JP7242963B2 - POWER CONTROLLER AND CURRENT SENSING BOARD - Google Patents

Description

The present disclosure relates to a power control device and a current sensing board.

Japanese Patent No. 6570797 discloses a power control device (rotating machine control device) that controls power supplied from a power supply to a power supply target (motor). In this power control device, the control circuit controls the switching of the switching element based on the value of the output current detected by the shunt resistor, and converts the DC current on the power supply side into AC current.

In the device described in Japanese Patent No. 6570797, when a large current flows in the control circuit, the amount of heat generated by the shunt resistor increases and the resistance value changes greatly. be. In addition, although the switching element in the device generates more heat than other electronic elements, the shunt resistor is also mounted on the board on which the switching element is mounted, so the shunt resistor will not affect the heat generation of the switching element. There is also the problem that the detection accuracy of the current is lowered due to this.

The present disclosure has been made to solve the above problems, and an object thereof is to improve current detection accuracy in a power control device including current detection means and a current detection substrate used in the power control device. .

A power control device according to the present disclosure includes a wiring pattern that electrically connects a power supply and a power supply target, a switch substrate that has a plurality of switching elements connected to the wiring pattern, and a through hole that penetrates in the plate thickness direction. and a coil substrate on which a Rogowski coil pattern is formed around the through-hole; and a power supply side terminal member for electrically connecting the power supply and the wiring pattern of the switch substrate, A coil substrate is arranged at a predetermined distance from the switch substrate, and the power-supply-side terminal members are arranged in a state of being inserted through the through holes of the coil substrate.

A current detection board according to the present disclosure includes: a wiring pattern for electrically connecting a power source and a power supply target; a switch substrate having a plurality of switching elements connected to the wiring pattern; A current detection substrate used in a power control device, comprising a power supply side terminal member electrically connecting to the wiring pattern, the substrate having a through hole penetrating in a plate thickness direction, and a logo around the through hole. A pattern of a ski coil is formed, and is arranged with a predetermined space from the switch board and with the power-supply-side terminal member inserted through the through-hole.

According to the current control device and the current detection board according to the present disclosure, the current flowing between the power supply and the power supply target is detected using the Rogowski coil, and the current detects the Rogowski coil itself. Since the current does not flow, the amount of heat generated by the Rogowski coil does not increase due to the current. Therefore, for example, even when a large current flows between the power supply and the object to which power is supplied, the large current can be detected with high accuracy using the Rogowski coil. In addition, since the coil substrate on which the Rogowski coil pattern is formed is arranged with a predetermined spacing from the switch substrate having a plurality of switching elements, the Rogowski coil is less likely to be affected by the heat generated by the switching elements. . As described above, the current detection accuracy can be improved.

1 is a perspective view of a power control device according to a first embodiment; FIG. 1 is an exploded perspective view of a power control device according to a first embodiment; FIG. 4 is a plan view of the switch substrate according to the first embodiment; FIG. 3 is a plan view of a control board according to the first embodiment; FIG. 4 is an enlarged plan view showing an enlarged pattern of Rogowski coils formed on the control board according to the first embodiment; FIG. FIG. 6 is an enlarged cross-sectional view showing an enlarged cut surface along the line VI-VI of FIG. 5; 3 is a partial perspective view showing partial configurations of a switch board and a control board according to the first embodiment; FIG. 1 is a circuit diagram of a power control device according to a first embodiment; FIG. 9 is a block diagram showing the configuration of a detection processing unit shown in FIG. 8; FIG. It is a top view which shows the power supply side terminal member which concerns on 1st Embodiment, and the modification 1 of the 3rd terminal member. FIG. 11 is a side view of a power supply side terminal member and a third terminal member according to modification 1; It is a perspective view which shows the modification 2 of the power supply side terminal member which concerns on 1st Embodiment, and a 3rd terminal member. It is a perspective view which shows the power supply side terminal member which concerns on 1st Embodiment, and the modification 3 of the 3rd terminal member. FIG. 11 is a perspective view showing a configuration of a coil substrate and its surroundings included in a power control device according to a second embodiment; FIG. 10 is a side view for explaining a modification of the configuration of the coil substrate and its periphery according to the second embodiment;

A first embodiment of the present disclosure will be described below with reference to FIGS. 1 to 9. FIG. In the present embodiment, for convenience of explanation, the directions indicated by upper, left, and front arrows in each drawing are defined as upper, left, and front of the power control device, respectively.

In the present embodiment, as an example of a power control device according to the present disclosure, a power control device 1 that controls power supply between a battery 2 (power source) and a three-phase AC motor 4 (power supply target) mounted on a vehicle. will be explained. As shown in FIG. 1, the power control device 1 includes a case 10 formed in the shape of a rectangular box, and a control board 60 in which a switch board 50 and a current detection board are integrated and housed inside the case 10. have.

As shown in FIG. 2, the case 10 is composed of a box-shaped case body 12 and a lid 14 that closes the opening of the case body 12 . The case body 12 is a metal rectangular box-shaped member having an opening 13 that opens upward. The case body 12 includes a front wall portion 12A, a rear wall portion 12B, a left wall portion 12C, a right wall portion 12D and a bottom wall portion 12E. A heat sink 12F is provided on the lower surface of the bottom wall portion 12E to dissipate the heat of the switch substrate 50, which will be described later, to the outside of the case main body 12. As shown in FIG.

