TWI457251B - 電動車輛控制裝置 - Google Patents

電動車輛控制裝置 Download PDF

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Publication number
TWI457251B
TWI457251B TW101105628A TW101105628A TWI457251B TW I457251 B TWI457251 B TW I457251B TW 101105628 A TW101105628 A TW 101105628A TW 101105628 A TW101105628 A TW 101105628A TW I457251 B TWI457251 B TW I457251B
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TW
Taiwan
Prior art keywords
battery
electric vehicle
voltage
power supply
control device
Prior art date
Application number
TW101105628A
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English (en)
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TW201244972A (en
Inventor
米花淳
Original Assignee
本田技研工業股份有限公司
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Publication of TW201244972A publication Critical patent/TW201244972A/zh
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Publication of TWI457251B publication Critical patent/TWI457251B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L1/00—Supplying electric power to auxiliary equipment of vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L1/00—Supplying electric power to auxiliary equipment of vehicles
    • B60L1/003—Supplying electric power to auxiliary equipment of vehicles to auxiliary motors, e.g. for pumps, compressors
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L15/00—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles
    • B60L15/007—Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/003—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to inverters
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    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
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    • B60L3/0084—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to control modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
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    • B60L50/00—Electric propulsion with power supplied within the vehicle
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    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/66—Arrangements of batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/12—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries responding to state of charge [SoC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/18—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules
    • B60L58/21—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules having the same nominal voltage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K11/00—Motorcycles, engine-assisted cycles or motor scooters with one or two wheels
    • B62K11/02—Frames
    • B62K11/10—Frames characterised by the engine being over or beside driven rear wheel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62M—RIDER PROPULSION OF WHEELED VEHICLES OR SLEDGES; POWERED PROPULSION OF SLEDGES OR SINGLE-TRACK CYCLES; TRANSMISSIONS SPECIALLY ADAPTED FOR SUCH VEHICLES
    • B62M7/00—Motorcycles characterised by position of motor or engine
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
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    • B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B62K2204/00—Adaptations for driving cycles by electric motor
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Description

電動車輛控制裝置
本發明是關於電動車輛控制裝置，特別是關於能簡化車載電池和用來對車輛的行走用馬達驅動電路之控制裝置供應電源的電路之電動車輛控制裝置。
以往，在電動車輛，具備有可控制用來驅動該電動車輛的行走用馬達之馬達控制裝置、和作為行走用馬達等的電力供應源之電池的管理裝置，在該等馬達控制裝置和電池管理裝置分別設置電源裝置的構造是已知的。
例如，專利文獻1揭示一種電動車輛控制裝置，係具有用來控制行走用馬達之VTC個人電腦(第1控制器)、和用來管理電池之BMC個人電腦(第2控制器)，且具備相互起動手段，當2個控制器的一方被起動時，可經由通訊路徑而使另一方的控制器起動。
[專利文獻1]日本特開2004-187329號公報
專利文獻1所記載的電動車輛控制裝置，因為第1及第2控制器雙方都要起動才能進行電池的充電，必須採用相互通訊的故障保安機制，而有系統變複雜且高成本的問題。
本發明的目的是為了解決上述課題而提供一種電動車輛控制裝置，可簡化車載電池和用來對行走用馬達驅動電路的控制裝置供應電力之電源電路。
