JP5936745B1 - Power converter for vehicle - Google Patents

Abstract

A power converter for a vehicle that can be downsized is provided. A power conversion device for a vehicle that converts electric power between a power storage device and a load, the power module converting DC power of the power storage device and AC power supplied to the load, and an external connector A charging device that converts the supplied AC power into DC power and outputs the DC power to the power storage device, and a capacitor module that is connected to the power module and the charging device and smoothes the voltage. [Selection] Figure 1

Description

  The present invention relates to a vehicle power conversion device mounted on an electric vehicle, a hybrid vehicle, or the like.

  BACKGROUND ART A power conversion device mounted on an electric vehicle, a hybrid vehicle, or the like drives a motor by converting DC power of a power storage device (battery) into AC power using an inverter.

  Among such power conversion devices, a device including a connector and a charger for charging a battery from an external commercial power source or the like is known (Patent Document 1).

JP 2010-259274 A

  In the prior art described in Patent Document 1, the circuit is switched by a relay between when the battery power is supplied to the inverter and when the battery is charged by the charger. Therefore, in addition to the smoothing capacitor used for the inverter, it is necessary to provide the charger with a smoothing capacitor that suppresses inrush power, and there is a problem that the power conversion device is increased in size and weight.

  The present invention has been made paying attention to such problems, and an object of the present invention is to provide a vehicular power conversion device capable of downsizing the device.

According to an embodiment of the present invention, a vehicle power conversion device that converts electric power between a power storage device and a load, the power module converting DC power of the power storage device and AC power supplied to the load; A charging device that converts alternating current power supplied via an external connector into direct current power and outputs the direct current power to a power storage device, and a capacitor module that is connected to the power module and the charging device and smoothes the voltage during each operation; The capacitor module includes a first bus bar fixed directly to a terminal corresponding to the three phases of the U phase, V phase, and W phase of the power module, a second bus bar connected to the power storage device, and a charging device. A power wiring to be connected is derived, and the first bus bar, the second bus bar, and the power wiring branch from the internal bus bar of the capacitor module .

  According to the present invention, since the capacitor module is connected to the power module and the charging device and is configured to smooth the voltage at the time of each operation, the capacitor module is shared by the power module and the charging device. Thus, the power converter can be miniaturized and the weight can be reduced.

It is a functional block diagram of the power converter of the embodiment of the present invention. 1 is a configuration block diagram of a power conversion device according to an embodiment of the present invention. 1 is a configuration block diagram of a power conversion device according to an embodiment of the present invention. It is an electric circuit diagram of the power converter of the embodiment of the present invention.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a functional block diagram of a power conversion device 1 according to an embodiment of the present invention.

  The power conversion device 1 (vehicle power conversion device) is provided in an electric vehicle or a plug-in hybrid vehicle, and converts the electric power of the power storage device (battery) 5 into electric power suitable for driving the rotating electrical machine (motor generator) 6. The motor generator 6 is driven by the electric power supplied from the power conversion device 1 to drive the vehicle.

  The power converter 1 converts the regenerative power of the motor generator 6 into DC power and charges the battery 5. Further, the power conversion device 1 charges the battery 5 by being supplied with power from a quick charging connector or a normal charging connector provided in the vehicle.

  The battery 5 is composed of, for example, a lithium ion secondary battery. The battery 5 supplies direct-current power to the power conversion device 1 and is charged by the direct-current power supplied from the power conversion device 1. The voltage of the battery 5 fluctuates between 240V and 400V, for example, and the battery 5 is charged by inputting a voltage higher than that.

  The motor generator 6 is configured as a permanent magnet synchronous motor, for example. Motor generator 6 is driven by AC power supplied from power conversion device 1 to drive the vehicle. When the vehicle decelerates, the motor generator 6 generates regenerative power.

  The power conversion device 1 includes a capacitor module 10, a power module 20, a DC / DC converter 30, a charging device 40, a charging / DCDC controller 50, and an inverter controller 70 in a case 2. These parts are electrically connected by a bus bar or wiring.