One connector mounting portion 16 is formed on the front wall portion 12A of the case body 12 . The connector mounting portion 16 is formed by a notch formed in a rectangular concave shape from the side of the opening 13 of the case body 12 . A power connector 18 is attached to the connector attachment portion 16 . The power-side connector 18 has a housing 18A mounted on the connector mounting portion 16 and two terminal members 20P and 20N projecting rearward from the rear surface of the housing 18A. When the power-side connector 18 is attached to the connector attachment portion 16, the two terminal members 20P and 20N protrude inside the case 10. As shown in FIG. The two terminal members 20P and 20N constitute the first terminal member 20 and are electrically connected to the positive and negative electrodes of the battery 2 (see FIG. 8), respectively. Hereinafter, the terminal member 20P on the positive electrode side will be referred to as a first terminal member 20P, and the terminal member 20N on the negative electrode side will be referred to as a first terminal member 20N. These first terminal members 20P and 20N are plate-shaped members arranged with the left-right direction as the plate thickness direction, and extend along the front-rear direction.

A cylindrical capacitor 3 is connected to two first terminal members 20P and 20N on the rear surface (side surface facing the inside of the case) of the housing 18A of the power connector 18. As shown in FIG. A capacitor 3 is connected in parallel with the battery 2 .

Three connector mounting portions 22 are provided on the rear wall portion 12B of the case main body 12 at predetermined intervals in the left-right direction. Similar to the connector mounting portion 16 described above, these connector mounting portions 22 are configured by notches formed in rectangular concave shapes from the side of the opening 13 of the case body 12 . A motor-side connector 24 is attached to each of these connector attachment portions 22 . Each of the three motor-side connectors 24 corresponds to each phase (U-phase, V-phase, W-phase) of the three-phase AC motor 4 (see FIG. 8). It has one terminal member 26 projecting forwardly from the front face of the housing. When each motor-side connector 24 is attached to the connector attachment portion 22 , the terminal member 26 protrudes inside the case 10 . The terminal member 26 electrically connects each phase coil of the stator of the three-phase AC motor 4 to a wiring pattern 52 of a switch board 50, which will be described later. The terminal member 26 is hereinafter referred to as a second terminal member 26 . The second terminal member 26 is a plate-like member arranged with the left-right direction as the plate thickness direction, and extends along the front-rear direction.

One connector mounting portion 28 is provided on the left wall portion 12</b>C of the case main body 12 . As with the connector mounting portion 16 described above, the connector mounting portion 28 is formed by a notch formed in a rectangular concave shape from the side of the opening 13 of the case body 12 . A sensor-side connector 30 is attached to the connector attachment portion 28 . The sensor-side connector 30 has a housing mounted on the connector mounting portion 28 and a plurality of connection terminals (not shown) provided on the housing. When the sensor-side connector 30 is attached to the connector attachment portion 28 , one end sides of the plurality of connection terminals protrude from the housing, extend inside the case 10 , and are connected to the control board 60 . Harnesses (cables) connected to electric devices such as various sensors mounted on the vehicle are connected to the sensor-side connector 30 via a connector (not shown).

The opening 13 of the case body 12 is closed from above by a lid 14 . The lid 14 is a rectangular plate-like member made of metal. The lid body 14 is fixed to the case body 12 with an adhesive applied to the upper ends of the front, rear, left, and right walls 12A to 12D of the case body 12. As shown in FIG. A housing space is formed inside the case 10 by fixing the lid 14 to the case body 12 .

Three capacitor modules 40 are arranged along the front wall portion 12A of the case body 12 in the front portion of the accommodation space in the case 10 . Each capacitor module 40 corresponds to each phase of the three-phase AC motor 4 and includes a holding member 44 holding two capacitors 3 and two third terminal members 46 provided on the holding member 44. there is The holding member 44 is a block-shaped member made of an insulating material. Two capacitors 3 are held side by side on the lower surface side of the holding member 44 . The two third terminal members 46 are plate-shaped terminal members extending in the front-rear direction with the left-right direction as the plate thickness direction. These third terminal members 46 are held by the holding member 44 while being connected to the two capacitors 3 and arranged in parallel.

Power supplied from the battery 2 is supplied to each phase of the three-phase AC motor 4 in the accommodation space between the power supply side connector 18 attached to the case body 12 and the three capacitor modules 40 arranged in the case 10 . A busbar module (not shown) is arranged to distribute the In each capacitor module 40, one end of the third terminal member 46 on one side is electrically connected to the first terminal member 20P on the positive electrode side of the power supply connector 18 via the bus bar module. One end of the third terminal member 46 on the other side is electrically connected to the first terminal member 20N on the negative electrode side of the power supply connector 18 via the busbar module. The other ends of the two third terminal members 46 are electrically connected to the wiring patterns 52 of the switch board 50 corresponding to each phase of the three-phase AC motor 4 respectively. Hereinafter, the terminal member 46 on the positive electrode side will be referred to as a third terminal member 46P, and the terminal member 46 on the negative electrode side will be referred to as a third terminal member 46N.

In each capacitor module 40 , the two capacitors 3 are connected to positive and negative third terminal members 46 P and 46 N and connected in parallel to the battery 2 . Thus, in the power control device 1 , a plurality of (seven) capacitors 3 held by the power supply side connector 18 and the three holding members 44 are connected in parallel to the battery 2 . Each capacitor 3 is an element for reducing noise generated in an inverter circuit 5 (see FIG. 8), which will be described later.

As shown in FIGS. 2 and 3, three switch boards 50 corresponding to each phase of the three-phase AC motor 4 are arranged behind the three capacitor modules 40 in the housing space within the case 10. . Each switch substrate 50 is formed in a rectangular plate shape in plan view with the vertical direction as the plate thickness direction. Consists of an insulating substrate. Each switch substrate 50 is placed on the bottom wall portion 12E of the case body 12, and the heat of each switch substrate 50 is transmitted to the heat sink 12F via the bottom wall portion 12E.

