WO2013081097A1

WO2013081097A1 - Power control unit

Info

Publication number: WO2013081097A1
Application number: PCT/JP2012/081048
Authority: WO
Inventors: 鈴木智幸; 友影良二; 久米泰尚
Original assignee: 本田技研工業株式会社
Priority date: 2011-11-30
Filing date: 2012-11-30
Publication date: 2013-06-06

Abstract

This power control unit (30) to be installed on a vehicle (10) is equipped with: a power conversion module (60) for converting direct-current power of a battery (18) into alternating-current power; and a capacitor module (80) for smoothing the electric power from the battery (18). The capacitor module (80) has power supply terminals (112a, 112b) for connecting to the battery (18), module terminals (112a, 112b) for connecting to the power conversion module (60), and electric device terminals (110a, 110b, 114a, 114b) for connecting to electric devices (62, 82, 84, 98a, 98b) other than the power conversion module (60). The power supply terminals (112a, 112b), the module terminals (112a, 112b), and the electric device terminals (110a, 110b, 114a, 114b) are electrically connected to one another.

Description

Power control unit

The present invention relates to a power control unit.

Japanese Patent Laid-Open No. 2011-20625 describes that current from a battery is input to a converter, and current from the battery is branched in the converter to supply current to an inverter, a quick charge port, a compressor, and the like. .

When branching current in this manner, it is common to use a current branching device. When an inverter, converter, etc. are housed in the power control unit, the power control unit is used when the current branching device is used. The size itself increases.

Therefore, an object of the present invention is to provide a power control unit that branches a current without using a current branching device and supplies the current to devices in the power control unit.

The present invention, in a power control unit mounted on a vehicle, includes a power conversion module that converts DC power of a battery into AC power, and a capacitor module that smoothes power from the battery, the capacitor module comprising: A power supply terminal for connecting to the battery; a module terminal for connecting to the power conversion module; and an electrical device terminal for connecting to an electrical device other than the power conversion module; The terminal for module, the terminal for module, and the terminal for electric device are electrically connected to each other.

In this way, the capacitor module is provided with the power supply terminal, the module terminal, and the electrical device terminal, so that the capacitor module can branch the current, and there is no need to use a separate current branching device. Thereby, a power control unit can be reduced in size.

The power conversion module may have a connection terminal connected to the module terminal of the capacitor module, and the power supply terminal may also serve as the module terminal. Thereby, the number of terminals to be provided can be reduced, and the cost can be suppressed.

The power conversion module, the capacitor module, and the electric device are housed in the same housing, and the electric device is at least one of a charger, a device for quick charging, a fuse, a DC / DC converter, and a contactor. It may be the above.

The power conversion module and the rapid charging device and / or fuse as the electric device are provided on the upper surface side of the heat sink, and the charger and the DC / DC converter as the electric device are provided on the lower surface side of the heat sink. The capacitor module is fixed on the power conversion module so as to be suspended from the inner wall of the casing of the power control unit, and a power cable connected to the battery passes through the through hole of the heat sink from below. Inserted into the power control unit and connected to the power supply terminal. The electrical device terminal includes a first electrical device terminal and a second electrical device terminal provided across the power supply terminal. And the through hole includes the first electric device terminal and the second electric device. Is formed from the scan terminals closer to the power supply terminal, the a first electrical device terminals and terminal the second electrical device may be connected to different said electrical device.

According to the power control unit of the present invention, the capacitor module has a power supply terminal, a module terminal, and an electrical device terminal, and the power supply terminal, the module terminal, and the electrical device terminal are electrically connected to each other. Therefore, the capacitor module can branch the current, and it is not necessary to use a separate current branching device, thereby reducing the size of the power control unit.

1 is a perspective view schematically illustrating a schematic configuration of an electric vehicle according to an embodiment. 1 is a schematic configuration side view schematically showing a schematic configuration of an electric vehicle according to an embodiment. It is an external appearance perspective view of the power control unit shown in FIG. FIG. 4 is an exploded perspective view of the power control unit shown in FIG. 3. It is a top view of the heat sink shown in FIG. It is a bottom view of the lower case shown in FIG. It is a circuit diagram of a power control unit. FIG. 6 is a cross-sectional view taken along line VIII-VIII in FIG. 5. FIG. 6 is a cross-sectional view taken along line IX-IX in FIG. 5. FIG. 6 is a top view when an upper case is disposed on the heat sink of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An electric vehicle having a power control unit according to the present invention will be described in detail below with reference to the accompanying drawings with preferred embodiments.

