WO2013078660A1 - 功率模块和变流器 - Google Patents

功率模块和变流器 Download PDF

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Publication number
WO2013078660A1
WO2013078660A1 PCT/CN2011/083306 CN2011083306W WO2013078660A1 WO 2013078660 A1 WO2013078660 A1 WO 2013078660A1 CN 2011083306 W CN2011083306 W CN 2011083306W WO 2013078660 A1 WO2013078660 A1 WO 2013078660A1
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WO
WIPO (PCT)
Prior art keywords
power
power module
igbt
busbar
electrically connected
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PCT/CN2011/083306
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English (en)
French (fr)
Inventor
张可飞
郭建斌
车向中
戴碧君
Original Assignee
中国北车股份有限公司大连电力牵引研发中心
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Application filed by 中国北车股份有限公司大连电力牵引研发中心 filed Critical 中国北车股份有限公司大连电力牵引研发中心
Priority to PCT/CN2011/083306 priority Critical patent/WO2013078660A1/zh
Publication of WO2013078660A1 publication Critical patent/WO2013078660A1/zh

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Definitions

  • the present invention relates to electronic technologies, and more particularly to a power module and a current transformer. Background technique
  • the power of the traction converter in the subway vehicle is relatively large, and its magnitude can reach 1 MW.
  • the components in the power module are bulky and have a large heat dissipation power, and at the same time, With the development of technology, the requirements for the size of the power module are getting higher and higher. Therefore, it is very important to effectively reduce the volume of the power module while ensuring the electrical performance of the power module.
  • the power module is a power component with an Insulated Gate Bipolar Transistor (IGBT) as a core, and is used as a power component of an inverter or a chopper in the converter, and mainly includes:
  • IGBT Insulated Gate Bipolar Transistor
  • the main function in the device acts as an inverter or chopper.
  • the power module in order to achieve effective heat dissipation, the power module usually adopts a water-cooling structure, and the power module of the structure can cool the IGBT by water cooling, but the power module of the structure needs to be separately set for cooling.
  • each power module in the prior art is separately set, that is, each power module includes only one set of power. Parts, which cause the height and volume to be too large when the power modules are assembled into the box of the converter.
  • there is also a power module using a traveling air-cooling structure and the power module also has a high height, and the power module is separately disposed, resulting in an excessively large overall volume of the converter.
  • the invention provides a power module and a current transformer, which can effectively overcome the problems of the prior art and reduce the volume and height of the power module.
  • the present invention provides a power module including a flat type heat sink, and the flat type heat sink
  • the row is provided with a plurality of sets of power units, and the power unit comprises:
  • An insulated gate bipolar transistor IGBT mounted on a surface of the planar heat sink;
  • a driving circuit board mounted on the IGBT and electrically connected to the IGBT;
  • the composite busbar includes a DC positive copper busbar and a DC negative copper busbar, and the DC negative copper busbar and the DC positive copper busbar are electrically connected to the IGBT respectively;
  • a surge capacitor mounted on the composite busbar, electrically connected to the DC negative copper busbar and the DC positive copper busbar on the composite busbar;
  • An AC busbar row is mounted on the composite busbar and electrically connected to the IGBT; the composite busbar in each power unit is an integral structure.
  • the number of the surge capacitors is at least two. Specifically, the number of the surge capacitors is 15.
  • connection terminals are fixed on the flat heat sink, and the connection terminals are electrically connected to the AC outlet copper bus .
  • the AC outlet copper busbar is sleeved on the terminal.
  • the flat heat sink is further provided with a capacitor support frame, and the capacitor support frame is mounted with a supporting capacitor, and the input ends of the support capacitors are respectively electrically connected to the main circuit on the current transformer.
  • the DC positive copper bus and the DC negative copper bus are electrically connected to the output terminals of the supporting capacitors, respectively.
  • the power module described above may further include:
  • a power distribution board the power distribution board has an input end and a plurality of output ends, and the DC power source input through the input end is connected to each driving circuit board through a plurality of output ends respectively.
  • the power units are three groups, which are used as power components of the inverter in the converter;
  • the power units are four groups, wherein any three groups serve as power components of the inverter in the converter, and the other group acts as a power component of the chopper in the converter.
  • the present invention also provides a current transformer comprising a main circuit and a power module, wherein the power module is a power module provided by the above invention.
  • the power module and the converter provided by the invention adopt a flat plate radiator and Multiple sets of power units are arranged on the heat exchanger, and the IGBT and the surge capacitors in each power unit can be electrically connected through the set composite busbar, so that the entire power module is compact in structure, small in height and volume, and can be adapted to have a small height.