A wiring pattern 52 (only part of which is shown) is provided on the mounting surface 50A, which is the upper surface of the switch substrate 50 . The wiring pattern 52 is a wiring pattern that electrically connects the battery 2 and the three-phase AC motor 4 . A plurality of switching elements 54 and a plurality of terminal members 56 and 58 are connected to the wiring pattern 52 . The wiring pattern 52, the switching element 54, and the like constitute a part of the inverter circuit 5 (see FIG. 8) that converts the DC current on the battery 2 side into AC current. Specifically, six switching elements 54 are mounted on the mounting surface 50A of each switch substrate 50 . These six switching elements 54 are composed of, for example, nMOSFETs (n-type MOS field effect transistors), and perform switching of power supplied to one of the phases of the three-phase AC motor 4 . In FIG. 3, as an example, a switch board 50U corresponding to the U phase of the three-phase AC motor 4 is shown in plan view.

On the mounting surface 50A of the switch substrate 50U, the three switching elements 54UH1, 54UH2, and 54UH3 mounted on the right side are electrically connected to the positive side of the battery 2 on the side with the higher U-phase voltage level. It constitutes a switching element 54UH. These three switching elements 54UH 1 , 54UH 2 and 54UH 3 are connected in parallel with each other, and each drain is electrically connected to the positive electrode side of the battery 2 . On the other hand, on the mounting surface 50A of the switch board 50U, the three switching elements 54UL1, 54UL2, and 54UL3 mounted on the left side are electrically connected to the lower U-phase voltage level side (negative side of the battery 2). ) constitutes a switching element 54UL. These three switching elements 54UL1, 54UL2, 54UL3 are connected in parallel with each other, and each source is electrically connected to the negative electrode side of the battery 2. A thermistor 55 is mounted near the switching element 54 on the mounting surface 50A of the switch substrate 50U. The thermistor 55 is a temperature sensor that senses the temperature associated with the heat generated by the inverter circuit 5 .

On the mounting surface 50A of the switch substrate 50U, two power supply side terminal members 56 are provided on both left and right sides at positions closer to the front end portion 50B than the switching elements 54UH and 54UL. Each power-supply-side terminal member 56 is an elongated plate-like member whose plate thickness direction is substantially in the left-right direction, and extends upward from the mounting surface 50A. A curved portion 56A (not shown in FIG. 2) curved in a U-shape is provided at the lower portion of each power supply side terminal member 56. As shown in FIG. The lower surface of the curved portion 56A is connected to the wiring pattern 52 by being placed on the mounting surface 50A and soldered. Each power supply side terminal member 56 linearly extends upward from the upper end of the curved portion 56A. When the switch board 50U is arranged in the case 10, the rear end sides of the two third terminal members 46P and 46N of the capacitor module 40 arranged in the case 10 and the upper end sides of the two power supply side terminal members 56 are connected. are arranged side by side in the horizontal direction. The upper end sides of these power supply side terminal members 56 and the rear end sides of the third terminal members 46P and 46N are joined by resistance welding or the like. Thereby, the battery 2 and the wiring pattern 52 are electrically connected via the two third terminal members 46P and 46N and the two power supply side terminal members 56. FIG. Hereinafter, the power supply side terminal member 56 on the positive side will be referred to as a power supply side terminal member 56P, and the power supply side terminal member 56 on the negative side will be referred to as a power supply side terminal member 56N.

One motor-side terminal member 58 is provided at a position closer to the rear end portion 50C than the switching elements 54UH and 54UL on the mounting surface 50A of the switch substrate 50U. The basic structure of the motor-side terminal member 58 is similar to that of the power-side terminal member 56 . The motor-side terminal member 58 is connected to the wiring pattern 52 by soldering the lower surface of the curved portion 58A of the motor-side terminal member 58 to the mounting surface 50A. The motor-side terminal member 58 linearly extends upward from the upper end of the curved portion 58A. When the switch board 50U is arranged in the case 10, the end side of the second terminal member 26 of the motor-side connector 24 attached to the case 10 and the upper end side of the motor-side terminal member 58 are aligned in the left-right direction. It is arranged in The upper end side of the motor-side terminal member 58 and the end portion side of the second terminal member 24 are joined by resistance welding or the like. Thereby, the three-phase AC motor 4 and the wiring pattern 52 are electrically connected via the second terminal member 24 and the motor-side terminal member 58 .

So far, the switch board 50U corresponding to the U-phase of the three-phase AC motor 4 has been described, but the switch boards 50V and 50W corresponding to the V-phase and W-phase are basically configured similarly. The six switching elements 54 mounted on the switch board 50V corresponding to the V phase are three switching elements 54VH (electrically connected to the positive electrode side of the battery 2) on the side with the higher voltage level of the V phase, and V It is composed of three switching elements 54VL (electrically connected to the negative electrode side of the battery 2) on the side where the voltage level of the phase is low. The power supply side terminal member 56 of the switch board 50V has a power supply side terminal member 56P joined to the positive side third terminal member 46P and a power supply side terminal member 56N joined to the negative side third terminal member 46N. is configured as The motor-side terminal member 58 of the switch board 50V is joined to the second terminal member 26 of the motor-side connector 24 corresponding to the V-phase.

In the switch board 50W corresponding to the W phase of the three-phase AC motor 4, the six switching elements 54 in the switch board 50W are on the side of the W phase with the higher voltage level (electrically connected to the positive electrode side of the battery 2). It is composed of three switching elements 54WH and three switching elements 54WL on the side where the W-phase voltage level is low (electrically connected to the negative electrode side of the battery 2). The power supply side terminal member 56 of the switch substrate 50W has a power supply side terminal member 56P joined to the positive third terminal member 46P and a power supply side terminal member 56N joined to the negative third terminal member 46N. is configured as The motor-side terminal member 58 of the switch board 50W is joined to the second terminal member 26 of the motor-side connector 24 corresponding to the W phase.

