WO2013015371A1

WO2013015371A1 - Case division structure of power conversion device

Info

Publication number: WO2013015371A1
Application number: PCT/JP2012/069000
Authority: WO
Inventors: 賢市郎中嶋; 佐々木　要; 篠原　秀一
Original assignee: 日立オートモティブシステムズ株式会社
Priority date: 2011-07-26
Filing date: 2012-07-26
Publication date: 2013-01-31
Also published as: JP2013027259A

Abstract

A power conversion device is provided with: a bus bar assembly including an AC bus bar; a power module having a switching element; a controller; a driver unit for outputting the drive signal of the switching element; a capacitor module; a first case part for housing the capacitor module and the power module, the first case part having a coolant channel in the interior; and a second case part for housing the bus bar assembly, the controller, and the driver unit, the second case part being bonded to the first case part. A control terminal of the power module is bonded to the driver unit at a location further on the second case side relative to a case division surface at which the first case part and the second case part are bonded to each other. The second case part has a partition for separating the driver unit and the controller.

Description

Case division structure of power converter

The present invention relates to a power converter used for converting DC power into AC power or converting AC power into DC power.

Generally, a power conversion device has a function of converting AC power into DC power, or a function of converting AC power generated by a motor into DC power. An example of a power converter is disclosed in Japanese Patent Application Laid-Open No. 2004-31866. In Japanese Patent Application Laid-Open No. 2004-31866, the inverter device incorporated in the inverter box is sealed with a lid and fixed with screws, and a liquid gasket is applied to the joint surface to improve airtightness, thereby suppressing moisture intrusion. Techniques to do this are disclosed.

Japanese Unexamined Patent Publication No. 2004-31866

However, in the technique disclosed in Japanese Patent Application Laid-Open No. 2004-31866, when assembling work is performed with the inverter placed in the inverter box, the work space for attaching the internal parts is reduced. There is a problem.

According to a first aspect of the present invention, a power converter includes a switching element that converts DC power into AC power, a bus bar assembly that includes an AC bus bar for transmitting AC power, a power module that includes the switching element, A control unit that outputs a control signal for controlling the switching element, a driver unit that outputs a drive signal of the switching element to the switching element using the control signal output by the control unit, a capacitor module that smoothes DC power, A capacitor module and a power module are accommodated, a first case portion having a coolant flow path for cooling the capacitor module and the power module therein, a bus bar assembly, a control portion, and a driver portion are accommodated. And a second case part joined to the case part. The control terminal of the power module is joined to the driver part on the second case side from the case dividing surface where the first case part and the second case part are joined to each other, and the second case part is connected to the driver part. A partition for separating the control unit is provided.
According to the second aspect of the present invention, in the power conversion device of the first aspect, the second case portion has an opening on a surface different from the case dividing surface, and the AC terminal of the power module faces the bus bar assembly. It is preferable that one end portion of the AC bus bar and the AC terminal of the power module are joined to each other, and the other end portion of the AC bus bar different from the one end portion is extended from the opening.
According to the third aspect of the present invention, in the power conversion device of the first or second aspect, the capacitor module is surrounded by the flow path and is disposed near the center of the first case portion. preferable.
According to a fourth aspect of the present invention, in the power conversion device according to any one of the first to third aspects, the bus bar assembly includes a current sensor for detecting an alternating current flowing through the alternating current bus bar. The case part has the inlet pipe and the outlet pipe of the flow path on the same surface different from the case dividing surface, and the signal terminals of the current sensor are along the extending direction of the same surface of the first case part. It is preferable that the signal terminals protrude toward the driver portion side.
According to the fifth aspect of the present invention, in the power conversion device of the first aspect, the control unit supplies a control signal to the driver unit, and the driver unit supplies a drive pulse as a drive signal to the switching element. Is preferred.

According to the present invention, the productivity at the time of assembling the power converter can be improved.

It is a figure which shows the control block of a hybrid vehicle. It is a figure explaining the structure of the electric circuit of the inverter circuit. 1 is an external perspective view of a power conversion device 200. FIG. 2 is an exploded perspective view of a power conversion device 200. FIG. 2 is an exploded perspective view of a power conversion device 200. FIG. 2 is an external perspective view of a flow path forming body 12 in which power modules 300U to 300W, a capacitor module 500, and a bus bar assembly 800 are assembled. FIG. It is a figure which shows the flow-path formation body 12 of the state which removed the bus-bar assembly 800. FIG. 3 is a perspective view of a flow path forming body 12. FIG. 2 is a perspective view of a bus bar assembly 800. FIG. FIG. 3 is a diagram showing a flow path forming body 12 on which power modules 300U to 300W and a capacitor module 500 are mounted. It is a figure which shows the cross section of the power converter device. It is a figure which shows the cross section of the power converter device.

In the technology disclosed in Japanese Patent Application Laid-Open No. 2004-31866, the main purpose is to stably store the inverter in the inverter box, and it is easy to assemble the power converter (for example, the inverter) itself. The study was insufficient. For this reason, the technology disclosed in Japanese Patent Application Laid-Open No. 2004-31866 only discloses a simple process of assembling the inverter and then putting it in the inverter box and covering the inverter box. No mention is made of the configuration in which the inverters are gradually assembled hierarchically.

As a result, in the technique disclosed in Japanese Patent Application Laid-Open No. 2004-31866, when an assembling operation is performed with the inverter placed in the inverter box, the work space for attaching the internal parts is reduced. There was a problem.

Also, there was a problem that there was no space for the welding tool to operate even when trying to adopt a welding structure suitable for miniaturization or automation.

Furthermore, even in the soldering operation to the control board or the like, there are problems that the access space of the soldering tool is restricted, and the fillet shape cannot be confirmed after the control pins are soldered to the board.