  The capacitor module 10 includes a plurality of capacitor elements (see FIG. 4). The capacitor module 10 performs noise removal and voltage fluctuation suppression by smoothing the voltage. The capacitor module 10 includes a first bus bar 11, a second bus bar 12, and a power wiring 13.

  The first bus bar 11 is connected to the power module 20. The second bus bar 12 is connected to the DC / DC converter 30, the relay 61, the battery 5 and the electric compressor 9. The power wiring 13 is configured by a flexible cable (for example, a litz wire) and is connected to the charging device 40. The first bus bar 11, the second bus bar 12, and the power wiring 13 share the positive electrode and the negative electrode inside the capacitor module 10.

  The power module 20 mutually converts DC power and AC power by turning on / off a plurality of power elements (see FIG. 4). ON / OFF of the plurality of power elements is controlled by a driver board 21 provided in the power module 20.

  The power module 20 is connected to the first bus bar 11 of the capacitor module 10. The first bus bar 11 includes three sets of bus bars including a positive electrode and a negative electrode. The power module 20 includes a three-phase output bus bar 24 including a U phase, a V phase, and a W phase. The output bus bar 24 is connected to the current sensor 22. The current sensor 22 includes a motor-side bus bar 25 that outputs three-phase AC power to the motor generator 6 side.

  The inverter controller 70 sends a signal for operating the power module 20 to the driver board 21 based on an instruction from a vehicle controller (not shown) and detection results of U-phase, V-phase, and W-phase currents from the current sensor 22. Output to. The driver board 21 controls the power module 20 based on a signal from the inverter controller 70. The inverter controller 70, the driver board 21, the power module 20, and the capacitor module 10 constitute an inverter module that mutually converts DC power and AC power.

  The DC / DC converter 30 converts the voltage of the DC power supplied from the battery 5 and supplies it to other devices. The DC / DC converter 30 steps down the DC power (for example, 400V) of the battery 5 to 12V DC power. The stepped-down DC power is supplied as a power source for a controller, lighting, fan or the like provided in the vehicle. The DC / DC converter 30 is connected to the capacitor module 10 and the battery 5 via the second bus bar 12.

  The charging device 40 converts a commercial power source (for example, AC 200V) supplied from a charging external connector provided in the vehicle via a normal charging connector 81 into DC power (for example, 500V). The DC power converted by the charging device 40 is supplied from the power wiring 13 to the battery 5 via the capacitor module 10. Thereby, the battery 5 is charged.

  The charging / DCDC controller 50 controls driving of the motor generator 6 and charging of the battery 5 by the power conversion device 1. Specifically, the charging / DCDC controller 50 charges the battery 5 via the normal charging connector 81 by the charging device 40, charges the battery 5 via the quick charging connector 63, based on an instruction from the vehicle controller. The motor generator 6 is controlled and the step-down by the DC / DC converter 30 is controlled.

  The relay controller 60 controls the on / off state of the relay 61 under the control of the charging / DCDC controller 50. The relay 61 includes a positive relay 61a and a negative relay 61b. The relay 61 is energized when connected from an external connector via the quick charge connector 63, and supplies DC power (for example, 500 V) supplied from the quick charge connector 63 to the second bus bar 12. The battery 5 is charged with the supplied DC power.

  2 and 3 are configuration block diagrams of the power conversion device 1 of the present embodiment. FIG. 2 is a top view of the power conversion device 1, and FIG. 3 is a side view of the power conversion device 1.

  Inside the case 2, the power module 20, the DC / DC converter 30, and the charging device 40 are disposed around the capacitor module 10.

  More specifically, the capacitor module 10 is disposed between the power module 20 and the charging device 40 inside the case 2. The capacitor module 10 is stacked on the DC / DC converter 30, and the DC / DC converter 30 is disposed below the capacitor module 10. The charging device 40 is stacked on the charging / DCDC controller 50, and the charging device 40 is disposed below the charging / DCDC controller 50.