As shown in FIGS. 1 and 2, the control board 60 is arranged above the three switch boards 50 at a predetermined distance from the switch boards 50 in the housing space in the case 10. . The control board 60 is a rectangular printed wiring board having predetermined widths in the front-rear direction and the left-right direction, and having a thickness direction in the vertical direction. The dimension of the control board 60 in the front-rear direction substantially matches the dimension of the switch board 50 in the front-rear direction. The horizontal dimension of the control board 60 is large enough to cover the three switch boards 50 arranged on the lower side. to some extent.

As shown in FIG. 4, six first through holes 62 are formed side by side in the left-right direction on the mounting surface 60C, which is the upper surface of the control board 60, at a position near the front end portion 60A of the control board 60. . These first through-holes 62 pass through the control board 60 in the plate thickness direction, and are formed in an oval shape whose longitudinal direction is the front-rear direction in a plan view. In addition, on the mounting surface 60C of the control board 60, three second through holes 63 are formed side by side in the left-right direction at positions near the rear end portion 60B of the control board 60. As shown in FIG. Like the first through holes 62, these second through holes 63 pass through the control board 60 in the plate thickness direction, and are formed in an oval shape whose longitudinal direction is the front-rear direction in a plan view.

As shown in FIGS. 4 and 7, a Rogowski coil pattern 70 forming part of the current detection sensor is formed around each of the six first through holes 62 in the control board 60 . The Rogowski coil pattern 70 is formed on the control board 60 as a wiring pattern and formed integrally with the control board 60 . These patterns 70 are hereinafter referred to as Rogowski coils 70 . When the control board 60 is arranged above the three switch boards 50 in the housing space in the case 10 , the power supply of the switch boards 50 is connected to the first through holes 62 around which the Rogowski coils 70 are formed. The side terminal member 56 is inserted through the edge of the first through hole 62 in a non-contact state. On the upper side of the control board 60 , the upper end side of the power supply side terminal member 56 that extends to the upper side of the control board 60 through the first through holes 62 is the first terminal member of the capacitor module 40 that extends parallel to the control board 60 . It is adapted to be joined to a three-terminal member 46 . As a result, the Rogowski coil 70 is used to sense the current flowing through the power supply side terminal member 56 . The six power supply side terminal members 56 inserted through the six first through holes 62 are arranged parallel to each other, and the inclination and distance of the Rogowski coil 70 with respect to each power supply side terminal member 56 are set to be the same. there is

When the control board 60 is arranged above the three switch boards 50 in the accommodation space in the case 10, the switch boards are inserted into the second through holes 63 formed on the rear end portion 60B side of the control board 60. A motor-side terminal member 58 of 50 is inserted through the edge of the second through hole 63 in a non-contact state. On the upper side of the control board 60 , the upper end side of the motor-side terminal member 58 extending to the upper side of the control board 60 through the second through hole 63 is connected to the motor-side connector 24 extending parallel to the control board 60 . It is adapted to be joined to the second terminal member 26 .

Next, the Rogowski coil 70 formed on the control board 60 will be described with reference to FIGS. 5 and 6. FIG. The Rogowski coil 70 is formed on the control board 60 , is spaced apart from the first through hole 62 , and is arranged in an annular region surrounding the first through hole 62 . One end of the Rogowski coil 70 is connected to the electrode connecting piece 75, and from there, along the circumference of the first through hole 62, the spiral shape (the shape of a spiral that turns clockwise in the traveling direction). A coil having a diameter equal to the thickness of the control board 60 is formed in the . The other end of the Rogowski coil 70 is connected to the return line 71 at a position that has been completed around the circumference of the first through hole 62 .

In the Rogowski coil 70, a plurality of conductor films 72 and 73 respectively formed on both surfaces of the control substrate 60 are connected through a plurality of vias 74 formed penetrating the control substrate 60 in the plate thickness direction. (see lower right diagram in FIG. 5). Thus, since the Rogowski coil 70 is an air core coil, the impedance is small and the power loss due to current measurement is small. Further, the Rogowski coil 70 does not saturate the magnetic flux and can be used for measurement of a large current.

The return line 71 has one end connected to the Rogowski coil 70 and is formed to surround the Rogowski coil 70 when viewed from the axial direction of the first through hole 62 . The other end of the return line 71 is connected to an electrode connection piece 76 arranged side by side with the electrode connection piece 75 . Therefore, the Rogowski coil 70 extends from the electrode connecting piece 75 to surround the first through hole 62, and the return line 71 is turned around from the electrode connecting piece 75 so as to extend the outside position of the Rogowski coil 70 in the opposite direction. At a position past the outer position of the electrode connecting piece 75 after making a full circle, it enters the inner position of the Rogowski coil 70 and is connected to the electrode connecting piece 76 . When a current flows through the conductor to be measured of the Rogowski coil 70 (the power supply side terminal member 56 in this embodiment), an induced electromotive force is generated in the electrode connection pieces 75 and 76 at both ends of the coil. This induced electromotive force is output as a signal output from the Rogowski coil 70 to the detection processing section 7, which will be described later. Based on the signal output from the Rogowski coil 70 , the detection processing unit 7 calculates the current value flowing through the power supply side terminal member 56 .

Due to the characteristics of the Rogowski coil 70, an induced current corresponding to the magnetic flux passing through the area surrounded by the Rogowski coil 70 is generated. , the current flowing through the power-supply-side terminal member 56 inserted into the first through-hole 62 can be accurately detected.