FIG. 1 is a schematic configuration perspective view schematically illustrating a schematic configuration of an electric vehicle (vehicle) 10, and FIG. 2 is a schematic configuration side view schematically illustrating the schematic configuration of the electric vehicle 10. In the present embodiment, the vertical direction of the vehicle body 12 is the vertical direction, and the direction perpendicular to the vertical direction is the horizontal direction. Further, the traveling direction of the electric vehicle 10 is the front, the backward direction is the rear, the left direction is the left and the right direction is the right toward the traveling direction.

The electric vehicle 10 includes a battery 18 that outputs a high voltage between the

front wheels

14L and 14R and the

rear wheels

16L and 16R and is provided at the bottom of the vehicle body 12, and a floor panel 20 inside the vehicle body 12. A vehicle compartment 22 provided above the battery 18, a motor room 24 separated from the vehicle compartment 22 and partitioned in front of the vehicle body 12, a dash panel 26 covering the motor room 24, and a lower part of the dash panel 26 And a power control unit (Power Control Unit) 30 mounted above a traveling motor (external electric device) 28 which is a kind of rotating electrical machine provided in the motor room 24. The dash panel 26 includes a dash panel lower 26a and a dash panel upper 26b. The dash panel 26 divides the motor room 24 and the vehicle compartment 22 and has a structure that prevents entry of dirt, water, odor, and the like from the motor room 24. In addition, the dash panel 26 has a water discharge function that prevents an inflow of water from the outside from flowing into the A / C (air conditioner) pipe.

The power cable 34 is for transmitting the power stored in the battery 18 to the power control unit 30. One end of the power cable 34 is connected to the power connector 36 of the battery 18, and the other end of the power control unit 30. It is connected to a power connector 94 (see FIG. 7). The power control unit 30 converts the DC power supplied from the battery 18 into three-phase (U, V, W-phase) AC power, and supplies the converted three-phase AC power to the traveling motor 28. The drive motor 28 is driven and controlled.

The power control unit 30 controls the power conversion module 60 (see FIGS. 4, 5, and 7) that converts DC power into three-phase AC and the ECU 70 that drives the traveling motor 28 by controlling the power conversion module 60 (see FIG. 4). 4 and FIG. 7). The traveling motor 28 and the power control unit 30 are connected via a three-phase AC power cable (power supply line) 38, and one end of the three-phase AC power cable 38 is connected to the power connector 40 of the traveling motor 28. The other end of the three-phase AC power cable 38 is connected to the power connector 42 (

power connectors

42a, 42b, 42c) of the power control unit 30. Since the power control unit 30 is disposed above the traveling motor 28, the high-voltage three-phase AC power cable 38 can be shortened.

3 is an external perspective view of the power control unit 30, and FIG. 4 is an exploded perspective view of the power control unit 30. The power control unit 30 includes a heat sink 50, an upper case 52 provided on the upper part of the heat sink 50, an upper cover 54 covering the upper part of the upper case 52, a lower case 56 provided on the lower part of the heat sink 50, and a lower part of the lower case 56. And a lower cover 58 for covering. The heat sink 50, the upper case 52, the upper cover 54, the lower case 56, and the lower cover 58 constitute a casing of the power control unit 30.

A power conversion module (electric device) 60 is provided at substantially the center of the upper surface of the heat sink 50, and a quick charging device (electric device) 62 used for charging the battery 18 from the outside, a

fuse

98a, 98b (see FIGS. 5 and 7) and the like, and on the upper left side of the heat sink 50, three-

phase terminals

64a, 64b, 64c for connecting the power conversion module 60 and the

power connectors

42a, 42b, 42c of the upper case 52 are provided. (Hereinafter, they may be collectively referred to as three-phase terminals 64). The power conversion module 60 converts the DC power of the battery 18 into three-phase (U, V, W phase) AC power and outputs the converted AC power of each phase to the three-

phase terminals

64a, 64b, 64c. The three-

phase terminals

64 a, 64 b, 64 c are supported from below by a three-phase terminal block 66 having an intermediate portion provided on the left side of the upper surface of the heat sink 50. The three-phase terminal block 66 includes a heat conductive member, and transfers heat of the three-

phase terminals

64 a, 64 b, 64 c to the heat sink 50.

