, wherein the insertion height is set to be larger than the diameter of the through hole.   The power converter according to claim 1, wherein the bus bar is fitted in a positioning portion provided in the case.

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