Further, since the current to be detected does not flow through the Rogowski coil 70 itself, the amount of heat generated by the Rogowski coil 70 does not increase due to energization. Suppression of the heat generation of the Rogowski coil 70 contributes to improvement in accuracy of current detection by the Rogowski coil 70 and the detection processing unit 7 (see FIG. 8) described later.

Furthermore, due to the characteristics of the Rogowski coil 70, the inclination of the Rogowski coil 70 with respect to the conductor is used to correct (calibrate) the error between the current value actually flowing through the conductor and the calculated value calculated by the calculation. values will be different. Therefore, in the stage after product assembly, initial value correction is performed to correct the error due to the inclination of the Rogowski coil 70 mounted in each power control device 1 . For this initial value correction, for example, an inspection board having a diagnostic function is connected to the control board 60, a correction value stored in advance in a memory mounted on the control board 60 is initialized, and calculation is performed based on the inspection current. This is done by newly storing the corrected correction value. For this reason, when a plurality of Rogowski coils 70 are mounted in the power control device 1 , if a structure is adopted in which the inclination of each Rogowski coil 70 varies, each single Rogowski coil 70 has the above-described initial Value correction is required. In addition, each single Rogowski coil 70 requires a connection terminal for connecting a substrate for inspection and a circuit for diagnosis.

However, according to this embodiment, a plurality of Rogowski coils 70 are formed on one control board 60 by wiring patterns. Therefore, since the inclination of each Rogowski coil 70 does not vary, initial value correction can be performed by using a common correction value for a plurality of Rogowski coils 70 . Therefore, the number of man-hours associated with initial value correction is reduced.

Furthermore, due to the characteristics of the Rogowski coil 70 described above, it is desirable to provide means for suppressing tilt displacement of the control board 60 caused by external environment such as vibration after the power control device 1 is assembled. In this embodiment, the inside of the case 10 is filled with a potting resin after assembly. As a result, the internal parts such as the control board 60 can be held at the position at the time of assembly, and the control board 60 can be prevented from being unintentionally displaced due to vibrations during running of the vehicle.

On the mounting surface 60C of the control board 60, circuits constituting the control section 6 and the detection processing section 7 shown in FIG. 8 are mounted. The control unit 6 has a CPU (Central Processing Unit) 64 (see FIG. 4) and controls the ON state and OFF state of the plurality of switching elements 54 . Various electronic components mounted on the control board 60 and various electronic components mounted on the switch board 50 are electrically connected by a plurality of vertically extending connection pins 66, as partially shown in FIG. . Also, the control board 60 is supported by these connection pins 66 with a predetermined gap with respect to the three switch boards 50 . In drawings other than FIG. 7, illustration of the connection pin 66 is omitted.

As shown in FIG. 4, the mounting surface 60C of the control board 60 is formed with a plurality of third through holes 68 penetrating through the control board 60 in the plate thickness direction at positions near the left end of the control board 60. there is Tip ends of a plurality of connection terminals of the sensor-side connector 30 are inserted through the third through holes 68 from below and soldered. The sensor-side connector 30 is thereby connected to the control board 60 . Signals detected by various sensors such as a vehicle speed sensor mounted on the vehicle are output to the control board 60 via the sensor-side connector 30, and output to the CPU 64 via the wiring pattern formed on the control board 60.

In this embodiment, the Rogowski coil 70 and the detection processing unit 7 (see FIG. 8) constitute a current detection sensor. The control unit 6 calculates a current value based on the signal input from the detection processing unit 7, switches the plurality of switching elements 54 between the ON state and the OFF state, and supplies power to each phase of the three-phase AC motor 4. is controlling These functions will be described below with reference to the block diagrams of FIGS. 8 and 9. FIG.

As shown in FIG. 8 , the power control device 1 includes inverter circuits 5 mounted on three switch substrates 50 . The inverter circuit 5 converts the DC current on the battery 2 side into AC current and supplies the AC current to each phase of the three-phase AC motor 4 . Drains of the switching elements 54UH, 54VH, 54WH on the side (High side) having a higher voltage level corresponding to the U-phase, V-phase, and W-phase are connected to the positive electrode side of the battery 2 . The sources of the switching elements 54UL, 54VL, and 54WL on the low side (Low side) of the voltage level corresponding to each phase are connected to the negative electrode side of the battery 2 . Gates of all the switching elements 54 are connected to signal lines for control signals output from the control section 6 .

The six Rogowski coils 70 are three Rogowski coils 70U1, 70V1, and 70W1 for measuring currents respectively flowing between the positive electrode of the battery 2 and the High-side switching elements 54UH, 54VH, and 54WH of the inverter circuit 5, and the battery. 2 and three Rogowski coils 70U2, 70V2, and 70W2 for measuring the currents flowing between the negative electrodes of the inverter circuit 5 and the low-side switching elements 54UL, 54VL, and 54WL of the inverter circuit 5, respectively. These six Rogowski coils 70 measure the current values at the moment when the switching elements 54 corresponding to the respective phases of the three-phase AC motor 4 are switched between the ON state and the OFF state. An output signal (induced electromotive force) output from each Rogowski coil 70 is input to the detection processing unit 7 mounted on the control board 60 .

As shown in FIG. 9, the detection processing unit 7 includes six integrating circuits 80 (A to F) corresponding to the six Rogowski coils 70 and three adders corresponding to the phases of the three-phase AC motor 4. 82 (U to W). In the detection processing unit 7, the output signals of the six Rogowski coils 70 are respectively input to the six integrating circuits 80 (A to F). Each integration circuit 80 is composed of, for example, an operational amplifier, a resistor and a capacitor. The integrating circuit 80 integrates the output signal from the Rogowski coil 70 and outputs a signal corresponding to a voltage waveform proportional to the measured current at each point.