The power conversion module 60 incorporates a switching module having a plurality of switching elements in the housing. By turning on and off the plurality of switching elements, the power conversion module 60 converts the DC power from the battery 18 into three-phase AC power, or the driving motor 28 converts the three-phase AC power into DC power. .

With the heat sink 50 and the upper case 52, a charging device chamber 72 for storing the quick charging device 62, a fuse chamber 74 for storing fuses (electric devices) 98a and 98b, a power conversion chamber 76 for storing the power conversion module 60, A three-phase terminal chamber 78 that houses the three-

phase terminals

64a, 64b, and 64c is formed. The charging device chamber 72 has a first opening (charging device chamber opening) 72a formed on the upper surface of the upper case 52 that allows access to the charging device chamber 72, and the fuse chamber 74 is a fuse chamber. The power conversion chamber 76 has a second opening (fuse chamber opening) 74 a formed on the upper surface of the upper case 52 that allows access to the inside of the power conversion chamber 74. The power conversion chamber 76 allows access to the power conversion chamber 76. The three-phase terminal chamber 78 has a third opening (power conversion chamber opening) 76 a formed on the upper surface of the upper case 52, and the three-phase terminal chamber 78 allows access to the three-phase terminal chamber 78. It has the 4th opening part (three-phase terminal chamber opening part) 78a formed in the upper surface (refer FIG. 4, FIG. 10). An ECU (control device) 70 that controls the power conversion module 60 is provided in the charging device chamber 72 above the quick charging device 62.

The upper cover 54 includes a first upper cover 54a that covers the first opening 72a, a second upper cover 54b that covers the second opening 74a, a third upper cover 54c that covers the third opening 76a, and a fourth opening. And a fourth upper cover 54d covering the portion 78a. Since the charging device chamber 72 is formed higher than the fuse chamber 74, the power conversion chamber 76, and the three-phase terminal chamber 78, the first opening 72a is compared to the second opening 74a to the fourth opening 78a. It is formed at a high position.

A capacitor module 80 having a smoothing capacitor 96 (see FIG. 7) is mounted on the inner wall of the upper case 52 above the power conversion module 60 and below the third opening 76a. The smoothing capacitor 96 is electrically connected to the power conversion module 60 and smoothes the power from the battery 18. The capacitor module 80 has a smoothing capacitor 96 housed in a housing.

On the bottom surface of the lower case 56, a battery charger (electric device) 82 for charging the battery 18 and a battery 18 for supplying low voltage power to a low voltage system device (electrical component) mounted on the electric vehicle 10 are provided. A DC / DC converter (electric device) 84 that reduces the voltage is provided. The DC / DC converter 84 and the charger 82 are housed in a rectangular casing, and the casing of the charger 82 that has a larger number of parts and is likely to be larger than the DC / DC converter 84 is the DC / DC converter 84. Larger than the housing.

The heat sink 50 has an inflow portion 86 into which a fluid flows and an outflow portion 88 from which the fluid flows out. A flow path (not shown) through which the fluid flows is formed by the bottom surface of the heat sink 50 and the upper surface of the lower case 56. The fluid flowing in from the inflow portion 86 flows out from the outflow portion 88 through the flow path formed by the heat sink 50 and the lower case 56. The fluid that flows in from the inflow portion 86 flows out from the outflow portion 88 through the flow path formed by the heat sink 50 and the lower case 56. As a result, the heat sink 50 generates heat from the power conversion module 60 and the quick charging device 62 provided on the upper surface side of the heat sink 50 and the charger 82 and the DC / DC converter 84 provided on the lower surface side of the heat sink 50. The amount of heat generated can be dissipated and cooled.

5 is a top view of the heat sink 50, FIG. 6 is a bottom view of the lower case 56, and FIG. 7 is a circuit diagram of the power control unit 30. 8 is a partial cross-sectional view taken along line VIII-VIII in FIG. 5, and FIG. 9 is a partial cross-sectional view taken along line IX-IX in FIG.