Also, the process of putting the lid in the inverter box after assembling the inverter needs to be fixed and assembled somewhere when assembling the inverter, and the inverter is gradually hierarchized with the inverter in the inverter box. Compared with the assembly method, the production efficiency is very difficult.

Furthermore, in the technology disclosed in Japanese Patent Application Laid-Open No. 2004-31866, capacitor terminals and AC bus bars, which are important parts, are housed in the inverter box. There are also problems such as damage due to damage, and problems such as being difficult to repair because the damaged portion cannot be visually recognized.

In addition, when the power module, the driver circuit board, and the control circuit board are arranged hierarchically in the height direction, there is a possibility that switching noise or the like is mixed into the control circuit board side.

In view of the above problems of the prior art, an object of the present invention is to improve the reliability against noise while improving the productivity.

In order to solve the problems of the above prior art, for example, in an inverter device having two housings, on the upper side of the surface (case dividing surface) between the upper housing and the lower housing, What is necessary is just to comprise so that a driver circuit board and the control terminal of a power module may be joined. With this configuration, it is possible to prevent interference to the periphery at the time of assembling the components, and it is easy to join the driver circuit board and the control terminal of the power module, and an improvement in productivity can be expected.

Here, the water channel, the power semiconductor module, and the capacitor module are accommodated in the lower housing, and the assembly joint component (power module control terminal, capacitor module terminal, driver circuit board, control circuit board or If it is configured to house components such as a bus bar assembly, a space for various joining processes can be secured, and productivity is improved. More specifically, before joining the upper housing and the lower housing, it is possible to remove a physical obstacle when attaching the assembly joint component on the upper side and secure a sufficient working space. Even if it is going to adopt the welding structure, it is possible to secure the working space of the welding tool.

Furthermore, when the power module, the driver circuit board, and the control circuit board are arranged hierarchically in the vertical direction in this way, since mixing of switching noise or the like becomes a big problem on the control circuit board side, the upper casing is mounted. A structure in which two layers are further provided by providing a partition or the like and noise to the control circuit board is removed may be employed.

Here, the case where the upper casing is made of two layers has been described, but it is sufficient if there is a configuration for shutting down noise between the driver circuit and the control circuit (for example, a partition wall, etc.). It doesn't matter if it has been.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. FIG. 1 is a diagram showing a control block of a hybrid vehicle (hereinafter referred to as “HEV”). Engine EGN and motor generator MG1 generate vehicle running torque. Motor generator MG1 not only generates rotational torque but also has a function of converting mechanical energy applied from the outside to motor generator MG1 into electric power.

The motor generator MG1 is, for example, a synchronous machine or an induction machine, and operates as a motor or a generator depending on the operation method as described above. When motor generator MG1 is mounted on an automobile, it is desirable to obtain a small and high output, and a permanent magnet type synchronous motor using a magnet such as neodymium is suitable. Further, the permanent magnet type synchronous motor generates less heat from the rotor than the induction motor, and is excellent for automobiles from this viewpoint.

The output torque on the output side of the engine EGN is transmitted to the motor generator MG1 via the power distribution mechanism TSM, and the rotation torque from the power distribution mechanism TSM or the rotation torque generated by the motor generator MG1 is transmitted via the transmission TM and the differential gear DEF. Transmitted to the wheels. On the other hand, during regenerative braking operation, rotational torque is transmitted from the wheels to motor generator MG1, and AC power is generated based on the supplied rotational torque. The generated AC power is converted to DC power by the power conversion device 200 as described later, and the high-voltage battery 136 is charged, and the charged power is used again as travel energy.

Next, the power conversion device 200 will be described. The inverter circuit 140 is electrically connected to the battery 136 via the DC connector 138, and power is exchanged between the battery 136 and the inverter circuit 140. When motor generator MG1 is operated as a motor, inverter circuit 140 generates AC power based on DC power supplied from battery 136 via DC connector 138 and supplies it to motor generator MG1 via AC terminal 188. . The configuration including motor generator MG1 and inverter circuit 140 operates as a motor generator unit.

In the present embodiment, the vehicle can be driven only by the power of the motor generator MG1 by operating the motor generator unit as an electric unit by the electric power of the battery 136. Further, in the present embodiment, the battery 136 can be charged by operating the motor generator unit as a power generator unit by the power of the engine EGN or the power from the wheels to generate power.

Although omitted in FIG. 1, the battery 136 is also used as a power source for driving an auxiliary motor. The auxiliary motor is, for example, a motor for driving a compressor of an air conditioner or a motor for driving a control hydraulic pump. DC power is supplied from the battery 136 to the auxiliary power module, and the auxiliary power module generates AC power and supplies it to the auxiliary motor. The auxiliary power module has basically the same circuit configuration and function as the inverter circuit 140, and controls the phase, frequency, and power of alternating current supplied to the auxiliary motor. The power conversion device 200 includes a capacitor module 500 for smoothing the DC power supplied to the inverter circuit 140.

The power conversion device 200 includes a communication connector 21 for receiving a command from a host control device or transmitting data representing a state to the host control device. Power conversion device 200 calculates a control amount of motor generator MG1 by control circuit 172 based on a command input from connector 21, further calculates whether to operate as a motor or a generator, and based on the calculation result. The control pulse is generated, and the control pulse is supplied to the driver circuit 174. The driver circuit 174 generates a driving pulse for controlling the inverter circuit 140 based on the supplied control pulse.

Next, the configuration of the electric circuit of the inverter circuit 140 will be described with reference to FIG. In the following description, an insulated gate bipolar transistor is used as a semiconductor element, and hereinafter abbreviated as IGBT. The IGBT 328 and the diode 156 that operate as the upper arm, and the IGBT 330 and the diode 166 that operate as the lower arm constitute the series circuit 150 of the upper and lower arms. The inverter circuit 140 includes the series circuit 150 corresponding to three phases of the U phase, the V phase, and the W phase of the AC power to be output.