The adder 82 includes an adder 82U corresponding to the U phase of the three-phase AC motor 4, an adder 82V corresponding to the V phase, and an adder 82W corresponding to the W phase. The adder 82U adds the voltage waveforms obtained by integrating the output signals of the two Rogowski coils 70U1 and 70U2 corresponding to the U phase. As a result, the detection value on the negative electrode side of the battery 2 is added to the detection value on the positive electrode side of the battery 2, and an output signal UC proportional to the DC current output from the battery 2 to the U phase can be obtained. Similarly, the adder 82V can obtain an output signal UV proportional to the DC current output from the battery 2 to the V phase. Further, the adder 82W can obtain an output signal UW proportional to the DC current output from the battery 2 to the W phase. Signals output from the adders 82U, 82V, and 82W are input to the control unit 6 and processed by the control unit 6 to obtain the output current output from the battery 2 to each phase of the three-phase AC motor 4. Obtainable.

(Action and effect)
Next, the operation and effects of this embodiment will be described.

According to the power control device 1 according to the present embodiment, the current flowing between the battery 2 and the three-phase AC motor 4 is detected using the Rogowski coil 70, and the current is detected by the Rogowski coil 70. Since the current does not flow through itself, the amount of heat generated by the Rogowski coil 70 does not increase due to energization. Therefore, even if a large current flows between the battery 2 and the three-phase AC motor 4, for example, the Rogowski coil 70 can be used to detect the large current with high accuracy. In addition, since the control board 60 on which the pattern of the Rogowski coil 70 is formed is arranged at a predetermined interval with respect to the switch board 50 having the plurality of switching elements 54, the influence of heat generated by the switching elements 54 can be minimized. The ski coil 70 is hard to receive. As described above, the current detection accuracy can be improved.

In addition, since the Rogowski coil 70 is formed on the control board 60 and the coil board on which the Rogowski coil 70 is formed and the control board 60 are integrated, the control board 60 and the coil board are separated. The number of parts constituting the power control device 1 can be reduced compared to the case of configuring as .

Further, according to this embodiment, the current flowing through the six power supply side terminal members 56 connected to the three switch boards 50U, 50V, and 50W corresponding to each phase of the three-phase AC motor 4 is controlled by one board. Detection is performed using six Rogowski coils 70 formed on the substrate 60 . In this way, since a plurality of Rogowski coils 70 are formed on one control board 60 (coil board), if the angle of each power supply side terminal member 56 with respect to the switch board 50 is the same angle (each power supply side If the terminal members 56 are parallel), the inclinations (distances) of the respective Rogowski coils 70 with respect to the respective power supply side terminal members 56 are aligned. Therefore, it is not necessary to perform the initial value correction (initialization) of the current detection for all the Rogowski coils 70. The initial value correction is performed for one Rogowski coil 70, and the corrected value is applied to the other Rogowski coils. 70, it is possible to reduce the man-hours for the initial value correction.

In addition, the power supply side terminal member 560 and the third terminal member 460 as Modified Example 1 shown in FIGS. 10 and 11 can also be used in the first embodiment. In addition, about the same component as 1st Embodiment mentioned above, the same number is attached and the description is abbreviate|omitted.

The power supply side terminal member 560 according to Modification 1 is characterized in that a joint portion 100 having a comb tooth shape in plan view (vertical view) is provided on the side surface of the upper end portion. The power-side terminal member 560 linearly extends upward from the upper end of the U-shaped curved portion 560</b>A and is inserted through the first through hole 62 of the control board 60 . The power-side terminal member 560 has a comb-shaped joint portion 100 provided on the side surface of the upper end portion that extends above the control board 60 through the first through hole 62 . In this modified example 1, the first through hole 62 formed in the control board 60 extends to the front end portion 60A of the control board 60 and also opens forward in order to insert the power supply side terminal member 560 into the first through hole 62. It has a slit shape. Note that when the first through-hole 62 is not the slit-shaped first through-hole 62 but the oval-shaped first through-hole 62 as in the first embodiment, the joint portion 100 is formed from the upper end portion of the power supply side terminal member 560. It may be formed so as to extend upward, and after the power supply side terminal member 560 is inserted into the first through hole 62 , the joint portion 100 may be formed by bending the power supply side terminal member 560 .

The third terminal member 460 according to Modification 1 is characterized in that a comb tooth-shaped joined portion 110 is provided at one end that is joined to the power supply side terminal member 560 . The third terminal member 460 extends in the front-rear direction with the vertical direction as the plate thickness direction. In addition, on the side surface of the distal end portion of the third terminal member 460, the joined portion 110 having a comb-teeth shape in plan view (vertical view) is provided. The joint portion 100 of the power-side terminal member 560 and the joint portion 110 of the third terminal member 460 are joined by soldering or the like in a state in which the comb teeth are meshed with each other without gaps. This engagement secures a contact area between the power supply side terminal member 560 and the third terminal member 460 .

According to the configuration of Modified Example 1, by engaging the comb-shaped joining portion 100 and the joined portion 110, the joining portion between the power supply side terminal member 560 and the third terminal member 460 can be miniaturized and the contact area can be reduced. It can be increased to ensure conductivity. For example, as shown by a chain double-dashed line in FIG. 11, the vertical dimension of the power supply side terminal member 560 is shortened compared to the configuration in which the side surfaces of the power supply side terminal member and the third terminal member are brought into contact with each other and joined. Therefore, the power control device 1 can be downsized in the vertical direction.

Moreover, from the same viewpoint as in Modification 1, the first embodiment can also use the power supply side terminal member 562 and the third terminal member 462 as Modification 2 shown in FIG. In addition, about the same component as the modification 1 mentioned above, the same number is attached and the description is abbreviate|omitted.