為了達成前述目的，本發明第1特徵在於，係具有：利用來自電池的電力來驅動車輛行走用馬達之馬達驅動電路、監視前述電池的狀態之電池監視裝置、以及用來控制前述馬達驅動電路之主CPU之電動車輛控制裝置；其具備BMU用電源裝置、降壓調節器及接觸器；該BMU用電源裝置，是將前述電池的輸出電壓降壓成與前述電池監視裝置的控制電壓匹配後輸出；該降壓調節器，是將前述電池的輸出電壓降壓成與用來形成前述主CPU的控制電壓之CPU用電源裝置的輸入匹配後輸出；該接觸器，是設置在用來連接前述電池與前述馬達驅動電路間之正側線上，根據來自前述主CPU的指令而進行開閉；前述降壓調節器的控制用電源是藉由前述BMU用電源裝置所形成；其第2特徵在於，進一步具備主開關，其能開閉用來將前述控制用電源的電壓輸入前述降壓調節器的路徑。
本發明的第3特徵在於，前述BMU用電源裝置的輸出，是透過主開關而作為前述降壓調節器的控制用電源被輸入。
本發明的第4特徵在於，是將前述馬達驅動電路、前述電池監視裝置、前述主CPU、前述BMU用電源裝置、前述降壓調節器、以及前述接觸器組裝在單一基板上而構成控制模組。
本發明的第5特徵在於，前述降壓調節器是採用返馳式或順向式的構造。
本發明的第6特徵在於，係適用於電動車輛之電動車輛控制裝置，該電動車輛是藉由被支承成相對於車架可朝上下方向擺動自如的擺臂來支承驅動輪；前述擺臂具有主體外殼，前述車輛行走用馬達、電池及前述控制模組組裝於前述擺臂的主體外殼內，在前述電池的正端子和前述控制模組的正端子之間設置保險絲，使前述電池及前述控制模組之負端子側接地於前述擺臂的主體外殼。
本發明的第6特徵在於，前述基板具有用來形成接地線之導體圖案，將該導體圖案和控制模組之導電材料所構成的外殼藉由螺釘結合，藉此使前述控制模組接地於外殼主體。
依據具有第1~3特徵之本發明，可從電池的輸出電壓獲得電池監視裝置用的電源而始終監視電池的狀態，只要接通主開關，馬上能讓降壓調節器動作而對主CPU供應電力，主CPU使接觸器導通而對馬達驅動電路供應電池電壓。特別是依據第1特徵，能使電池監視裝置與主CPU分離，而利用電池的電源本身就能讓電池監視裝置動作。
此外，藉由將主開關導通而使降壓調節器動作，可將來自電池的輸入電壓降壓而作為動作電壓供應給主CPU。因此，不須在充電器電路內設置專用於充電時起動主CPU的電源，能使充電器電路小型化。依據第2特徵，由於將主開關設置於低電壓系統，能使主開關本身成為低容量， 且容易保護配線。再者，在電池充電時，僅從降壓調節器起動主CPU而使接觸器導通就能充電，電池監視裝置可個別地監視電池的充電狀態。
依據具有第4特徵之本發明，因為是在單一基板上配置要素而構成控制模組，可縮短個別要素間的配線而謀求小型化，且在電動車輛上的組裝作業也變簡單。
依據具有第5特徵之本發明，前述降壓調節器是採用返馳式或順向式的構造而具有優異的絕緣性。
依據具有第6特徵之本發明，因為在控制模組的正端子和電池之間設有保險絲，且將電池及控制模組的負端子側接地於前述擺臂的主體外殼，而能將電池電壓與外部阻隔。
依據具有第7特徵之本發明，將基板上的導體圖案和控制模組之導電材料所構成的外殼藉由螺釘連接於擺臂的外殼主體，因此能簡化接地構造。
以下參照圖式詳細說明本發明的較佳實施方式。第1圖係具有本發明的一實施方式之電動車輛控制裝置的電動車輛之側視圖。電動車輛1是具有低踏板16之速克達型的騎乘型2輪車輛，藉由收納於擺臂(擺搖單元)30之電動馬達M來驅動後輪WR。在車架2的前部結合頭管3，該頭管3將柱軸(未圖示)予以可旋轉自如地軸支承。在柱軸的一端(上部)結合被把手蓋11覆蓋之轉向把手 8，在另一端(下部)結合左右一對的前叉6，該前叉6是藉由車軸7將前輪WF予以可轉動自如地軸支承。
車架2係具備：從頭管3的後部往下方延伸之主管4、連結於主管4的後端部而朝車體後部上方延伸之後車架5。在低踏板16的下部朝向車體前後方向的部分之主管4上，安裝用來支承低踏板16之踏板架15。在主管4與後車架5的結合部，安裝左右一對的樞接板17。
擺臂30，是僅在車寬方向左側具有臂部之懸臂式，安裝於樞接板17之連桿18是透過貫穿車寬方向的擺動軸19而可擺動自如地藉由車架2軸支承。擺臂30是由鋁等的金屬構成之局部中空的構造體，在主體外殼31的車寬方向左側安裝擺臂蓋35。在擺臂30內部，在車軸32附近收納電動馬達M，在電動馬達M的車體前方側配設：作為電動馬達M的控制裝置而具有主CPU、電池管理裝置(BMU)之電力控制裝置(PCU)50。構成對電動馬達M等供應電力的電池之電池模組40a、40b，是在擺臂30之靠車體前方的位置配設於PCU50的車寬方向右側。