These three phases correspond to the three-phase windings of the armature winding of the motor generator MG1 in this embodiment. The series circuit 150 of the upper and lower arms of each of the three phases outputs an alternating current from the intermediate electrode 169 that is the midpoint portion of the series circuit. The intermediate electrode 169 is connected through an AC terminal 159 to an AC bus bar 802 described below, which is an AC power line to the motor generator MG1.

The collector electrode 153 of the IGBT 328 of the upper arm is electrically connected to the capacitor terminal 506 on the positive electrode side of the capacitor module 500 via the positive electrode terminal 157. The emitter electrode of the IGBT 330 of the lower arm is electrically connected to the capacitor terminal 504 on the negative electrode side of the capacitor module 500 via the negative electrode terminal 158.

As described above, the control circuit 172 receives a control command from the host control device via the connector 21, and based on this, the IGBT 328 that configures the upper arm or the lower arm of each phase series circuit 150 that constitutes the inverter circuit 140. And a control pulse that is a control signal for controlling the IGBT 330 is generated and supplied to the driver circuit 174.

The driver circuit 174 supplies a drive pulse for controlling the IGBT 328 and IGBT 330 constituting the upper arm or lower arm of each phase series circuit 150 to the IGBT 328 and IGBT 330 of each phase based on the control pulse. IGBT 328 and IGBT 330 perform conduction or cutoff operation based on the drive pulse from driver circuit 174, convert DC power supplied from battery 136 into three-phase AC power, and supply the converted power to motor generator MG1. Is done.

The IGBT 328 includes a collector electrode 153, a signal emitter electrode 155, and a gate electrode 154. The IGBT 330 includes a collector electrode 163, a signal emitter electrode 165, and a gate electrode 164. A diode 156 is electrically connected between the collector electrode 153 and the emitter electrode 155. A diode 166 is electrically connected between the collector electrode 163 and the emitter electrode 165.

The above-described IGBT 328, IGBT 330, diode 156, and diode 166 constitute a switching power semiconductor element. As the power semiconductor element for switching, a metal oxide semiconductor field effect transistor (hereinafter abbreviated as MOSFET) may be used. In this case, the diode 156 and the diode 166 are unnecessary. When the DC voltage is relatively high, IGBT is suitable as the switching power semiconductor element. When the DC voltage is relatively low, a MOSFET is suitable as a switching power semiconductor element.

The capacitor module 500 includes a positive capacitor terminal 506, a negative capacitor terminal 504, a positive power terminal 509, and a negative power terminal 508. The high-voltage DC power from the battery 136 is supplied to the positive-side power terminal 509 and the negative-side power terminal 508 via the DC connector 138, and the positive-side capacitor terminal 506 and the negative-side capacitor of the capacitor module 500. The voltage is supplied from the terminal 504 to the inverter circuit 140.

On the other hand, the DC power converted from the AC power by the inverter circuit 140 is supplied to the capacitor module 500 from the positive capacitor terminal 506 and the negative capacitor terminal 504, and is connected to the positive power terminal 509 and the negative power terminal 508. Is supplied to the battery 136 via the DC connector 138 and accumulated in the battery 136.

The control circuit 172 includes a microcomputer (hereinafter referred to as “microcomputer”) for performing arithmetic processing on the switching timing of the IGBT 328 and the IGBT 330. The input information to the microcomputer includes a target torque value required for the motor generator MG1, a current value supplied from the series circuit 150 to the motor generator MG1, and a magnetic pole position of the rotor of the motor generator MG1.

The target torque value is based on a command signal output from a host controller (not shown). The current value is detected based on a detection signal from the current sensor 180. The magnetic pole position is detected based on a detection signal output from a rotating magnetic pole sensor (not shown) such as a resolver provided in the motor generator MG1. In this embodiment, the current sensor 180 detects the current value of three phases, but the current value for two phases may be detected and the current for three phases may be obtained by calculation. .

The microcomputer in the control circuit 172 calculates the d-axis and q-axis current command values of the motor generator MG1 based on the target torque value, the calculated d-axis and q-axis current command values, and the detected d The voltage command values for the d-axis and q-axis are calculated based on the difference between the current values for the axes and q-axis, and the calculated voltage command values for the d-axis and q-axis are calculated based on the detected magnetic pole position. It is converted into voltage command values for phase, V phase, and W phase. Then, the microcomputer generates a pulse-like modulated wave based on a comparison between the fundamental wave (sine wave) and the carrier wave (triangular wave) based on the voltage command values of the U phase, V phase, and W phase, and the generated modulation wave The wave is output to the driver circuit 174 as a PWM (pulse width modulation) signal.

When driving the lower arm, the driver circuit 174 outputs a drive signal obtained by amplifying the PWM signal to the gate electrode of the corresponding IGBT 330 of the lower arm. Further, when driving the upper arm, the driver circuit 174 amplifies the PWM signal after shifting the level of the reference potential of the PWM signal to the level of the reference potential of the upper arm, and uses this as a drive signal as a corresponding upper arm. Are output to the gate electrodes of the IGBTs 328 respectively.

In addition, the microcomputer in the control circuit 172 detects abnormality (overcurrent, overvoltage, overtemperature, etc.) and protects the series circuit 150. For this reason, sensing information is input to the control circuit 172. For example, information on the current flowing through the emitter electrodes of the IGBTs 328 and IGBTs 330 is input to the corresponding drive units (ICs) from the signal emitter electrode 155 and the signal emitter electrode 165 of each arm. Thereby, each drive part (IC) detects an overcurrent, and when an overcurrent is detected, the switching operation of the corresponding IGBT 328 and IGBT 330 is stopped, and the corresponding IGBT 328 and IGBT 330 are protected from the overcurrent.