The power supply side terminal member 562 according to Modification 2 is characterized in that a joint portion 100 having a comb tooth shape in a front view (front-rear direction view) is formed at the upper end portion. The power supply side terminal member 562 extends upward with the front-rear direction as the plate thickness direction. The third terminal member 462 according to Modification 2 is characterized in that a comb tooth-shaped joined portion 110 is provided at one end that is joined to the power supply side terminal member 562 . The third terminal member 462 extends in the front-rear direction with the vertical direction as the plate thickness direction. In addition, the tip of the third terminal member 462 is provided with a joined portion 110 having a comb-tooth shape in plan view (up-down direction view). The joint portion 100 of the power-side terminal member 562 and the joint portion 110 of the third terminal member 462 are joined by soldering or the like in a state in which comb teeth arranged in orthogonal postures are engaged with each other without gaps. Even when this configuration is applied, it is possible to reduce the size of the joint portion between the power supply side terminal member 562 and the third terminal member 462 and increase the contact area to ensure the conductivity rate. contribute to

Moreover, the power supply side terminal member 564 and the third terminal member 464 as the modification 3 shown in FIG. 13 can also be used in the first embodiment. In addition, about the same component as the modification 1 mentioned above, the same number is attached and the description is abbreviate|omitted.

The power-side terminal member 564 linearly extends upward from the upper end of a U-shaped curved portion (not shown). The power-side terminal member 564 extends vertically with the front-rear direction as the plate thickness direction. The power-side terminal member 564 has a joint portion 105 formed by bending the upper end portion side of the power-side terminal member 564 forward at a substantially right angle. The third terminal member 464 extends in the front-rear direction with the vertical direction as the plate thickness direction. Also, the third terminal member 464 is integrally formed with a joint piece 120 having a width narrower than that of the power supply side terminal member 564 at the tip. The joint piece 120 is overlaid on the joint portion 105 of the power-supply terminal member 564 from above, and is soldered while being in contact with the upper surface of the joint portion 105 . Even when this configuration is applied, the vertical dimension of the power supply side terminal member 564 can be shortened, so that the power control device 1 can be miniaturized in the vertical direction. In addition, since the connecting portion between the power supply side terminal member 564 and the third terminal member 464 can be formed in a simple shape, production is easy.

Next, a power control device 200 according to a second embodiment will be described with reference to FIG. In addition, about the same component as 1st Embodiment mentioned above, the same number is attached and the description is abbreviate|omitted. The second embodiment differs from the power control device 1 of the first embodiment in that the control board 600 and the coil board 610 on which the Rogowski coil 70 is formed are configured separately. This coil substrate 610 corresponds to the current detection substrate in the present invention. Other configurations are the same as those of the first embodiment.

In the present embodiment, the control board 60 described in the first embodiment consists of a control board 600 on which circuits constituting the control section 6 and the detection processing section 7 are mounted, and a coil board on which a plurality of Rogowski coils 70 are formed. 610. Since the plurality of Rogowski coils 70 are not formed on the front end portion 600A side of the mounting surface 600C of the control board 600, various circuits can be mounted on the front end portion 600A side of the mounting surface 600C. It is formed slightly smaller than the control board 60 described above.

Coil substrate 610 is a long printed wiring board extending in the left-right direction. The coil substrate 610 is provided at a position on the front end portion 600A side of the surface of the control substrate 600 opposite to the mounting surface 600C (the surface facing the switch substrate 50), and is arranged between the switch substrate 50 and the control substrate 600. ing. The coil board 610 has a plate thickness direction in the front-rear direction, and is arranged in an upright posture with respect to the control board 600 . Six first through holes 62 are formed in the coil substrate 610 along the left-right direction. A Rogowski coil 70 is formed around each of the six first through holes 62 .

Connection pins 620 are connected to the electrode connection pieces 75 and 76 connected to both ends of each Rogowski coil 70 . These connection pins 620 extend from the upper end of the coil board 610 toward the control board 600 and are connected to wiring patterns formed on the mounting surface 600C of the control board 600 . Thereby, a signal (induced electromotive force) output from each Rogowski coil 70 is output to the detection processing section 7 formed on the control board 600 . Also, the coil board 610 is attached to the control board 600 via these connection pins 620 .

The third terminal member 46 projecting from the holding member 44 of the capacitor module 40 is inserted through the first through hole 62 of the coil substrate 610 without contacting the edge of the first through hole 62 . Thus, in this embodiment, the third terminal member 46 constitutes the "power source side terminal member" of the invention. Further, the tip side of the third terminal member 46 is joined to the tip side of the power supply side terminal member 56 between the switch board 50 and the control board 600 .

(Action and effect)
As described above, the power control device 200 according to the present embodiment includes the coil substrate 610 that is separate from the switch substrate 50 and the control substrate 600 . placed in between. Therefore, compared to a configuration in which the coil board is integrally formed with the control board, the mounting area of the control board 600 can be expanded and the control board 600 can be miniaturized.

[supplementary explanation]
In each of the above-described embodiments and modifications, the power supply in the present invention is the battery 2, and the power supply target in the present invention is the three-phase AC motor 4, but the present invention is not limited to this. The power supply and power supply target can be set as appropriate. For example, the power source may be a power generator or a power source that can be taken from an outlet. In addition, a single-phase AC motor, a three-phase or higher AC motor such as a four-phase AC motor, a five-phase AC motor, or various electric devices can be appropriately adopted as the power supply object.