  • the assembly of each power unit can be facilitated, the convenience of power module assembly can be improved, and the overall size of the power module caused by the separate setting of each power unit can be avoided.
  • the problem can be applied to converter applications with small height and volume requirements.
  • 1 is a schematic structural diagram of a power module according to an embodiment of the present invention
  • FIG. 2 is a schematic structural view showing only an IGBT, a wiring terminal, and a driving circuit board mounted on a flat plate heat sink according to an embodiment of the present invention
  • Figure 3 is a schematic view showing the structure of a composite busbar, a surge capacitor, and an AC outlet copper bus on the basis of Figure 2;
  • FIG. 4 is a schematic structural view of a capacitor support frame mounted on the basis of FIG. 3;
  • FIG. 5 is a schematic structural view of the supporting capacitor and the power distribution board mounted on the basis of FIG. 4.
  • FIG. 1 is a schematic structural diagram of a power module according to an embodiment of the present invention. As shown in FIG. 1 , the power module of the embodiment includes a flat heat sink 1 , and the flat heat sink 1 is provided with a plurality of power units 2 , each of which includes an IGBT 21 , a driving circuit board 22 , and a composite bus bar 23 . , surge capacitor 24 and AC outlet copper bus 25.
  • the IGBT 21 is directly mounted on the surface of the planar heat sink 1, the driving circuit board 22 is mounted on the IGBT 21, and is electrically connected to the IGBT 21; the composite busbar 23 is mounted on the IGBT 21 and the driving circuit board 22, and the composite busbar 23 includes a DC positive copper bus bar 231 and a DC negative copper bus bar 232.
  • the DC negative copper bus bar 232 and the DC positive copper bus bar 231 are electrically connected to the IGBT 21, respectively; the surge capacitor 24 is mounted on the composite bus bar 23, and the composite bus bar 23 The DC positive copper busbar 231 and the DC negative copper busbar 232 are electrically connected; the AC outgoing copper busbar 25 is mounted on the composite busbar 23 and electrically connected to the IGBT 21; the composite busbar 23 in each power unit 2 is an integral structure.
  • the surge capacitor 24 and the IGBT 21 in each power unit 2 are electrically connected to the composite busbar 23 of the integrated structure, respectively.
  • the power units 2 of the power module are arranged side by side on the flat heat sink 1.
  • the power units 2 are simple and compact in structure, and the height and volume of the entire power module are small, and the power in the converter can be used.
  • the components are grouped together to reduce the volume and height of the entire converter, meeting the converter's low height and volume requirements.
  • any three sets of power units 2 can be connected to the main circuit of the converter as power components of the inverter on the main circuit.
  • another set of power units 2 can be used as a power component of the chopper in the converter as a circuit in the chopper.
  • an appropriate number of power units 2 can be set as needed to integrate the power components in the converter, which can effectively improve the compactness of the power component structure, reduce the volume occupied by the power components, and effectively reduce the current flow.
  • the overall volume and height of the device can be set as needed to integrate the power components in the converter, which can effectively improve the compactness of the power component structure, reduce the volume occupied by the power components, and effectively reduce the current flow.
  • the power unit 2 may include two IGBTs 21, and each of the IGBTs 21 is mounted with a driving circuit board 22, wherein the driving circuit board 22 is mainly used to control the operation of the IGBT 21, and the converter.
  • the control circuit board is connected, and the driving circuit board 22 can be specifically fixed to the IGBT 21 by bolts, and the driving circuit board 22 can be electrically connected to the IGBT 21 through bolts.
  • the composite bus bar 23 is formed by a DC positive copper bus bar 231 and a DC negative copper bus bar 232 through an insulating film for connecting the DC power coming from the main circuit to the IGBTs 21 through the composite bus bar 23 and On the wave capacitor 24, it will be understood by those skilled in the art that the composite busbar 23 can be electrically connected to the corresponding connection terminals of the IGBT 21 and the surge capacitor 24 through the connection protrusions provided thereon.
  • the composite busbar 23 to connect the IGBT 21 and the surge capacitor 24, the current carrying capacity of the entire power module can be effectively increased, the stray inductance can be reduced, and a capacitive effect can be generated between the DC positive copper bus bar 231 and the DC negative copper bus bar 232. It facilitates the absorption of the IGBT 21 turn-off overvoltage and improves the electrical performance of the entire power module.
  • the number of the surge capacitors 24 in each power unit 2 is at least two, for suppressing the pulse signal in the circuit.
  • each power unit 2 is provided with 5 surge capacitors 24.