在擺臂30藉由車軸32將後輪WR可旋轉自如地予以軸支承，擺臂30的後端部是透過後緩衝器26而懸吊於後車架5。在座墊20的下部，構成置物空間之收納箱21配設於左右一對的後車架5間。
車架2的主管4，從車體前方側被前罩13覆蓋，從車體後方側被腿部護罩12覆蓋。在把手蓋11的上部配設儀錶裝置9，在儀錶裝置9之車體前方側配置前燈10。在 前叉6的上部固定著覆蓋前輪WF之前擋泥板14。
後車架5之車寬方向外側是被座墊罩23覆蓋，在座墊罩23的後端部安裝尾燈裝置24。在尾燈裝置24的上方突設與後車架5結合之後載架22，在尾燈裝置24的下方設有用來覆蓋後輪WR的後方上方之後擋泥板25。
在擺臂30之靠車體前方的上面，安裝著中空管狀的導管60之一端部。導管60之另一端部，是連接於作為車體側連接部之收納箱21底部。此外，從擺臂30的內部，讓連接於油門開度感測器(參照第3圖)之油門線49突出。油門線49的端部沿著車架2繞到車體前方，而連接於安裝在轉向把手8右端之油門握把(未圖示)。
第2、3、4圖係擺臂30的分解立體圖。第2圖係顯示從擺臂主體外殼31將擺臂蓋35卸下的狀態，第3圖係顯示從主體外殼31進一步將PCU50及電動馬達M卸下的狀態，第4圖係顯示從主體外殼31進一步將電池模組40a、40b卸下的狀態。
擺臂30如前述般是鋁等金屬所構成的局部中空的構造體，是採用將後輪WR藉由車寬方向左側的臂部33予以支承之懸臂式。在第4圖中，在主體外殼31之車體前方側下部設置左右一對的樞接凸緣37，在樞接凸緣37形成有讓擺動軸19(參照第1圖)貫穿之貫通孔19a。
第4圖中，具有相同構造之電池模組40a、40b分別從車寬方向左側挿入形成於主體外殼31的車體前方側之寬廣外殼部34內部。使用鋰離子之電池模組40a、40b是 由複數個電池構成，例如沿車寬方向排列5個電池而構成一個模組。
電池模組40a、40b分別在車寬方向左側的側面設置正端子41a、41b及負端子42a、42b。藉由導體之母線(busbar)43將電池模組40a的正端子41a與負端子42b連接，而使電池模組40a、40b串聯。負側配線44的一端側連接於電池模組40a的負端子42a。
在後輪WR的車軸32上，透過未圖示的減速機構連結電動馬達M的轉子45。在主體外殼31的後端上部，形成有用來安裝後緩衝器26(參照第1圖)之安裝孔26a。
在第2圖、第3圖中，電池模組40a、40b被收納於主體外殼31內，在主體外殼31，藉由複數個螺栓等安裝用來覆蓋電池模組40a、40b的車寬方向左側面而由樹脂等的絕緣構件所構成的隔板56。如第3圖所示般，一端側連接於電池模組40a的負端子42a之負側配線44的另一端側、和一端側連接於電池模組40b的正端子41b之正側配線47的另一端側，是分別從形成於隔板56的上下方之間隙朝車寬方向左側突出。
電動馬達M的定子46，是以從車寬方向左側覆蓋轉子45的方式固定於主體外殼31。在定子46之車體前方側配設PCU50。PCU50具有鋁等製之熱傳導性佳的PCU外殼(後述)，在該PCU外殼之車寬方向左側設置多數個冷卻散熱片51。在PCU50之車體前方側的端部，與PCU外殼電絕緣地設置連接器52、53，該連接器52、53 是分別連接繞到車體側之導線(harness)52a、53a。
作為電氣配線之導線52a、53a，除了將電池模組40a、40b連接於外部電源(例如100V的商用電源)而進行充電之配線以外，也包含偵測前輪WF的旋轉速度之車速感測器信號、點火開關的操作信號等的配線。
在PCU50之車體前方側，配設藉由油門線49驅動之油門開度感測器48。油門開度感測器48是藉由螺栓等固定於隔板56。此外，PCU50之車體前方側固定於隔板56，車體後方側是藉由螺栓等固定於主體外殼31。在此，PCU50之車體後方側，從車體側面視是延伸到與臂部33重疊的位置，因此藉由螺栓固定PCU50，能利用PCU外殼作為主體外殼31之剛性構件而提高臂部33的剛性。
在主體外殼31上完成定子46、PCU50及油門開度感測器48的安裝後，安裝用來從PCU50對定子46供應電力之3相母線54和中空管狀的導管60。由於將PCU50和定子46近接地配置，可縮短3相母線54的全長。
導管60，是利用形成於寬廣外殼部34的車寬方向左側端面之導管用缺口60a(參照第3圖)來安裝。此外，油門開度感測器48之油門線49，是收納於與導管用缺口60a之車體前方側鄰接之線用缺口49a(參照第3圖)。