Information on the temperature of the series circuit 150 is input to the microcomputer from a temperature sensor (not shown) provided in the series circuit 150. In addition, voltage information on the DC positive side of the series circuit 150 is input to the microcomputer. The microcomputer performs over-temperature detection and over-voltage detection based on the information, and stops switching operations of all the IGBTs 328 and IGBTs 330 when an over-temperature or over-voltage is detected.

FIG. 3 is an external perspective view of a power conversion device 200 as an embodiment according to the present invention. The power conversion device 200 according to the present embodiment has an effect that the planar shape is a rectangular parallelepiped shape, which can be reduced in size and can be easily attached to the vehicle. The power converter 200 includes a lid 8, a housing 10, a flow path forming body 12, a cooling medium inlet pipe 13, a cooling medium outlet pipe 14, a lower cover 420, and a signal connector provided for connection to the outside. 21 is included. In the present embodiment, “up” means the direction from the flow path forming body 12 toward the lid 8, and “down” means the opposite direction.

The lid 8 is fixed to the upper opening of the housing 10 in which circuit components constituting the power conversion device 200 are accommodated. The flow path forming body 12 fixed to the lower part of the housing 10 holds a power module 300 and a capacitor module 500, which will be described later, and cools them with a cooling medium. For example, water is often used as the cooling medium, and will be described as cooling water below. The inlet pipe 13 and the outlet pipe 14 are provided on one side surface of the flow path forming body 12, and the cooling water supplied from the inlet pipe 13 flows into a flow path 19 to be described later in the flow path forming body 12 and from the outlet pipe 14. Discharged.

The AC interface 185 and the DC interface 137 are provided on the side surface of the housing 10. The AC interface 185 is provided on the side surface where the

pipes

13 and 14 are provided, and the DC interface 137 is provided on the side surface adjacent to the side surface where the AC interface 185 is provided.

Further, the housing 10 and the flow path forming body 12 have a trapezoidal cross section, and the productivity when using a manufacturing method such as casting is very good.

FIG. 4 is an exploded perspective view of the power converter 200. FIG. 5 is a view showing a state where the housing 10 is removed from the flow path forming body 12. Here, it demonstrates from FIG. 5 for convenience. In FIG. 5, the housing 10 has two storage spaces, and is divided into an upper storage space and a lower storage space by a partition wall 10c. The control circuit board 20 to which the connector 21 is fixed is stored in the upper storage space, and the driver circuit board 22 and a bus bar assembly 800 described later are stored in the lower storage space. A control circuit 172 shown in FIG. 2 is mounted on the control circuit board 20, and a driver circuit 174 is mounted on the driver circuit board 22. The control circuit board 20 and the driver circuit board 22 are connected by a flat cable (not shown), and the flat cable is drawn from the lower storage space to the upper storage space through the slit-shaped opening 10d formed in the partition wall 10c. It is.

In addition, here, the lower surface of the housing 10 and the upper surface (case dividing surface 12e) of the flow path forming body 12 are joined.

4, the control circuit board 20 on which the control circuit 172 is mounted as described above is disposed inside the lid 8, that is, in the upper storage space of the housing 10. The lid 8 has an opening for the connector 21. Low voltage DC power for operating the control circuit in the power converter 200 is supplied from the connector 21.

Although details will be described later, the flow path forming body 12 is formed with a flow path through which the cooling water flowing from the inlet pipe 13 flows. The flow path forms a U-shaped flow path that flows along the three side surfaces of the flow path forming body 12. The cooling water flowing in from the inlet pipe 13 flows into the flow path from one end of the U-shaped flow path, flows through the flow path, and then flows out from the outlet pipe 14 connected to the other end of the flow path. .

Three openings 402a to 402c are formed on the upper surface of the flow path, and the

power modules

300U, 300V, and 300W incorporating the series circuit 150 (see FIG. 2) are inserted into the flow path from the openings 402a to 402c. Inserted. The power module 300U includes a U-phase series circuit 150, the power module 300V includes a V-phase series circuit 150, and the power module 300W includes a W-phase series circuit 150. These power modules 300U to 300W have the same configuration and the same external shape. The openings 402a to 402c are closed by the flange portions of the inserted power modules 300U to 300W.

A storage space 405 for storing electrical components is formed in the flow path forming body 12 so as to be surrounded by the U-shaped flow path. In the present embodiment, the capacitor module 500 is stored in the storage space 405. The capacitor module 500 stored in the storage space 405 is cooled by cooling water flowing in the flow path. Above the capacitor module 500, a bus bar assembly 800 to which AC bus bars 802U to 802W are attached is disposed. The bus bar assembly 800 is fixed to the upper surface of the flow path forming body 12. A current sensor 180 is modularized and fixed to the bus bar assembly 800.

The driver circuit board 22 is disposed above the bus bar assembly 800 by being fixed to a support member 807a provided in the bus bar assembly 800. As described above, the control circuit board 20 and the driver circuit board 22 are connected by a flat cable. The flat cable is pulled out from the lower storage space to the upper storage space through a slit-shaped opening 10d formed in the partition wall 10c.

As described above, the power modules 300U to 300W, the driver circuit board 22 and the control circuit board 20 are hierarchically arranged in the height direction, and the control circuit board 20 is arranged at a place farthest from the high power system power modules 300U to 300W. Therefore, it is possible to reduce mixing of switching noise and the like on the control circuit board 20 side. Furthermore, since the driver circuit board 22 and the control circuit board 20 are arranged in different storage spaces partitioned by the partition wall 10c, the partition wall 10c functions as an electromagnetic shield and enters the control circuit board 20 from the driver circuit board 22. Noise can be reduced. In addition, although the housing 10 is formed with metal materials, such as aluminum, it is not limited to this.