  • an appropriate number of surge capacitors 24 can be set according to the circuit requirements of the power module to process the pulse signals generated in the circuit to eliminate the influence of the pulse signals.
  • a terminal 26 is further disposed at both ends of the alternating current copper busbar 25, and the terminal 26 is fixed on the flat heatsink 1, and the terminal 26 and the alternating current copper busbar 25 electrical connection, so that the AC generated by the entire circuit can be passed through the terminal block
  • a capacitor support frame 27 may be disposed on the flat heat sink 1 .
  • the capacitor support frame 27 may be mounted with a supporting capacitor 28 , and the input end of the supporting capacitor 28 is used for changing.
  • the main circuit in the flow device is electrically connected, and the output end is electrically connected to the DC positive copper bus bar 231 and the DC negative copper bus bar 232 in the composite bus bar 23, respectively.
  • the supporting capacitor 28 is mainly used for storing the direct current in the active circuit, and is input to each IGBT 21 through the composite bus bar 23 to convert the direct current into alternating current. Since the volume and weight of the supporting capacitor 28 are large, by providing the capacitor supporting frame 27, the supporting capacitor 28 can be effectively integrated on the power module, so that the power module is compact.
  • each driving circuit board needs to be connected to a DC power supply in the converter, in order to facilitate supplying DC power to the driving circuit board in each power module, a power distribution board may be disposed, thereby passing the power distribution line.
  • the board provides DC power for each driving circuit board, wherein the power dividing board can have an input end and a plurality of output ends, the input end is used for connecting with a DC power supply in an external control circuit, and the output end is used for a driving circuit board. Connect the power input on the top.
  • the power dividing board can have an input end and a plurality of output ends, the input end is used for connecting with a DC power supply in an external control circuit, and the output end is used for a driving circuit board. Connect the power input on the top.
  • the power dividing board can have an input end and a plurality of output ends, the input end is used for connecting with a DC power supply in an external control circuit, and the output end is used for a driving circuit board. Connect the power input on the top.
  • each of the power distribution boards 29 can have an input end 291 and four output ends 292.
  • the two power distribution boards 29 can be respectively connected to the power input ends of the eight driving circuit boards 22 by wires. It is convenient to connect the externally input direct current to each of the driving circuit boards 22, and at the same time, the problem that the connecting lines are confusing when the wires are connected can be avoided.
  • each of the heat dissipating fins of the flat heat sink 1 may be provided with protrusions to increase the heat dissipation area of the heat sink and increase the wind resistance, so that the entire heat sink can have good heat dissipation performance.
  • the size of the periphery of the heat sink substrate can be set larger than the size of the heat dissipating fin.
  • the edge of the substrate can also be utilized. Carry the power module.
  • the power module Since the power module is large in size, and the converter is usually hoisted under the vehicle, when the power module is installed and disassembled, it can only be carried out through the side, and the jack can be utilized by setting a large size around the substrate of the heat sink. Auxiliary tools such as forklifts are operated around the substrate to facilitate the removal and installation of the power module.
  • FIG. 2 is a schematic structural view showing only an IGBT, a wiring terminal, and a driving circuit board mounted on a flat plate heat sink according to an embodiment of the present invention
  • FIG. 3 is a composite bus bar, a surge capacitor, and a structure mounted on the basis of FIG.
  • FIG. 4 is a schematic structural view of a capacitor support frame mounted on the basis of FIG. 3
  • FIG. 5 is a schematic structural view of a support capacitor and a power distribution board mounted on the basis of FIG.
  • the assembly process may include the following steps:
  • Step 101 Install the IGBTs 21 on the surface of the flat heat sink 1 in the designed arrangement. At the same time, install the terminal 26 on both sides of one power unit 2, and mount the driving circuit board 22 on the IGBT 21. The assembled structure is shown in Figure 2.
  • the IGBT 21 and the terminal 26 can be bolted to the flat heat sink 1 to improve the stability and firmness of the installation.
  • the contact surface between the IGBT 21 and the heat sink 1 is coated with thermal grease.
  • the heat sink 1 is used to dissipate heat from the IGBT 21 in operation; the drive circuit board 22 can also be fixedly mounted on the IGBT 21 by bolts, and at the same time, the bolt is used as a conductor for electrically connecting the drive circuit board 22 and the IGBT 21.
  • Step 102 Install 15 surge capacitors 24 on the composite busbar 23.
  • the composite busbar 23 is mounted on the IGBT 21, and after the composite busbar 23 is mounted, the AC outgoing copper busbar 25 can be Pressed on the composite busbar 23, the two ends are sleeved on the terminal block 26, and the assembled structure is as shown in FIG.