In each of the above-described embodiments and modifications, the case where power is supplied from the battery 2 to the three-phase AC motor 4 has been described. can also be used for

In each of the above-described embodiments and modifications, the six Rogowski coils 70 corresponding to the positive terminal member 56P and the negative terminal member 56N of the power supply terminal member 56 are formed on one substrate. It is not limited to this. The six Rogowski coils 70 may be divided and formed on a plurality of substrates. For example, a first coil substrate on which three Rogowski coils 70 corresponding to the positive terminal member 56P of the power supply side terminal member 56 are formed, and three Rogowski coil substrates corresponding to the negative terminal member 56N of the power supply side terminal member 56 are formed. and a second coil substrate on which the coil 70 is formed.

In each of the above-described embodiments and modifications, the currents of the positive terminal member 56P and the negative terminal member 56N of the switch board 50 corresponding to each phase (U, V, W) of the three-phase AC motor 4 are detected. However, the present invention is not limited to this. For example, if it is possible to detect currents corresponding to two phases of a three-phase AC motor, it is possible to use the detected values of the currents to calculate and control power to be supplied to the remaining one phase. In this case, any configuration may be used as long as it detects the current of the positive terminal member 56P and the negative terminal member 56N of the switch board 50 corresponding to any two phases of each phase of the three-phase AC motor. In this case, four Rogowski coils 70 are formed on the coil substrate.

In the power control devices 1 and 200 in each of the above embodiments, the seven capacitors 3 are connected in parallel to the battery 2, but the configuration without the capacitors 3 is also possible. In this case, the capacitor module 40 may be dispensed with, and the positive and negative terminals of the bus bar may be connected to the positive terminal member 56P and the negative terminal member 56N of the power supply terminal member 56, respectively.

In Modification 3, the joint piece 120 of the third terminal member 464 is joined to the upper surface of the joint portion 105 of the power supply side terminal member 564, but the present invention is not limited to this. The joint piece 120 of the third terminal member 462 may be joined to the lower surface of the joint portion 105 . Also, a configuration may be adopted in which a joint piece 120 is formed at the tip of the joint portion 105 of the power supply side terminal member 564 and joined to one end of the third terminal member 464 .

In the second embodiment, the coil board 610 is arranged in an upright posture with respect to the control board 600, but the present invention is not limited to this. The coil substrate 610 may be arranged parallel or substantially parallel to the control substrate 600 so that the power-supply-side terminal member 56 of the switch substrate 50 is inserted into the first through hole 62 of the coil substrate 610. good.

In the second embodiment, the coil substrate 610 is arranged between the switch substrate 50 and the control substrate 600, but the present invention is not limited to this. As in coil substrate positions A (1 to 4) shown in FIG. At the coil board positions A1, A2, and A3 shown in FIG. 15, the coil board 610 is arranged in a posture parallel or substantially parallel to the switch board 50 (and the control board 600). Then, the power supply side terminal member 56 of the switch board 50 is inserted into the first through hole 62 of the coil board 610, and is positioned below the control board 600 (position A1) or on the same plane as the control board 600 (position A2). position), or on the upper side of the control board 600 (A3 position). At the coil substrate position A4 shown in FIG. 15, the coil substrate 610 is in a posture that stands upright with respect to the switch substrate 50 (and the control substrate 600), and is spaced in front of the control substrate 600. As shown in FIG. The third terminal member 46 of the capacitor module 40 as a power source side terminal member is inserted through the first through hole 62 of the coil substrate 610 .

The disclosure of Japanese Patent Application No. 2020-072590 filed on April 14, 2020 is incorporated herein by reference in its entirety.
All publications, patent applications and technical standards mentioned herein are to the same extent as if each individual publication, patent application and technical standard were specifically and individually noted to be incorporated by reference. incorporated herein by reference.

Claims (6)

a switch substrate having a wiring pattern for electrically connecting a power supply and a power supply target, and a plurality of switching elements connected to the wiring pattern;
a coil substrate having a through-hole penetrating in the plate thickness direction and having a Rogowski coil pattern formed around the through-hole;
a power supply side terminal member that electrically connects the power supply and the wiring pattern of the switch substrate;
A power control device according to claim 1, wherein the coil substrate is arranged with a predetermined distance from the switch substrate, and the power supply side terminal members are arranged in a state of being inserted into the through holes of the coil substrate. The power source side terminal member has a positive side terminal member that electrically connects the positive electrode of the power source and the wiring pattern, and a negative electrode side terminal member that electrically connects the negative electrode of the power source and the wiring pattern. death,
The coil substrate has two through-holes through which the positive terminal member and the negative terminal member are respectively inserted, and the Rogowski coil patterns are formed around the two through-holes. 2. The power controller of claim 1. The power supply target is a three-phase AC motor,
The power supply side terminal member has three of the positive side terminal members and three of the negative side terminal members corresponding to each phase of the three-phase AC motor,
The coil substrate has six through-holes through which the three positive-side terminal members and the three negative-side terminal members are respectively inserted, and the Rogowski coil pattern is formed around the six through-holes. 3. The power control device of claim 2, wherein is formed. A control board that controls the plurality of switching elements based on a current value detected using the Rogowski coil,
The power control device according to any one of claims 1 to 3, wherein the coil board is formed integrally with the control board. A control board that controls the plurality of switching elements based on a current value detected using the Rogowski coil,
The power control device according to any one of claims 1 to 3, wherein the coil board is arranged between the switch board and the control board. a switch substrate having a wiring pattern for electrically connecting a power supply and a power supply target, and a plurality of switching elements connected to the wiring pattern;
A current detection board used in a power control device comprising a power supply side terminal member electrically connecting the power supply and the wiring pattern of the switch board,
Having a through hole penetrating in the plate thickness direction, a Rogowski coil pattern is formed around the through hole,
A current detection board arranged with a predetermined gap from the switch board and with the power supply side terminal member inserted through the through hole.

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