Furthermore, since the control circuit board 20 is fixed to the partition wall 10c formed integrally with the housing 10, the mechanical resonance frequency of the control circuit board 20 is increased against external vibration. Therefore, it is difficult to be affected by vibration from the vehicle side, and reliability is improved.

Next, the flow path forming body 12, the capacitor module 500 and the bus bar assembly 800 fixed to the flow path forming body 12 will be described in more detail below.

FIG. 6 is an external perspective view in which the power modules 300U to 300W, the capacitor module 500, and the bus bar assembly 800 are assembled to the flow path forming body 12. FIG. 7 shows a state where the bus bar assembly 800 is removed from the flow path forming body 12. The bus bar assembly 800 is bolted to the flow path forming body 12.

First, the flow path forming body 12 will be described with reference to FIG. FIG. 8 is a perspective view of the flow path forming body 12. The flow path forming body 12 has a rectangular parallelepiped shape in plan view, and an inlet pipe 13 and an outlet pipe 14 are provided on a side surface 12d thereof. In addition, the side surface 12d is formed in a stepped portion where the

pipes

13 and 14 are provided. The flow path 19 is formed in a U shape so as to extend along the remaining three side surfaces 12a to 12c.

As shown in FIG. 8, on the upper surface side of the flow path forming body 12, a rectangular opening 402a is formed at a position parallel to the side surface 12a, and a rectangular opening 402b is formed at a position parallel to the side surface 12b. A rectangular opening 402c is formed at a position parallel to the side surface 12c. The power modules 300U to 300W are inserted into the flow path 19 through these openings 402a to 402c.

As shown in FIG. 8, the flow path forming body 12 is provided with a rectangular storage space 405 formed so that three sides are surrounded by the flow path 19. The capacitor module 500 is stored in the storage space 405. Since the storage space 405 surrounded by the flow path 19 has a rectangular parallelepiped shape, the capacitor module 500 can be formed into a rectangular parallelepiped shape, and the productivity of the capacitor module 500 is improved.

FIG. 9 is a perspective view of the bus bar assembly 800. Bus bar assembly 800 detects U, V, and W phase AC bus bars 802U, 802V, and 802W, a holding member 803 for holding and fixing AC bus bars 802U to 802W, and an AC current flowing through AC bus bars 802U to 802W. Current sensor 180. AC bus bars 802U to 802W are each formed of a wide conductor. A plurality of support members 807 a for holding the driver circuit board 22 are formed on the holding member 803 made of an insulating material such as resin so as to protrude upward from the holding member 803.

As shown in FIG. 6, the current sensor 180 is parallel to the side surface 12d at a position close to the side surface 12d of the flow path forming body 12 when the bus bar assembly 800 is solidified on the flow path forming body 12. The bus bar assembly 800 is disposed. As shown in FIG. 9, through holes 181 through which AC bus bars 802U to 802W are passed are formed on the side surfaces of the current sensor 180, respectively. A sensor element is provided in a portion where the through hole 181 of the current sensor 180 is formed, and a signal terminal 182 a of each sensor element protrudes from the upper surface of the current sensor 180. Each sensor element is arranged side by side in the extending direction of the current sensor 180, that is, in the extending direction of the side surface 12 d of the flow path forming body 12. The AC bus bars 802U to 802W pass through the respective through holes 181 and their tip portions protrude in parallel.

The holding member 803 is formed with

positioning protrusions

806a and 806b protruding upward. The current sensor 180 is fixed to the holding member 803 by screwing. At this time, the

protrusions

806a and 806b are engaged with positioning holes formed in the frame of the current sensor 180, thereby positioning the current sensor 180. Is done. Further, when the driver circuit board 22 is fixed to the support member 807a, the

positioning protrusions

806a and 806b are engaged with the positioning holes formed on the driver circuit board 22 side, whereby the signal terminal 182a of the current sensor 180 is The driver circuit board 22 is positioned in the through hole. The signal terminal 182a is joined to the wiring pattern of the driver circuit board 22 by solder. As described above, the signal terminal 182 a protrudes from the current sensor 180 toward the driver circuit board 22. Thereby, a relative positional shift with respect to the driver circuit board 22 can be reduced, and positioning with the through hole is facilitated.

In this embodiment, the holding member 803, the support member 807a, and the

protrusions

806a and 806b are integrally formed of resin. As described above, since the holding member 803 has a function of positioning the current sensor 180 and the driver circuit board 22, assembly and solder connection work between the signal terminal 182a and the driver circuit board 22 are facilitated. Further, by providing the holding member 803 with a mechanism for holding the current sensor 180 and the driver circuit board 22, the number of components as the whole power conversion device can be reduced.

AC bus bars 802U to 802W are fixed to the holding member 803 so that the wide surface is horizontal. As shown in FIGS. 6 and 7, each AC terminal 159 of the power modules 300U to 300W rises vertically toward the bus bar assembly and is joined to the connection portion 805 of each AC bus bar 802U to 802W. A connecting portion 805 connected to each AC terminal 159 also stands vertically in the same direction as each AC terminal 159. The connecting portion 805 has a concavo-convex shape at the tip, and has a shape in which heat concentrates on the concavo-convex portion during welding.

As described above, since the current sensor 180 is arranged in parallel to the side surface 12d of the flow path forming body 12, the AC bus bars 802U to 802W protruding from the through holes 181 of the current sensor 180 are connected to the side surface of the flow path forming body 12. 12d. Since each of the power modules 300U to 300W is disposed along the side surfaces 12a, 12b, and 12c of the flow path forming body 12, the connection portion 805 of the AC bus bars 802U to 802W corresponds to the side surfaces 12a to 12c of the bus bar assembly 800. Placed in position. As a result, as shown in FIG. 6, the U-phase AC bus bar 802U extends from the power module 300U disposed in the vicinity of the side surface 12b to the side surface 12d, and the V-phase AC bus bar 802V is disposed in the vicinity of the side surface 12a. Extending from module 300V to side surface 12d, W-phase AC bus bar 802W extends from power module 300W disposed in the vicinity of side surface 12c to side surface 12d.