  The first bus bar 11 protrudes from one side surface of the capacitor module 10. The power module 20 is directly connected to the first bus bar 11 by screwing or the like. In the power module 20, a three-phase output bus bar 24 including a U phase, a V phase, and a W phase protrudes on the side opposite to the first bus bar 11.

  The current sensor 22 is directly connected to the output bus bar 24 by screwing or the like. A motor-side bus bar 25 protrudes below the current sensor 22 (see FIG. 3). The motor-side bus bar 25 is directly connected to each of the U-phase, V-phase, and W-phase of the output bus bar 24 of the power module 20 and outputs three-phase AC power. The motor side bus bar 25 is configured to be exposed from the case 2 and connected to the motor generator 6 by a harness or the like.

  A driver substrate 21 is laminated on the upper surface of the power module 20. Above the driver board 21, an inverter controller 70 and a relay controller 60 are stacked.

  The second bus bar 12 protrudes from the bottom surface side of the capacitor module 10. The second bus bar 12 is directly screwed to the DC / DC converter 30 disposed below the capacitor module 10 in a stacked manner. The second bus bar 12 is also connected to a positive relay 61a and a negative relay 61b (see FIG. 1).

  The second bus bar 12 is connected to the battery side connector 51 to which the battery 5 is connected and the compressor side connector 52 to which the electric compressor 9 is connected via the bus bar 14.

  The DC / DC converter 30 is connected to the vehicle-side connector 82 via the bus bar 31. The vehicle-side connector 82 is connected to a harness or the like that supplies DC power output from the DC / DC converter 30 to each part of the vehicle.

  On the opposite side of the capacitor module 10 from the first bus bar 11, a power wiring 13 protrudes. The power wiring 13 is a flexible cable having flexibility, and is connected to the charging device 40. The charging device 40 is connected to the normal charging connector 81 via the bus bar 41.

  The signal line connector 65 connects signal lines connected to the DC / DC converter 30, the charging device 40, the charging / DCDC controller 50, and the inverter controller 70 of the power conversion device 1 to the outside of the case 2.

  A signal line 55 is connected from the signal line connector 65 to the charging / DCDC controller 50. The signal line 55 is bundled with the signal line 62 from the charging / DCDC controller 50 to the relay controller 60, passes through the upper surface of the capacitor module 10, and is connected to the connector 56 of the charging / DCDC controller 50. A guide portion 58 that supports the signal line 55 and the signal line 62 is formed on the upper surface of the capacitor module 10.

  The case 2 is composed of an upper case 2a and a lower case 2b. A cooling water flow path 4 is formed in the lower case 2b. The cooling water flow path 4 is configured such that cooling water flows, and the power module 20, the DC / DC converter 30, and the charging device 40 placed immediately above the cooling water flow path 4 are cooled.

  As described above, the capacitor module 10 is connected to the power module 20, the DC / DC converter 30, and the charging device 40 via the first bus bar 11, the second bus bar 12, and the power wiring 13. With such a configuration, the distance between the capacitor module 10 and the power module 20, the DC / DC converter 30 and the charging device 40 can be shortened, so that the resistance (R) and inductance (L) in the DC power path are reduced. Power loss and electrical noise can be reduced.

  Furthermore, since the capacitor module 10 is disposed between the power module 20 and the charging device 40 that generate a large amount of heat, the power module 20 and the charging device 40 can be prevented from being affected by heat. In particular, the operation of the power module 20 (powering and regeneration of the motor generator 6) and the operation of the charging device 40 (charging of the battery 5 by the normal charging connector 81) are not performed at the same time. The influence of heat can be eliminated.

  Next, the configuration of the capacitor module 10 will be described.

  FIG. 4 is an electric circuit diagram centering on the capacitor module 10 of the present embodiment.