  • the composite busbar 23 is provided with protrusions electrically connected to the surge capacitor 24 and the IGBT 21, so that the protrusions can be used to establish electrical connection with the surge capacitor 24 and the IGBT 21, wherein the composite busbar 23 is During the manufacturing process, corresponding protrusions may be preset according to the installation position to cooperate with the parts to be connected in the respective components to establish electrical connection with the components.
  • the AC outlet copper busbar 25 is also electrically connected to the IGBT 21 through the protrusions provided, and the ends are electrically connected to the terminals. It will be understood by those skilled in the art that the composite busbar 23 and the AC outgoing copper busbar 25 are electrically insulated except for the portions electrically connected to other components.
  • Step 103 On the basis of FIG. 3, a capacitor support frame 27 can be mounted on the flat heat sink 1.
  • the capacitor support frame 27 is spanned over other components to facilitate mounting the supporting capacitor 28.
  • the assembled structure is shown in FIG. Shown.
  • Step 104 On the basis of FIG. 3, the input/output terminal portion of the supporting capacitor 28 is inserted into the reserved hole in the composite busbar 23, and is mounted on the capacitor supporting frame 27. The assembled structure is as shown in FIG. .
  • the forklift, the jack, etc. can be horizontally placed into the converter box of the vehicle to realize the overall installation of the power module.
  • the power module provided by the embodiment provides multiple sets of power units on the flat-type heat sink by using a flat-type heat sink, and the IGBT and the surge capacitor in each power unit can be electrically connected through the set composite busbar.
  • the whole power module is compact, high in height and volume, and can be suitable for applications with small height and volume requirements.
  • assembly of power units can be facilitated and power can be increased.
  • the convenience of module assembly avoids the problem of large overall power module volume caused by separate setting of power units, and can be applied to converter applications with small height and volume requirements.