設有正側配線47，其一端透過保險絲105(關於第5圖、第9圖等而隨後敘述)而與電池40b的正端子41b連接，另一端與形成於PCU50上面之PCU側正端子55a連接。在PCU50的下面設置同樣的基板側負端子56a(關於 第8圖而隨後敘述)，該負端子56a與前述負側配線44(參照第4圖)連接。
第2圖所示之擺臂蓋35，是為了防止水分、塵埃等從外部侵入而安裝成將主體外殼31密閉。藉此，在車輛行走時，即使因電池模組40a、40b、PCU50及電動馬達M所產生的熱而使擺臂30的內部空間溫度上昇的情況，不僅能利用行走風而在主體外殼31的表面進行散熱，且能透過導管60而往擺臂30外部有效地排熱。在本實施方式，藉由讓繞到車體側之導線52a、53a通過該導管60，能將作為電動馬達M等發熱構件的冷卻構造而發揮作用之導管60，也兼用為導線52a、53a的保護構件。
此外，不僅電動馬達M，由於將電池模組40a、40b及PCU50也配置於擺臂30內部，除了導管60以外不須設置其他冷卻構造，可謀求車體構造的簡化及減少零件數。
導管60的上端部，除了連接於收納箱21(參照第1圖)底部以外，也能連接於車體側之各種的連接部。例如，設置收納有電動風扇之冷卻箱，在該冷卻箱連接導管60亦可。此外，導管60的上端開口部之指向方向也能實施各種變更，例如可朝向車體前方側或後方側。
第5圖係電動車輛控制裝置的電力系統之整體概略圖，與第2圖~第4圖相同的符號是表示相同或等效的部分。在第5圖，電池模組40a、40b是透過保險絲105而對PCU50內的降壓調節器80施加高電壓(例如48伏特)。 電池模組40a的負側是透過接地線GND連接於擺臂30的主體外殼31。
降壓調節器80係具備一次側線圈L1和二次側線圈L2，一次側線圈L1的負側是透過開關元件(FET)82連接於接地線GND。在二次側線圈L2串聯二極體D5，且並聯電容器81。降壓調節器80的輸出側，通過擺臂30的主體外殼31連接於設置在車架2側之輔助控制電路106。亦即，藉由降壓調節器80降壓至低電壓(例如14伏特)後之電池模組40a、40b的電壓被輸入輔助控制電路106。輔助控制電路106，除了控制電動馬達M、電池模組40a、40b以外，還進行前燈10、尾燈裝置等的燈裝置等、一般電裝零件的控制、儀錶裝置9的顯示控制等。
依據第5圖所示的構造，由於在主體外殼31內配置電池模組40a、40b、保險絲105及馬達M，可將高電壓區域與外部阻隔。此外，即使是電池電壓(例如48伏特)接觸到主體外殼31的狀態，由於接地線GND連接於主體外殼31，藉由主體外殼31可確保讓流到外部的電流變得非常低之電阻值。
第6圖係PCU50的前視圖，第7圖係第6圖的A-A截面圖，第8圖係將具有冷卻散熱片51之PCU外殼卸下之PCU主體的前視圖。在第6圖~第8圖，與第2圖~第5圖相同的符號是表示相同或等效的部分。
參照第8圖，PCU50是在板狀的基板57表面組裝各種電子機器而構成。如第8圖所示般，在基板57上組裝 有：大致分成充電器電路70、降壓調節器80、半導體式接觸器90、馬達驅動電路100所構成的4群電子機器。
充電器電路70係包含FET元件71、變壓器72、73及電容器74，而配置於靠車體前方。降壓調節器80係包含電容器81、2個FET元件82及變壓器83。半導體式接觸器90係包含3個FET元件91所構成之FET接觸器。而且，配設於靠車體後方之馬達驅動電路100，是由6個FET元件101、3個電容器103及6個FET元件102所構成。
在PCU50往車體安裝的姿勢下，在充電器電路70之前方側的上下方分別安裝具有端子蓋55、56之基板側正端子55a及基板側負端子56a。在基板57的前端部，安裝用來連接導線52a、53a(參照第2圖、第3圖)之連接器52、53，在基板57的後端部設置：讓3根母線54(參照第3圖)連接之U相電極54a、V相電極54b及W相電極54c。
U相電極54a、V相電極54b及W相電極54c具有電絕緣性的電極蓋54。如第6圖所示般，在PCU外殼58的4個角落設置能讓螺栓貫穿的螺栓通孔59，該螺栓是用來將PCU50安裝於隔板56(參照第3圖)及主體外殼31。基板57具有形成接地線GND之導體圖案，如第7圖所示般，該導體圖案與PCU外殼58是在PCU外殼58的背側、亦即擺臂30側藉由螺釘61予以連結，而使PCU50的接地等同於外殼主體31的接地。