  The capacitor module 10 is configured by housing a plurality of capacitors 120 inside a capacitor case 110. The capacitor module 10 includes a pair of internal bus bars 130 composed of a positive electrode and a negative electrode, and a plurality of capacitors 120 are connected in parallel between the pair of internal bus bars 130. Capacitor 120 and internal bus bar 130 are molded of a resin material.

  The internal bus bar 130 branches to the first bus bar 11, the second bus bar 12, and the power wiring 13, respectively.

  The first bus bar 11 includes three sets of positive and negative bus bars corresponding to the three phases of the U, V, and W phases of the power module 20, and protrudes from the bottom surface of the capacitor case 110 to one side surface. .

  The second bus bar 12 includes a pair of positive and negative bus bars, and protrudes from the bottom surface of the capacitor case 110 to the second side surface adjacent to the one side surface. The power wiring 13 is made of a flexible cable having a positive electrode and a negative electrode, and extends to the bottom surface side of the capacitor case 110.

  The first bus bar 11 has a shape in contact with terminals corresponding to the three phases of the U phase, the V phase, and the W phase provided in the power module 20 located on one side of the capacitor module 10 in a state of being housed in the case 2. Has been. The first bus bar 11 is connected by screwing or the like while being in contact with the terminal of the power module 20.

  The second bus bar 12 has a shape in contact with a terminal included in the DC / DC converter 30 located on the bottom surface side of the capacitor module 10 in a state of being housed in the case 2. The second bus bar 12 is connected by screwing or the like in contact with the terminal of the DC / DC converter 30. The bus bar 14 is connected to a terminal of the DC / DC converter 30. The bus bar 14 is connected to the relay 61, the battery side connector 51, and the compressor side connector 52.

  The power wiring 13 is connected to a terminal included in the charging device 40 located on a side surface facing the one side surface of the capacitor module 10 in a state of being housed in the case 2. Since the power wiring 13 is flexible, it is connected to the terminal of the charging device 40 while avoiding the charging / DCDC controller 50 disposed above the charging device 40 and other components and structures provided in the case 2. Is done.

  With such a configuration, the power module 20 operates during power running and regeneration of the motor generator 6 (when the charging device 40 is not operating), and the capacitor module 10 smoothes the DC power of the power module 20 at this time. To do. The charging device 40 operates when the battery 5 is charged by the normal charging connector 81 where the power module 20 is not operating, and the capacitor module 10 smoothes the DC power of the charging device 40 at this time. Thus, the capacitor module 10 functions as a smoothing capacitor that smoothes the DC power between the power module 20 and the charging device 40.

  As described above, in the embodiment of the present invention, the power conversion device 1 converts and supplies power between the power storage device (battery 5) and the load (motor generator 6), A power module 20 that converts AC power supplied to the motor generator 6, a charging device 40 that charges the battery 5 with power supplied via an external connector (normal charging connector 81), the power module 20, and the charging device 40 And the power module 20 and the charging device 40 are configured to include a capacitor module that smoothes the voltage during each operation.

  With this configuration, the capacitor module 10 is provided on the power line between the power module 20 and the charging device 40. That is, since the capacitor module 10 is shared by the power module 20 and the charging device 40, it is not necessary to separately provide a capacitor, the size of the power conversion device 1 can be reduced, and the power conversion device Weight can be reduced.

  The power conversion device 1 according to the embodiment of the present invention includes a DC / DC converter 30 that converts a DC voltage of the battery 5. The DC / DC converter 30 is connected to the capacitor module 10, and the capacitor module 10 The module 20, the charging device 40, and the DC / DC converter 30 smooth the voltage during each operation.

  With this configuration, it is not necessary to provide a smoothing capacitor in the DC / DC converter 30, the size of the power converter 1 can be reduced, and the weight of the power converter can be reduced. .