FIG. 10 is a diagram showing the flow path forming body 12 in which the power modules 300U to 300W are fixed to the openings 402a to 402c and the capacitor module 500 is stored in the storage space 405. In the example shown in FIG. 10, the U-phase power module 300U is fixed to the opening 402b, the V-phase power module 300V is fixed to the opening 402a, and the W-phase power module 300W is fixed to the opening 402c. Thereafter, the capacitor module 500 is stored in the storage space 405, and the terminals on the capacitor side and the terminals of each power module are connected by welding or the like. Each terminal protrudes from the upper end surface of the flow path forming body 12, and a welding operation is performed by approaching a welding machine from above.

The positive and

negative terminals

157 and 158 of the power modules 300U to 300W arranged in a U-shape are connected to capacitor terminals 503a to 503c provided to protrude from the upper surface of the capacitor module 500. Since the three power modules 300U to 300W are provided so as to surround the capacitor module 500, the positional relationship of the power modules 300U to 300W with respect to the capacitor module 500 is equivalent, and the capacitor terminals 503a to 503c having the same shape are used. The capacitor module 500 can be connected in a well-balanced manner. For this reason, the circuit constants of the capacitor module 500 and the power modules 300U to 300W are easily balanced in each of the three phases, and the current can be easily taken in and out.

Here, the capacitor terminals 503a to 503c are formed corresponding to the positive terminal 157 and the negative terminal 158 of each power module 300. The capacitor terminals 503a to 503c have substantially the same shape, and an insulating sheet is provided between the negative electrode side capacitor terminal 504 and the positive electrode side capacitor terminal 506 constituting the capacitor terminals 503a to 503c, thereby ensuring insulation between the terminals. Has been.

Further, since the flow path 19 is provided so as to surround the three sides of the capacitor module 500, the capacitor module 500 can be effectively cooled. By the way, the power converter device 200 in this Embodiment is for vehicle-mounted, and is generally arrange | positioned in an engine room in many cases. Since the inside of the engine room becomes relatively high due to heat from the engine, the traveling motor, etc., heat intrusion from the surroundings to the power conversion device 200 becomes a problem. However, since the capacitor module 500 is surrounded on the three sides by the flow path 19 through which the cooling water flows, it is possible to effectively block heat intrusion from around the apparatus.

When the power modules 300U to 300W and the capacitor module 500 are arranged in the flow path forming body 12 as shown in FIG. 10, the bus bar assembly 800 is fixed above the capacitor module 500 as shown in FIG. I do. In the present embodiment, the bus bars 802U to 802W connected to the terminals of the power modules 300U to 300W arranged in a U-shape are routed above the capacitor module 500 so as to be separated from the respective connection portions, thereby forming a flow path forming body. 12 is pulled out from the side surface 12d side. Therefore, the bus bar does not cross the power module, and the bus bars 802U to 802W can be concentrated in one place, that is, the region of the opening 10a of the housing 10 to which the AC interface 185 is attached while ensuring sufficient insulation. it can.

With such a bus bar structure, the power modules 300U to 300W can be moved away from the AC connector portion where heat is easily generated and the temperature is likely to rise, and heat is transferred to the power modules 300U to 300W via the bus bars 802U to 802W. Can be suppressed. Further, by arranging the bus bars 802U to 802W so as to avoid the upper side of the flow path 19, even when water leaks from the flow path 19, the possibility of electric leakage due to water leakage can be reduced.

In addition, since the bus bar assembly 800 is fixed to the flow path forming body 12 through which the cooling water flows, not only the temperature rise of the bus bar assembly 800 can be suppressed, but also the temperature of the current sensor 180 held by the bus bar assembly 800. The rise can be suppressed. The sensor element provided in the current sensor 180 has a characteristic that is weak against heat, and the reliability of the current sensor 180 can be improved by adopting the above structure.

After the bus bar assembly 800 is fixed to the flow path forming body 12 as shown in FIG. 6 and the terminal welding operation is performed, the support member 807a formed on the holding member 803 of the bus bar assembly 800, as shown in FIG. The driver circuit board 22 is fixed. The power conversion device 200 mounted on the vehicle is easily affected by vibrations from the vehicle. Therefore, the plurality of support members 807a formed on the holding member 803 are configured to support not only the periphery of the driver circuit board 22, but also the vicinity of the center, thereby reducing the influence of vibration applied to the driver circuit board 22.

For example, by supporting the central portion of the driver circuit board 22 by the support member 807a, the resonance frequency of the driver circuit board 22 can be made higher than the frequency of vibration transmitted from the vehicle side. The influence of vibration can be reduced. The driver circuit board 22 is screwed to the support member 807a.

After the driver circuit board 22 is fixed above the bus bar assembly 800, the housing 10 is bolted to the flow path forming body 12 as shown in FIG. 5, and further, the upper storage space and the lower storage space of the housing 10 are partitioned. The control circuit board 20 is fixed on the partition wall 10c. The driver circuit board 22 in the lower storage space and the control circuit board 20 in the upper storage space are connected by a flat cable. As described above, the partition wall 10c is formed with the slit-shaped opening 10d for drawing the flat cable from the lower storage space to the upper storage space.

Since the power modules 300U to 300W are arranged in a U shape along the three

side surfaces

12b, 12a, and 12c of the flow path forming body 12, the power modules 300U to 300W are connected to the driver circuit board 22 from the power modules 300U to 300W. The

control terminals

310U, 310V, and 310W are also arranged in a U shape along the side corresponding to the side surfaces 12b, 12a, and 12c of the driver circuit board 22, as shown in FIG. FIG. 5 shows a state where the tips of the

control terminals

310U, 310V, 310W from the power modules 300U to 300W joined to the driver circuit board 22 are exposed through the driver circuit board 22. The control signal for driving and controlling the power modules 300U to 300W is a high voltage, while the sensor signal of the current sensor 180 and the signal from the flat cable are low voltage. In order to reduce the influence of high-voltage noise on the low-voltage system, the high-voltage wiring and the low-voltage wiring are preferably arranged separately.