第9圖係電動車輛控制裝置的要部電路圖。PCU50除了前述般具有充電器電路70、降壓調節器80、接觸器(FET接觸器)90及馬達驅動電路100以外，還具備主CPU108及BMU(BMU-CPU)109以及2個降壓電路。降壓電路的其中之一，是監視電池模組40a、40b的充電狀態，將電池40的輸出電壓降壓後供應給用來管理充電．放電的BMU109之BMU用電源裝置110；另外一個是將降壓調節器80的輸出電壓降壓後作為控制電壓Vcc供應給主CPU108之CPU用電源裝置(5V-REG)111。BMU用電源裝置110及CPU用電源裝置111可由3端子調節器構成。又在以下的說明，將電池模組40a、40b一併表示的情況是稱為「電池40」。
充電器電路70，實質上為AC/DC轉換器，輸入30伏特的交流電壓AC而將48伏特的直流電壓輸出。BMU用電源裝置110，是從電池40輸入電池電壓Vb0(48伏特)而降壓成BMU控制用電壓(5伏特)後供應給BMU109。電池電壓是輸入BMU用電源裝置110並供應給降壓調節器80。在降壓調節器80，除了從電池40直接施加電池電壓V0，並透過接觸器90間接地施加電池電壓Vb1。在施加電壓Vb1的路徑上，在充電時也能施加從充電器電路70輸入的電壓。
接觸器90是設置在電池40的正線上，接觸器90的一端是透過PCU側的正端子55a、正側配線47及保險絲105而連接於電池的正端子41b。接觸器90的另一端是連 接於降壓調節器80的輸入側及充電器電路70的輸出側。再者，接觸器90的前述另一端也連接於馬達驅動電路100。馬達驅動電路100是包含：複數個FET元件構成的反相器、用來驅動反相器之預驅動器。
馬達驅動電路100之3相輸出，是透過3相母線54連接於電動馬達M之U相、V相、W相的各繞線。在電動馬達M設置：用來檢測轉子45(參照第2、3圖等)的旋轉角度之磁極感測器(角度感測器)112。
在擺臂30內的外側、亦即車架2側，設置主開關113、一般電裝零件114、油門開度感測器48、儀錶裝置9等，主開關113是介在BMU用電源裝置110和降壓調節器80之間。對一般電裝零件114，施加經由降壓調節器80降壓後的電壓(14伏特)。油門開度感測器48，是檢測出電動車輛的油門操作(加速操作)的操作量(油門量)，將檢測信號輸入主CPU108。此外，儀錶裝置9是藉由主CPU108驅動。角度感測器112之檢測信號輸入主CPU108，而用來控制馬達驅動電路100。
在透過負側配線44與電池40a的負端子42a連接之接地線GND設置分流器116、117。一方的分流器116所檢測出的電流被輸入BMU109，另一方的分流器117所檢測出的電流被輸入主CPU108及馬達驅動電路100的預驅動器。在分流器116和117之間設置電容器118。
在主開關113和BMU用電源裝置110之間連接作為限制電阻之電阻器R1，在從電阻器R1和主開關113間往 接地線GND分歧之線上連接定電壓二極體ZD。藉由設置電阻器R1及定電壓二極體ZD，可限制主開關113和BMU用電源裝置110之間的電壓及電流。進一步在CPU用電源裝置111的輸出側和BMU109之間連接二極體D1。
第10圖係顯示降壓調節器80的電路例。降壓調節器80係具有控制IC119，該控制IC119所形成的輸出可驅動設置於一次側線圈L1和接地線GND間之第1FET82。在一次側線圈L1，透過二極體D2從電池40將電池電壓Vb0輸入，且透過二極體D3將經由接觸器90之電池電壓Vb1輸入(電壓Vb0及Vb1都是48伏特)。
二極體D2、D3的陰極側連接於一次側線圈L1，在從用來連接二極體D2、D3和一次側線圈L1間之線分歧而連接於控制IC119的輸入側之分歧線上，設置二極體D4及電阻器R2及第2FET120。在第2FET120的閘極連接主開關113。
在二次側線圈L2的輸出線上串聯二極體D5，在二極體D5的陰極側連接與二次線圈L2並聯的電容器81。如此般，降壓調節器80是構成返馳式的調節器。降壓調節器80並不限定於返馳式，也可以是順向式。
第11圖係第10圖的要部之更具體的電路圖。在第11圖中，主開關113的輸入連接於電阻R3及電阻R4，電阻R3和電阻R4的連接點是連接於第1電晶體(雙極電晶體)86的基極。第1電晶體86的射極接地，集極透 過電阻R5連接於第2FET120的閘極。電池電壓Vb0是透過二極體D2、D4及電阻R2連接於2FET120的汲極，第2FET120的源極連接於控制IC119(第10圖)的電源端子。再者，在第2FET120的閘極及汲極，透過二極體D6及電阻R6連接驅動電壓(14伏特)。