The power conversion module 60 is connected to a power connector 94 (see FIG. 7), and the power conversion module 60 and the battery 18 are connected by connecting the battery 18 to the power connector 94 via the power cable 34. A smoothing capacitor 96 of a capacitor module 80 for smoothing the voltage is connected in parallel between the power conversion module 60 and the battery 18. The capacitor module 80 is electrically connected to the DC / DC converter 84, the charger 82, the rapid charging device 62, and the

fuses

98a and 98b by a bus bar.

Thus, the DC / DC converter 84, the charger 82, the quick charging device 62, and the

fuses

98a and 98b are connected to the battery 18. The bus bar is formed by punching a metal plate such as a copper plate. The rapid charging device 62 includes a diode (rapid charging diode) 100, a first main contactor (first rapid charging contactor) 102, a second main contactor (second rapid charging contactor) 104, a resistor R, and a pre-contactor. 106. In this way, high voltage components (power conversion module 60, DC / DC converter 84, charger 82, and quick charge device 62) are housed in a single housing, so that they can be connected by a bus bar without using a high voltage cable. Thus, the power control unit 30 can be reduced in size, and the cost can be reduced.

As shown in FIG. 5, the capacitor module 80 includes a first positive terminal 110 a and a first negative terminal 110 b (electric device terminal, first electric device terminal), a second positive terminal 112 a and a second negative terminal 112 b ( A power source terminal, a module terminal), a third positive terminal 114a and a third negative terminal 114b (an electrical device terminal, a second electrical device terminal), and a first positive terminal 110a and a second positive terminal 112a. , And the third positive terminal 114a are electrically connected to each other, and the first negative terminal 110b, the second negative terminal 112b, and the third negative terminal 114b are electrically connected to each other. The second positive terminal 112a and the second negative terminal 112b are connected to the power connector 94 via the

bus bars

115a and 115b and the

power cables

94a and 94b (see FIG. 6), whereby the second positive terminal 112a. Are connected to the positive side of the battery 18 and the second negative terminal 112b is connected to the negative side of the battery 18, respectively.

The first positive terminal 110a, the first negative terminal 110b, the second positive terminal 112a, the second negative terminal 112b, the third positive terminal 114a, and the third negative terminal 114b are provided in a row in the above order, and the first positive terminal The terminal 110a and the first negative terminal 110b, and the third positive terminal 114a and the third negative terminal 114b are provided across the second positive terminal 112a and the second negative terminal 112b.

As shown in FIG. 8, the power conversion module 60 includes a connection positive terminal 117a (connection terminal) connected to the second positive terminal 112a, and includes a connection positive terminal 117a, a second positive terminal 112a, and a bus bar 115a. One end is fixed in contact with a bolt B. As shown in FIG. 9, the power conversion module 60 has a connection negative terminal 117b (connection terminal) connected to the second negative terminal 112b, and includes a connection negative terminal 117b, a second negative terminal 112b, and a bus bar 115b. One end is fixed in contact with a bolt B.

The

power cables

94a and 94b are inserted into the power control unit 30 through the through

holes

50a and 50b formed in the heat sink 50 from below and connected to the other ends of the

bus bars

115a and 115b. The through

holes

50a and 50b are the second of the first positive terminal 110a and the first negative terminal 110b, the second positive terminal 112a and the second negative terminal 112b, and the third positive terminal 114a and the third negative terminal 114b. It may be formed at a position closest to the positive terminal 112a and the second negative terminal 112b.

The second positive terminal 112a and the second negative terminal 112b function as terminals connected to the connection positive terminal 117a and connection negative terminal 117b, and function as terminals connected to the

bus bars

115a and 115b. You may make it provide separately the terminal (module terminal) connected to 117a and the connection negative terminal 117b, and the terminal (power supply terminal) connected to bus-

bar

115a, 115b. Also in this case, the module terminal, the power supply terminal, the first positive terminal 110a and the first negative terminal 110b, and the third positive terminal 114a and the third negative terminal 114b are electrically connected to each other. .