In the present embodiment, since the power modules 300U to 300W are arranged in a U shape along the side surfaces 12b, 12a, and 12c, the region near the side corresponding to the side surface 12d on the driver circuit board 22 is controlled. It can be used as a space away from the terminal. In the present embodiment, since the bus bars 802U to 802W that are detection targets of the current sensor 180 are concentrated on the side surface 12d side, the current sensor 180 is arranged in parallel near the side surface 12d. *

Therefore, the signal terminal 182a is disposed in a region in the vicinity of the side corresponding to the side surface 12d of the driver circuit board 22 described above, and a sufficient distance can be maintained from the high-voltage control terminal.

In the driver circuit board 22, the flat cable is arranged on the side corresponding to the side surface 12c of the driver circuit board 22. However, on the board in the vicinity of the side surface 12d away from the control terminal so that the influence from the control terminal is reduced. It is connected to the. As a result, the low-voltage signal pattern and the high-voltage signal pattern can be easily separated on the driver circuit board 22.

Further, the low-voltage control circuit board 20 is disposed in the upper storage space separated by the partition wall 10c, and the flat cable is drawn from the lower storage space through the elongated slit-shaped opening 10d, whereby the control circuit board 20 is provided. The effect of noise is reduced. Thus, in the power conversion device 200 of the present embodiment, noise countermeasures are sufficiently taken.

Further, in the power conversion device 200 of the present embodiment, the capacitor module 500 and the power modules 300U to 300W are arranged on the flow path forming body 12, and the work of fixing necessary components such as the bus bar assembly 800 and the substrate is performed in order from the bottom. Productivity and reliability are improved because it is configured so that it can be performed.

FIG. 11 is a view showing a cross section of the power conversion device 200, and is a cross-sectional view of the power conversion device 200 as viewed from the direction of the

pipes

13 and 14. The openings 402a to 402c formed in the flow path forming body 12 are closed by flanges 304b provided in the module cases 304 of the power modules 300U to 300W.

Note that a sealing material is provided between the flange 304b and the flow path forming body 12 to ensure airtightness. In the power modules 300U to 300W, the heat radiation surface area where the fins 305 for heat radiation are provided is arranged in the flow path 19, and the lower end portion where the fins 305 are not provided is the protrusion 406 formed on the lower cover 420. It is stored inside the inner depression.

Thereby, it is possible to prevent the cooling water from flowing into the space where the fins 305 are not formed.

11 shows that the

control terminals

310U and 310W of the

power modules

300U and 300W are both joined to the driver circuit board 22 on the housing 10 side above the case dividing surface 12e. Although not shown in FIG. 11, the control terminal 310V of the power module 300V is also joined to the driver circuit board 22 on the housing 10 side above the case dividing surface 12e.

In the power conversion device 200 according to the present embodiment, as shown in FIG. 11, the relatively heavy capacitor module 500 is arranged at the lower center of the power conversion device 200, so that the center of gravity balance of the power conversion device 200 is good. When the vibration is applied, the power conversion device 200 is not easily ramped. *

The following is a summary of the main configuration and effects of the embodiment described above.

The power conversion device 200 of this embodiment is connected to the power modules 300U to 300W, the flow path forming body 12, and the AC output terminals of the power modules 300U to 300W, and forms a flow path through the storage space 405. Bus bars 802U to 802W drawn to the side surface 12d of the body 12 and the housing 10 are provided.

Here, the housing 10 has an opening on the lower surface side, and terminals and signal lines of the power modules 300U to 300W, terminals of the capacitor module and bus bars 802U to 802W, After assembling and assembling and joining parts of the power converter such as a driver circuit board, the opening on the lower surface side of the housing 10 is closed with the upper surface of the flow path forming body 12.

As a result, it is possible to prevent interference to the periphery when assembling the parts, and to improve the productivity of the power conversion device 200.

More specifically, before the flow path forming body 12 is covered with the housing 10 (upper lid), the assembly / joint parts (power module terminal, capacitor module terminal, driver circuit and bus bar above the flow path forming body 12 are covered. It is possible to remove a physical obstacle when attaching components (such as the assembly 800) and secure a sufficient working space. Needless to say, a space for operating the welding tool can be secured even if the welding structure is adopted.

In the present embodiment, a process of sequentially laminating and fixing the power modules 300U to 300W, the capacitor module 500, the bus bar assembly 800, and the driver circuit board 22 to the flow path forming body 12 is assumed. However, the present invention is not limited to this. .

Further, the assembly / joining part exposed above the flow path forming body 12 (for example, the signal terminal 182a of the current sensor 180 protrudes from the upper end surface of the flow path forming body 12, and is soldered by approaching a soldering iron from above. In the soldering operation (which is easy to work), it is possible to secure the access space of the soldering tool, and easily check the fillet shape after soldering the control pins etc. to the board You can also. For this reason, improvement in workability at the time of assembly can be expected.

Further, here, by providing the bus bars 802U to 802W that are connected to the AC output terminals of the power modules 300U to 300W and are drawn out to the side surface 12d of the flow path forming body 12 through the storage space 405. Further, since the members provided protruding from the side surfaces of the flow path forming body 12, that is, the AC connectors and the

pipes

13 and 14 connected to the bus bars 802U to 802W are concentrated on one surface 12d, the power conversion device 200 is downsized. it can.

Further, since the bus bars 802U to 802W are routed to the side surface 12d that is an empty space without straddling the flow path 19, the insulation of the bus bars 802U to 802W can be improved.