  In the power conversion device 1 according to the embodiment of the present invention, the capacitor module 10 includes the first terminal (first bus bar 11), the second terminal (second bus bar 12), and the third terminal (power wiring 13). The first terminal is connected to the power module 20, the second terminal is connected to the DC / DC converter 30, and the third terminal is opposite to the side of the capacitor module 10 where the first terminal is provided. And is connected to the charging device 40. With such a configuration, the power path of the capacitor module 10, the power module 20, the DC / DC converter 30, and the charging device 40 can be shortened in the case 2, so that the resistance (R) and inductance (L ) Can be reduced, power loss and electrical noise can be reduced, and the power converter 1 can be downsized.

  In addition, the power conversion device 1 according to the embodiment of the present invention includes a compressor-side connector 52 connected to the electric compressor 9 different from the load (motor generator 6), and a fourth connector that connects the capacitor module 10 and the compressor-side connector 52. Since the terminal (bus bar 14) is provided, the fourth terminal noise connected to the electric compressor 9 that may generate noise can be smoothed by the capacitor module 10.

  The embodiment of the present invention has been described above, but the above embodiment is merely one example of application of the present invention, and the technical scope of the present invention is limited to the specific configuration of the above embodiment. is not.

  In the above embodiment, the capacitor module 10 and the charging device 40 are connected by a flexible cable (power wiring 13), but the present invention is not limited to this. The capacitor module 10 and the charging device 40 may be connected by a bus bar, or the capacitor module 10 and the power module 20 or the DC / DC converter 30 may be connected by a flexible cable. .

1 Power converter (Vehicle power converter)
2 Case 2a Upper case 2b Lower case 4 Cooling water flow path 5 Power storage device (battery)
6 Electric motor
DESCRIPTION OF SYMBOLS 9 Electric compressor 10 Capacitor module 11 1st bus bar 12 2nd bus bar 13 Electric power wiring 14 Bus bar 20 Power module 30 DC / DC converter 40 Charging device 50 Charging / DCDC controller 52 Compressor side connector 60 Relay controller 61 Relay 70 Inverter controller 81 Normal charging Connector 82 Vehicle side connector 110 Capacitor case 120 Capacitor 130 Internal bus bar

Claims (6)

A vehicle power conversion device that converts power between a power storage device and a load,
A power module that converts DC power of the power storage device and AC power supplied to the load;
A charging device for charging the power storage device by converting AC power supplied via an external connector into DC power;
A capacitor module that is connected to the power module and the charging device and smoothes a voltage during each operation;
Equipped with a,
The capacitor module includes a first bus bar directly fixed to terminals corresponding to three phases of the U phase, V phase, and W phase of the power module, a second bus bar connected to the power storage device, and the charging device. The power wiring to be connected is derived,
The vehicular power conversion device , wherein the first bus bar, the second bus bar, and the power wiring branch from an internal bus bar of the capacitor module .   The vehicle power conversion device according to claim 1,
  The capacitor module is disposed adjacent to the power module and the charging device.
A vehicular power conversion device. The vehicle power conversion device according to claim 1,
A DC / DC converter for converting a DC voltage supplied from the power storage device;
The DC / DC converter is connected to the capacitor module;
The vehicular power converter , wherein the capacitor module smoothes the voltage when the power module, the charging device, and the DC / DC converter are activated .   The vehicle power conversion device according to claim 3,
  A case for accommodating the power module, the DC / DC converter, the charging device, and the capacitor module;
  The power module, the DC / DC converter, the charging device, and the capacitor module are provided in the same space in the case.
A vehicular power conversion device.   The vehicle power conversion device according to claim 3 or 4,
  The power wiring is provided on the other side of the capacitor module facing the one side where the first bus bar and the second bus bar are provided, and is connected to the charging device.
A vehicular power conversion device.   The vehicle power conversion device according to claim 5,
  A vehicle power converter comprising: a connector connected to an electric compressor different from the load; and a third bus bar for connecting the capacitor module and the connector.

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