  • the embodiment of the present invention further provides a current transformer, which includes a main circuit and a power module, and the power module is a power module provided by the embodiment of the present invention.
  • a current transformer which includes a main circuit and a power module
  • the power module is a power module provided by the embodiment of the present invention. The specific structure is not described herein.
  • the converter belongs to the traction converter, and the main circuit can realize three-phase inverter control, and converts the direct current (750VDC or 1500VDC) of the contact network into three-phase alternating current with adjustable voltage and frequency for controlling Traction motor traction and braking work.
  • the power module is the product that realizes the core circuit function in the main circuit.
  • the IGBT is its core device and belongs to the inverter bridge part in the main circuit. It is worth noting that this power is a versatile 4-phase bridge arm structure that can be used not only for the inverter of this converter, but also for the rectifier, which can be connected in parallel to increase the output current if needed.
  • the core of the control circuit is mainly the TCU (traction control unit).
  • the driver board After the TCU is calculated, it sends out the control command and sends it to the driver board PWM signal on the power module.
  • the driver board amplifies the control signal and triggers the control terminal of the IGBT to control the IGBT.
  • the main circuit performs PWM pulse chopping operation according to a certain timing to complete the work under different working conditions of the converter.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)

Abstract

一种功率模块和交流器。该功率模块包括：平板式散热器（1），所述平板式散热器（1）上并排设置有多组功率单元（2），所述功率单元（2）包括：绝缘栅双极型晶体管IGBT（21），安装在所述平板式散热器（1）的表面；驱动电路板（22），安装在所述IGBT（21）上，并与所述IGBT（21）电连接；复合母排（23），安装在所述IGBT（21）和驱动电路板（22）上，所述复合母排（23）包括直流正铜排（231）和直流负铜排（232），所述直流负铜排（232）和直流正铜排（231）分别与所述IGBT（21）电连接；突波电容（24），安装在所述复合母排（23）上，与所述复合母排（23）上的直流负铜排（232）和直流正铜排（231）电连接；交流出线铜排（25），安装在所述复合母排（23）上，与所述IGBT（21）电连接；各功率单元（2）中的复合母排（23）为一体结构，其结构简单，实现方便，可有效减少功率模块的体积。

Description

功率模块和变流器
技术领域 本发明涉及电子技术， 尤其涉及一种功率模块和变流器。 背景技术
地铁车辆中牵引变流器的功率较大， 其数量级可达 1MW, 其中， 作为变 流器中的核心部件， 功率模块中的各部件体积较大， 且具有较大的散热功率， 同时， 随着技术的发展， 对功率模块体积的要求也越来越高， 因此， 在确保 功率模块电气性能的同时， 如何有效减少功率模块的体积变得非常重要。