電池電壓Vb1是透過齊納二極體84及電阻R7連接於第2電晶體(雙極電晶體)87的基極，第2電晶體87的射極接地，集極是透過電阻R5連接於第2FET120。電阻R7和第2電晶體87的基極之連接點是透過電阻R8接地。藉由齊納二極體84、電阻R7、R8及第2電晶體87構成充電時起動電路88。
接著說明具有第9圖~第11圖所示的電路構造之電動車輛控制裝置的動作。在初期狀態，主開關113及接觸器90斷關，未對主CPU108和馬達驅動電路100供應控制用電壓。另一方面，對BMU用電源裝置110施加電池電壓Vb0，BMU用電源裝置110將電池電壓Vb0變壓成BMU用電壓BMU-VCC並對BMU109施加定電壓。因此，BMU109獲得動作電源而能始終監視電池40的狀態。由於設有二極體D1，可阻止BMU用電源裝置110的輸出施加給主CPU108。
當主開關113導通時，若透過電阻器R1及主開關113對第1電晶體86的基極施加電池電壓Vb0，第1電晶體86被驅動而使第2FET120的閘極電壓降低成為導通。如此，使用電池電壓Vb0作為電壓電源Vcc而施加給 控制IC119，控制IC119變成可動作。控制IC119是以預定的ON．OFF時間比將第1FET82導通、斷開。一次側線圈L1的電流，在第1FET82導通的期間增加，當第1FET82斷開時，在二次側線圈L2有電流流過，透過二極體D5輸出而使電容器81充電。藉由二次側線圈L2對電容器81充電的電壓，亦即降壓調節器80的輸出電壓例如降壓成14伏特。經由降壓調節器80降壓後的電壓，是藉由CPU用電源裝置111降壓成5伏特，作為CPU控制用電壓VCC而輸入主CPU108。
當主CPU108有CPU控制用電壓VCC輸入時，開始動作，對接觸器90供應導通信號。在接觸器90施加有來自降壓調節器80的電壓，應答於來自主CPU108的導通信號而成為導通。當接觸器90導通時，對馬達驅動電路100施加來自電池40的電池電壓Vb1而將主CPU108起動。當從主CPU108將動作指示輸入馬達驅動電路100時，其內部的反相器會應答而動作，對電動馬達M供應驅動電流。電動馬達M的驅動電流是根據從油門開度感測器48輸入之油門量而決定。電動馬達M的朝U相、V相、W相之電流供應切換時點是根據角度感測器112的檢測信號而決定。
在電池40進行充電時，充電器電路70連接於未圖示的交流電源。當例如商用100伏特的交流電壓經由未圖示的變壓器變壓成(例如30伏特)後輸入充電器電路70時，將該交流AC/DC轉換成直流(48伏特)後供應給接觸 器90及降壓調節器80。充電時藉由主開關113之導通，降壓調節器80起動主CPU108，主CPU108使接觸器90導通而開始進行電池40的充電。BMU109始終監視電池的充電狀態等，主CPU108根據從BMU109輸入之電池狀態，在充電不足的情況使接觸器90導通，在充滿電的情況或是檢測出既定電池電壓的情況，使接觸器90斷開而停止充電。
在充電時，使充電時起動電路88動作，在電池電壓Vb1為齊納二極體84所設定之既定電壓(Vb2)以上的期間，維持第2電晶體87的導通狀態。藉此保持第2FET120的導通狀態。
如此般，依據本實施方式，是構成將電池40的控制要素組裝在單一基板上之PCU50，因此能使電動車輛控制裝置的構造變得極簡單。又充電器電路70並不限定於要與PCU50一體化，也能另外設置。
本實施方式之電動車輛控制裝置的構造簡單，因此對於在擺臂內部收納電動馬達、電池及電動車輛控制裝置之電動二輪車，可謀求省空間、組裝容易性以及低成本化。
又本實施方式僅是本發明的一實施方式，所屬技術領域具有通常知識者可運用周知技術而予以變更。例如，電池40雖是藉由二個電池模組來產生48伏特的電池電壓，但電池40的電壓並不限定於48伏特，藉由三個電池模組來產生72伏特的電壓亦可。此外，電動車輛並不限定於電動二輪車，也可以是具有擺臂之騎乘型的三/四輪車等 的各種車輛。
1‧‧‧電動車輛
2‧‧‧車架
19‧‧‧擺動軸
30‧‧‧擺臂
31‧‧‧主體外殼
35‧‧‧擺臂蓋
40‧‧‧電池
40a、40b‧‧‧電池模組
48‧‧‧油門開度感測器
49‧‧‧油門線
50‧‧‧PCU
57‧‧‧基板
61‧‧‧螺釘
70‧‧‧充電器電路
80‧‧‧降壓調節器
83‧‧‧變壓器
90‧‧‧接觸器
100‧‧‧馬達驅動電路
105‧‧‧保險絲
108‧‧‧主CPU
109‧‧‧BMU
110‧‧‧BMU用電源裝置