Further, since the distance between the connector portions of the bus bars 802U to 802W and the power modules 300U to 300W is increased, it is possible to reduce the heat generated in the connector portion from being transferred to the power modules 300U to 300W.

In the power conversion device 200 of the present embodiment, the housing 10 fixed to the flow path forming body 12 has two storage spaces, and is partitioned into an upper storage space and a lower storage space by a partition wall 10c. The control circuit board 20 to which the connector 21 is fixed is stored in the upper storage space, and the driver circuit board 22 and the bus bar assembly 800 are stored in the lower storage space.

As a result, the driver circuit board 22 and the control circuit board 20 are arranged in different storage spaces partitioned by the partition wall 10c, so that the partition wall 10c functions as an electromagnetic shield and is mixed into the control circuit board 20 from the driver circuit board 22. Noise can be reduced.

The power conversion device 200 of the present embodiment includes a holding member 803 formed of an insulating material such as a resin, and a plurality of support members 807a for holding the driver circuit board 22 are held by the holding member 803. It is formed so as to protrude upward from 803.

By providing such a support member 807a, the assembly can be performed in a state where there is no partition wall on the upper surface of the flow path forming body 12, and then the operation of covering the flow path forming body 12 with the housing 10 can be easily performed. .

In the power conversion device 200 of the present embodiment, the connection part 805 of the AC bus bars 802U to 802W and the

connection terminals

504 and 506 of the capacitor module 500 are respectively connected to the AC terminal 159 and the DC terminal (positive terminal 157, negative terminal 158) of the power module 300. ) By welding or the like. Each connection portion has a concavo-convex shape at the tip, and heat is concentrated on the concavo-convex portion during welding. Moreover, each terminal protrudes from the upper end surface of the flow-path formation body 12, and has a structure which is easy to perform welding work by approaching a welding machine from upper direction.

In the power conversion device 200 of the present embodiment, the capacitor module 500 that is a heavy object is stored in a storage space 405 that is formed at substantially the center of the flow path forming body 12 and is surrounded by the flow path 19. It is possible to prevent heat from entering the capacitor module 500 from the outside. Moreover, since a heavy object is arrange | positioned in the flow-path formation body 12, a gravity center balance becomes good and the rampage of the power converter device 200 when a vibration is added from the outside can be prevented. Furthermore, the connection relationship between the capacitor module 500 and the three power modules 300U to 300W can be made equal, and current can be easily taken in and out.

In the power conversion device 200 of the present embodiment, since the current sensor 180 is arranged so that the sensor elements for detecting the current flowing through the bus bars 802U to 802W are arranged along the extending direction of the side surface 12d, the low-power sensor The signal line can be wired away from the high power system power modules 300U to 300W, and the influence of noise can be reduced.

In the above embodiment, the description has been made on the assumption that assembly / joining parts (terminals and signal lines of power modules 300U to 300W, or terminals and bus bars of capacitors) are configured above the case dividing surface 12e. In this sense, there is no need to be above the case dividing surface 12e. For example, as shown in FIG. 12, a configuration in which the above-described assembled joint components are assembled in layers from slightly below the case dividing surface 12e is also conceivable. Even in this case, depending on the tool shape of soldering work or welding work, assembly work becomes easy. However, it goes without saying that it is basically desirable to be above the case dividing surface 12e.

The power conversion device described in the above-described embodiment and the system using this device solve various problems that are desired to be solved for commercialization. One of the various problems solved by these embodiments is an improvement in productivity. The above problem can be solved not only by the configuration described above but also by other configurations.

The embodiments described above may be used alone or in combination. This is because the effects of the respective embodiments can be achieved independently or synergistically. In addition, the present invention is not limited to the above embodiment as long as the characteristics of the present invention are not impaired. Other embodiments conceivable within the scope of the technical idea of the present invention are also included in the scope of the present invention.

The disclosure of the following priority application is hereby incorporated by reference.
Japanese Patent Application 2011-162750 (filed July 26, 2011)

Claims

A switching element that converts DC power to AC power;
A bus bar assembly including an AC bus bar for transmitting the AC power;
A power module having the switching element;
A control unit that outputs a control signal for controlling the switching element;
A driver unit that outputs a drive signal of the switching element to the switching element using the control signal output by the control unit;
A capacitor module for smoothing the DC power;
A first case portion that houses the capacitor module and the power module, and has a refrigerant flow path for cooling the capacitor module and the power module;
The bus bar assembly, the control unit, and the driver unit are housed, and the second case unit is joined to the first case unit,
The control terminal of the power module is joined to the driver part on the second case side from the case dividing surface where the first case part and the second case part are joined to each other,
The second case unit is a power conversion device having a partition for separating the driver unit and the control unit.
The power conversion device according to claim 1,
The second case portion has an opening on a surface different from the case dividing surface,
The AC terminal of the power module protrudes toward the bus bar assembly,
One end of the AC bus bar and the AC terminal of the power module are joined together,
The power conversion device in which the other end portion of the AC bus bar different from the one end portion is extended from the opening.
In the power converter device according to claim 1 or 2,
The said capacitor | condenser module is a power converter device enclosed by the said flow path and arrange | positioned in the center vicinity of the said 1st case part.
The power conversion device according to any one of claims 1 to 3,
The bus bar assembly has a current sensor for detecting an alternating current flowing through the alternating current bus bar,
The first case portion has an inlet pipe and an outlet pipe of the flow path on the same surface different from the case dividing surface,
The signal terminal of the current sensor is disposed along the extending direction of the same surface of the first case portion,
The power conversion device in which the signal terminal protrudes toward the driver unit side.
The power conversion device according to claim 1,
The control unit supplies the control signal to the driver unit,
The driver unit is a power conversion device that supplies a driving pulse to the switching element as the driving signal.