其中， 功率模块是以绝缘栅双极型晶体管 （Insulated Gate Bipolar Transistor, IGBT )为核心的功率部件， 在变流器中作为逆变器或斩波器的功 率部件， 其主要包括： 是变流器中的主要功能部件， 起到逆变器或斩波器的 作用。 现有技术中， 为实现有效散热， 功率模块通常采用水冷结构， 该种结 构的功率模块可通过水冷方式对 IGBT进行冷却， 但是， 该种结构的功率模 块中， 需要单独设置用于起冷却作用的水管、 水泵等附加部件， 使得功率模 块的高度和体积较大， 无法适合对体积要求较高的场合； 此外， 现有技术中 各功率模块分别单独设置， 即各功率模块仅包括一组功率部件， 这会使得各 功率模块组装到变流器的箱内时， 高度和体积过大。 此外， 现有技术中也有 采用走行风冷结构的功率模块， 该种功率模块同样存在高度较高， 且功率模 块为单独设置而导致变流器整体体积过大的问题。
综上， 现有采用水冷结构或走行风冷结构的功率模块中， 使得使用该种 功率模块变流器的高度较高， 体积较大， 不适合应用于要求较小高度和体积 的变流器中。 发明内容
本发明提供一种功率模块和变流器， 可有效克服现有技术存在问题， 减 少功率模块的体积和高度。
本发明提供一种功率模块， 包括平板式散热器， 所述平板式散热器上并 排设置有多组功率单元， 所述功率单元包括：
绝缘栅双极型晶体管 IGBT, 安装在所述平板式散热器的表面；
驱动电路板， 安装在所述 IGBT上， 并与所述 IGBT电连接；
复合母排， 安装在所述 IGBT和驱动电路板上， 所述复合母排包括直流 正铜排和直流负铜排， 所述直流负铜排和直流正铜排分别与所述 IGBT 电连 接；
突波电容， 安装在所述复合母排上， 与所述复合母排上的直流负铜排和 直流正铜排电连接；
交流出线铜排， 安装在所述复合母排上， 与所述 IGBT电连接； 各功率单元中的复合母排为一体结构。
上述的功率模块中， 所述突波电容的数量至少为 2个。 具体地， 所述突 波电容的数量为 15个。
上述的功率模块中， 所述交流出线铜排的两端分别设置有接线端子， 所 述接线端子固设在所述平板式散热器上， 且所述接线端子与所述交流出线铜 排电连接。 且所述交流出线铜排套设在所述接线端子上。
上述的功率模块中， 所述平板式散热器上还设置有电容支撑架， 所述电 容支撑架上安装有支撑电容， 所述支撑电容的输入端分别与变流器上的主电 路电连接。
上述的功率模块中， 所述直流正铜排和直流负铜排分别与所述支撑电容 的输出端电连接。
上述的功率模块还可包括：
电源分线板， 所述电源分线板具有一个输入端和多个输出端， 用于将外 界通过输入端输入的直流电源，分别通过多个输出端连接到各驱动电路板上。
上述的功率模块中， 所述功率单元为 3组， 用于作为变流器中逆变器的 功率部件；
或者， 所述功率单元为 4组， 其中任意三组作为变流器中逆变器的功率 部件， 另一组作为变流器中斩波器的功率部件。
本发明还提供一种变流器， 包括主电路和功率模块， 其中， 所述功率模 块为采用上述本发明提供的功率模块。
本发明提供的功率模块和变流器， 通过采用平板式散热器， 在平板式散 热器上设置多组功率单元， 各功率单元中的 IGBT和突波电容可通过设置的 复合母排进行电连接， 使得整个功率模块结构紧凑， 高度和体积均较小， 可 适合具有较小高度和体积要求的应用中； 同时， 通过将多个功率模块集成在 一起， 可便于各功率单元的组装， 提高功率模块组装的便利性， 避免各功率 单元单独设置而造成的功率模块整体体积较大的问题， 可适用于具有较小高 度和体积要求的变流器应用中。 附图说明 图 1为本发明实施例提供的功率模块的结构示意图；
图 2为本发明实施例中在平板式散热器上仅安装有 IGBT、接线端子和驱 动电路板的结构示意图；
图 3为在图 2基础上安装有复合母排、 突波电容和交流出线铜排的结构 示意图；
图 4为在图 3基础上安装有电容支撑架的结构示意图；
图 5为在图 4基础上安装有支撑电容和电源分线板的结构示意图。 具体实施方式 图 1为本发明实施例提供的功率模块的结构示意图。 如图 1所示， 本实 施例功率模块包括平板式散热器 1 , 平板式散热器 1上设置有多组功率单元 2, 各功率单元 2均包括 IGBT 21、 驱动电路板 22、 复合母排 23、 突波电容 24和交流出线铜排 25。 其中， IGBT 21直接安装在平板式散热器 1的表面， 驱动电路板 22安装在 IGBT 21上， 并与 IGBT 21电连接； 复合母排 23安装 在 IGBT 21和驱动电路板 22上，复合母排 23包括直流正铜排 231和直流负 铜排 232, 直流负铜排 232和直流正铜排 231分别与 IGBT 21电连接； 突波 电容 24安装在复合母排 23上， 并与复合母排 23上的直流正铜排 231和直 流负铜排 232电连接；交流出线铜排 25安装在复合母排 23上，并与 IGBT 21 电连接； 各功率单元 2中的复合母排 23为一体结构， 使得各功率单元 2中 的突波电容 24、 IGBT 21可分别与该一体结构的复合母排 23电连接。 本实 施例功率模块各功率单元 2并排设置在平板式散热器 1上，各功率单元 2结 构简单、 紧凑， 整个功率模块的高度和体积均较小， 可将变流器中的各功率 部件集中在一起， 可有效减少整个变流器的体积和高度， 满足变流器在较小 高度和体积要求的应用场合。
本实施例中， 在平板式散热器 1 上， 并排设置有四组功率单元 2, 其中 任意三组功率单元 2可与变流器主电路连接， 以作为主电路上的逆变器的功 率部件， 作为逆变器中的电路； 而另外一组功率单元 2可作为变流器中斩波 器的功率部件， 以作为斩波器中的电路。 实际应用中， 可根据需要设置合适 数量的功率单元 2, 以便将变流器中各功率部件集成在一起， 可有效提高功 率部件结构的紧凑性， 减少功率部件占用的体积， 可有效减少变流器的整体 体积和高度。