111‧‧‧CPU用電源裝置
第1圖係具有本發明的一實施方式之電動車輛控制裝置的電動車輛之側視圖。
第2圖係顯示從擺臂的主體外殼將擺臂蓋卸下的狀態之立體圖。
第3圖係顯示從主體外殼進一步將PCU及電動馬達卸下的狀態之立體圖。
第4圖係顯示從主體外殼進一步將電池模組卸下的狀態之立體圖。
第5圖係電動車輛控制裝置的電力系統之整體概略圖。
第6圖係PCU的前視圖。
第7圖係第6圖的A-A截面圖。
第8圖係將具有冷卻散熱片之PCU外殼卸下的PCU主體之前視圖。
第9圖係電動車輛控制裝置的要部電路圖。
第10圖係顯示降壓調節器的電路例。
第11圖係降壓調節器的要部之更具體的電路圖。
9‧‧‧儀錶裝置
40a、40b‧‧‧電池模組
41a、41b‧‧‧正端子
42a、42b‧‧‧負端子
44‧‧‧負側配線
47‧‧‧正側配線
48‧‧‧油門開度感測器
50‧‧‧PCU(電力控制裝置)
54‧‧‧3相母線
55a‧‧‧PCU側正端子
56a‧‧‧基板側負端子
70‧‧‧充電器電路(AC/DC)
80‧‧‧降壓調節器
90‧‧‧FET接觸器
100‧‧‧馬達驅動電路(反相器，預驅動器電路)
105‧‧‧保險絲
108‧‧‧主CPU
109‧‧‧BMU(電池管理裝置)
110‧‧‧BMU用電源裝置
111‧‧‧CPU用電源裝置
112‧‧‧角度感測器
113‧‧‧主開關
114‧‧‧一般電裝零件
116、117‧‧‧分流器
118‧‧‧電容器
AC‧‧‧交流電壓
D1‧‧‧二極體
M‧‧‧馬達
R1‧‧‧電阻器
ZD‧‧‧定電壓二極體

Claims (7)

  1. 一種電動車輛控制裝置，係具有：利用來自電池(40)的電力來驅動車輛行走用馬達(M)之馬達驅動電路(100)、監視前述電池(40)的狀態之電池監視裝置(109)、以及用來控制前述馬達驅動電路(100)之主CPU(108)；該電動車輛控制裝置具備BMU用電源裝置(110)、降壓調節器(80)及接觸器(90)；該BMU用電源裝置(110)，是將前述電池(40)的輸出電壓降壓成與前述電池監視裝置(109)的控制電壓匹配後輸出；該降壓調節器(80)，是將前述電池(40)的輸出電壓降壓成與用來形成前述主CPU(108)的控制電壓之CPU用電源裝置(111)的輸入匹配後輸出；該接觸器(90)，是設置在用來連接前述電池(40)與前述馬達驅動電路(100)間之正側線上，根據來自前述主CPU(108)的指令而進行開閉；前述降壓調節器(80)的控制用電源是藉由前述BMU用電源裝置(11)所形成。
  2. 如申請專利範圍第1項所述之電動車輛控制裝置，其中，進一步具備主開關(113)，其能開閉用來將前述控制用電源的電壓輸入前述降壓調節器(80)的路徑。
  3. 如申請專利範圍第2項所述之電動車輛控制裝置 ，其中，前述BMU用電源裝置(110)的輸出，是透過前述主開關(113)而作為前述降壓調節器(80)的控制用電源被輸入。
  4. 如申請專利範圍第1至3項中任一項所述之電動車輛控制裝置，其中，將前述馬達驅動電路(100)、前述電池監視裝置(109)、前述主CPU(108)、前述BMU用電源裝置(110)、前述降壓調節器(80)、以及前述接觸器(90)組裝在單一基板(57)上而構成控制模組(50)。
  5. 如申請專利範圍第1至3項中任一項所述之電動車輛控制裝置，其中，前述降壓調節器(80)是採用返馳式或順向式的構造。
  6. 如申請專利範圍第1至3項中任一項所述之電動車輛控制裝置，是適用於電動車輛之電動車輛控制裝置，該電動車輛具有是藉由被支承成相對於車架(2)可朝上下方向擺動自如的擺臂(30)來支承驅動輪(WR)之構造；前述擺臂(30)具有主體外殼(31)，前述車輛行走用馬達(M)、電池(40)及前述控制模組(50)組裝於前述擺臂(30)的主體外殼(31)內，在前述電池(40)的正端子(41b)和前述控制模組(50)的正端子(55a)之間設置保險絲(105)，使前述 電池(40)及前述控制模組(50)之負端子(42a、56a)側接地於前述擺臂(30)的主體外殼(31)。
  7. 如申請專利範圍第6項所述之電動車輛控制裝置，其中，前述基板(57)具有用來形成接地線(GND)之導體圖案，將該導體圖案和控制模組之導電材料所構成的外殼(58)藉由螺釘(61)結合，藉此使前述控制模組(50)接地於外殼主體(31)。
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