本实施例中， 功率单元 2可包括有 2个 IGBT 21 , 且每个 IGBT 21上均 安装有驱动电路板 22, 其中， 驱动电路板 22主要用来控制 IGBT 21的工作， 与变流器中的控制电路连接，驱动电路板 22具体可通过螺栓安装固定在 IGBT 21上， 且驱动电路板 22可通过螺栓与 IGBT 21建立电连接。
本实施例中，复合母排 23为直流正铜排 231和直流负铜排 232通过绝缘 压膜的形式制成，用于将主电路过来的直流电通过复合母排 23连接到各 IGBT 21以及突波电容 24上， 本领域技术人员可以理解， 复合母排 23可通过其上 设置的连接突起， 分别与 IGBT 21和突波电容 24上相应的连接端子配合， 实 现电连接。 通过采用复合母排 23连接 IGBT 21和突波电容 24, 可有效增加 整个功率模块的载流能力， 减少杂散电感， 同时可使得直流正铜排 231和直 流负铜排 232之间产生电容效应， 方便对 IGBT 21关断过电压的吸收， 提高 整个功率模块的电气性能。
本实施例中， 各功率单元 2中设置的突波电容 24的数量至少为 2个， 以 用于抑制电路中的脉冲信号， 具体地， 本实施例中， 每个功率单元 2中均设 置有 5个突波电容 24。 实际应用中， 可根据功率模块的电路需要， 设置合适 数量的突波电容 24, 以便对电路中产生的脉冲信号进行处理， 消除脉冲信号 的影响。
本实施例中， 为便于将交流电输出， 在交流出线铜排 25的两端还分别设 置有接线端子 26, 接线端子 26固设在平板式散热器 1上， 且接线端子 26与 交流出线铜排 25 电连接， 这样， 可将整个电路产生的交流电通过接线端子 本实施例中， 如图 1所示， 在平板式散热器 1上还可设置有电容支撑架 27, 该电容支撑架 27上可安装有支撑电容 28, 支撑电容 28的输入端用于与 变流器中的主电路电连接，且输出端与复合母排 23中的直流正铜排 231和直 流负铜排 232分别电连接。 其中， 支撑电容 28主要用于对主动电路中的直流 电进行存储，以通过复合母排 23输入到各 IGBT 21，将直流电转换成交流电。 由于支撑电容 28的体积和重量较大， 通过设置电容支撑架 27, 可有效将支 撑电容 28集成在功率模块上， 使得功率模块紧凑。
本实施例中， 由于各驱动电路板均需要连接变流器中的直流电源， 为便 于为各功率模块中的驱动电路板提供直流电源， 还可设置有电源分线板， 从 而通过电源分线板为各驱动电路板提供直流电源， 其中， 该电源分线板可具 有一个输入端和多个输出端，输入端用于与外界控制电路中的直流电源连接， 输出端用于与驱动电路板上的电源输入端连接。 具体地， 本实施例中， 四组 功率单元 2中， 共有 8个 IGBT 21和驱动电路板 22, 而每个驱动电路板 22 均需要直流电源， 因此， 本实施例中采用 2个电源分线板 29, 每个电源分线 板 29可具有一个输入端 291和四个输出端 292, 这样， 可利用两块电源分线 板 29分别与 8个驱动电路板 22的电源输入端通过导线连接， 便于将外界输 入的直流电分别连接到各驱动电路板 22上， 同时， 可避免导线连接时连接线 混乱的问题。
本实施例中， 上述的平板式散热器 1 的每个散热翅上可设置有突起， 以 提高散热器的散热面积， 增加风阻， 使得整个散热器可具有良好的散热性能。 此外， 为便于功率模块在变流器中的安装和拆卸， 可将散热器基板四周尺寸 设置大于散热翅的尺寸， 除了可利用散热器基板的边缘进行安装和密封外， 还可利用基板的边缘进行功率模块的搬运。 由于功率模块体积较大， 且变流 器通常是吊装于车辆的车下， 在功率模块安装和拆卸时， 仅能通过侧面进行， 通过将散热器的基板四周设置较大尺寸， 从而可利用千斤顶、 叉车等辅助工 具在基板四周进行操作， 便于对功率模块进行拆卸和安装中的搬运。
为便于对本发明技术方案进行更好的了解， 下面对本发明实施例的具体 组装过程进行说明。
图 2为本发明实施例中在平板式散热器上仅安装有 IGBT、接线端子和驱 动电路板的结构示意图； 图 3为在图 2基础上安装有复合母排、 突波电容和 交流出线铜排的结构示意图； 图 4为在图 3基础上安装有电容支撑架的结构 示意图； 图 5为在图 4基础上安装有支撑电容和电源分线板的结构示意图。 并结合图 1 , 本实施例功率模块组装时， 其组装过程可包括以下步骤：
步骤 101、 将各 IGBT 21按设计的排列方式顺序安装在平板式散热器 1 的表面， 同时， 在一个功率单元 2的两侧分别安装接线端子 26, 并将驱动电 路板 22安装在 IGBT 21上， 组装后的结构如图 2所示。
其中 , IGBT 21和接线端子 26均可采用螺栓固定安装在平板式散热器 1 上， 以提高安装的稳定性和牢固性， IGBT 21与散热器 1的接触面之间涂有 导热硅脂， 以实现散热器 1为工作中的 IGBT 21散热的作用； 驱动电路板 22 也可通过螺栓固定安装在 IGBT 21上， 同时， 利用该螺栓作为驱动电路板 22 与 IGBT 21之间电连接的导体。
步骤 102、将 15个突波电容 24安装在复合母排 23上，在图 2的基础上， 将复合母排 23安装在 IGBT 21上， 复合母排 23安装后 , 可将交流出线铜排 25压在复合母排 23上， 两端套在接线端子 26上，组装后的结构如图 3所示。
其中，复合母排 23上设置有与突波电容 24、 IGBT 21进行电连接的突起， 从而可利用该些突起建立与突波电容 24、 IGBT 21之间的电连接， 其中复合 母排 23在制作过程中， 可根据安装位置预先设置有相应的突起， 以便与各部 件中的待连接部分配合， 建立与各部件的电连接。 类似的， 交流出线铜排 25 也是通过设置的突起来与 IGBT 21进行电连接， 且端部与接线端子电连接。 本领域技术人员可以理解， 复合母排 23和交流出线铜排 25上除了与其它部 件电连接的部位外， 其它部分均是电绝缘的。
步骤 103、 在图 3的基础上， 可在平板式散热器 1上安装电容支撑架 27, 该电容支撑架 27跨在其它部件之上， 以便于安装支撑电容 28, 组装后的结 构如图 4所示。
步骤 104、 在图 3的基础上， 将支撑电容 28的输入输出端子部分插入在 复合母排 23上预留的孔中， 并安装在电容支撑架 27上， 组装后的结构如图 5所示。
本实施例功率模块组装完毕后， 即可利用叉车、 千斤顶等将其水平放入 车辆的变流器箱体中， 实现功率模块的整体安装。
本领域技术人员可以理解的是， 上述主要是对本实施例中功率模块中各 部件的设置和组装方式进行说明， 各功率模块中各部件的电连接关系、 以及 与变流器中主电路和控制电路之间的连接关系可与现有技术中的变流器相同 或类似， 在此不再赘述。
综上， 本实施例提供的功率模块， 通过采用平板式散热器， 在平板式散 热器上设置多组功率单元， 各功率单元中的 IGBT和突波电容可通过设置的 复合母排进行电连接， 使得整个功率模块结构紧凑， 高度和体积均较小， 可 适合具有较小高度和体积要求的应用中； 同时， 通过将多个功率单元集成在 一起， 可便于各功率单元的组装， 提高功率模块组装的便利性， 避免各功率 单元单独设置而造成的功率模块整体体积较大的问题， 可适用于具有较小高 度和体积要求的变流器应用中。
此外， 本发明实施例还提供一种变流器， 该变流器包括主电路和功率模 块， 该功率模块为采用上述本发明实施例提供的功率模块， 其具体结构在此 不再赘述。
本实施例中， 变流器属于牵引变流器， 其主电路可实现三相逆变控制， 将接触网的直流电 （750VDC或 1500VDC ) 变换成可调节电压和频率的三相 交流电， 用来控制牵引电机的牵引及制动等工作。 功率模块是主电路中实现 核心电路功能的产品， 以 IGBT为其核心器件， 属于主电路中的逆变桥部分。 值得说明的是， 该功率是通用的 4相桥臂结构， 不仅能够用于本变流器的逆 变器， 也可以用于整流器， 在需要的情况下能够实现 IGBT并联以增大输出 电流。 控制电路的核心主要是 TCU (牵引控制单元）， TCU经过计算后发出控 制指令， 并发给功率模块上的驱动板 PWM信号， 驱动板将该控制信号放大 后触发 IGBT的控制端，从而控制 IGBT实现主电路按照一定的时序进行 PWM 脉冲斩波工作， 以完成变流器不同工况下的工作。
最后应说明的是： 以上实施例仅用以说明本发明的技术方案， 而非对其 限制； 尽管参照前述实施例对本发明进行了详细的说明， 本领域的普通技术 人员应当理解： 其依然可以对前述各实施例所记载的技术方案进行修改， 或 者对其中部分技术特征进行等同替换； 而这些修改或者替换， 并不使相应技 术方案的本质脱离本发明各实施例技术方案的精神和范围。

Claims

权利 要求 书
1、 一种功率模块， 其特征在于， 包括平板式散热器， 所述平板式散热器 上并排设置有多组功率单元， 所述功率单元包括：
绝缘栅双极型晶体管 IGBT, 安装在所述平板式散热器的表面；
驱动电路板， 安装在所述 IGBT上， 并与所述 IGBT电连接；
复合母排， 安装在所述 IGBT和驱动电路板上， 所述复合母排包括直流 正铜排和直流负铜排， 所述直流负铜排和直流正铜排分别与所述 IGBT电连 接；
突波电容， 安装在所述复合母排上， 与所述复合母排上的直流负铜排和 直流正铜排电连接；
交流出线铜排， 安装在所述复合母排上， 与所述 IGBT电连接； 各功率单元中的复合母排为一体结构。
2、 根据权利要求 1所述的功率模块， 其特征在于， 所述突波电容的数量 至少为 2个。
3、 根据权利要求 2所述的功率模块， 其特征在于， 所述突波电容的数量 为 15个。
4、 根据权利要求 1所述的功率模块， 其特征在于， 所述交流出线铜排的 两端分别设置有接线端子， 所述接线端子固设在所述平板式散热器上， 且所 述接线端子与所述交流出线铜排电连接。
5、 根据权利要求 4所述的功率模块， 其特征在于， 所述交流出线铜排套 设在所述接线端子上。
6、 根据权利要求 1所述的功率模块， 其特征在于， 所述平板式散热器上 还设置有电容支撑架， 所述电容支撑架上安装有支撑电容， 所述支撑电容的 输入端分别与变流器上的主电路电连接。
7、 根据权利要求 6所述的功率模块， 其特征在于， 所述直流正铜排和直 流负铜排分别与所述支撑电容的输出端电连接。
8、 根据权利要求 7所述的功率模块， 其特征在于， 还包括：
电源分线板， 所述电源分线板具有一个输入端和多个输出端， 用于将外 界通过输入端输入的直流电源分别通过多个输出端连接到各驱动电路板上。
9、根据权利要求 1所述的功率模块，其特征在于，所述功率单元为 3组， 用于作为变流器中逆变器的功率部件；
或者， 所述功率单元为 4组， 其中任意三组作为变流器中逆变器的功率 部件， 另一组作为变流器中斩波器的功率部件。
10、 一种变流器， 包括主电路和功率模块， 其特征在于， 所述功率模块 为采用权利要求 1 ~ 9任一所述的功率模块。
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