The first positive terminal 110a, one end of the

fuses

98a and 98b, and the cathode of the diode 100 are connected by a single bus bar 116, and the bus bar 116 and the battery 18 are at the same potential. The other end of the fuse 98a not connected to the first positive terminal 110a is connected to the air conditioner compressor (air conditioning compressor) 118, and the other end of the fuse 98b not connected to the first positive terminal 110a is connected to the heater 120. (See FIG. 7). The power control unit 30 may include a normal mode coil or a common mode coil in the fuse chamber 74, and a normal mode coil or a common mode coil may be connected to the other end of the fuse 98a.

The cathode of the diode 100 is connected to one end of the first main contactor 102 via the resistor R and the pre-contactor 106, and the anode of the diode 100 is connected to the one end of the first main contactor 102 by the bus bar 122. The first negative terminal 110 b is connected to one end of the second main contactor 104 by the bus bar 124.

5 and 6, the third positive terminal 114a is connected to the fourth positive terminal 130a of the charger 82 by the bus bars 126 and 128, and the fifth positive terminal 134a of the DC / DC converter 84 by the bus bars 126 and 132. The third negative terminal 114b is connected to the fourth negative terminal 130b of the charger 82 by the bus bars 136 and 138 and to the fifth negative terminal 134b of the DC / DC converter 84 by the bus bars 136 and 140. .

The sixth positive terminal 142a and the sixth negative terminal 142b of the charger 82 are connected to the connector 92 via the cable 92a, and the seventh positive terminal 144a and the seventh negative terminal 144b of the DC / DC converter 84 are connected to the power control unit 30. Is connected to a cable 146 led out to the outside. As a result, the power stepped down by the DC / DC converter 84 can be supplied to the low-voltage device mounted on the electric vehicle 10 by the cable 146.

As shown in FIG. 5, the power conversion module 60 has a U-phase terminal 148a, a V-phase terminal 148b, and a W-phase terminal 148c. A three-phase terminal 64a is connected to the U-phase terminal 148a, and a V-phase terminal 148b. Are connected to the three-phase terminal 64b, and the W-phase terminal 148c is connected to the three-phase terminal 64c.

As shown in FIG. 6, the DC / DC converter 84 and the charger 82 are arranged so that their longitudinal directions are orthogonal to each other, and the long side of the DC / DC converter 84 and the short side of the charger 82 are adjacent to each other. Has been placed.

When the plug 93 connected to the connector 92 is connected to a commercial outlet, 100V or 200V AC power is supplied to the charger 82, and the charger 82 normally charges the battery 18 (see FIG. 7).

Note that reference numeral 214 is a current sensor that detects a current flowing through each of the three-

phase terminals

64a, 64b, and 64c.

FIG. 10 is a top view when the upper case 52 is disposed above the heat sink 50 of FIG. In FIG. 10, the illustration of the capacitor module 80 is omitted. The upper case 52 is provided with a quick charging connector 152. The other end of the first main contactor 102 and the other end of the second main contactor 104 are connected to the quick charging connector 152 via

bus bars

154a and 154b. Is done. Connected to the quick charging connector 152 is a connector 158 that is connected to a charger-side connector 156 of a quick charger (not shown) for supplying high-voltage DC power (not shown) provided in a service area or a power supply station (see FIG. 7). . By connecting the charger side connector 156 and the connector 158 of the quick charger, the quick charger rapidly charges the battery 18.

Thus, the capacitor module 80 is provided with the first positive terminal 110a and the first negative terminal 110b, the second positive terminal 112a and the second negative terminal 112b, the third positive terminal 114a and the third negative terminal 114b, The first positive terminal 110a, the second positive terminal 112a, and the third positive terminal 114a are electrically connected (electrically connected), and the first negative terminal 110b, the second negative terminal 112b, and the third negative terminal 114b are electrically connected ( Therefore, the capacitor module 80 can branch the current, so that it is not necessary to use a separate current branching device, whereby the power control unit 30 can be downsized.

Further, the second positive terminal 112a and the second negative terminal 112b of the capacitor module 80 function as terminals connected to the connection positive terminal 117a and the connection negative terminal 117b of the power conversion module 60, and are also terminals connected to the battery 18. Therefore, it is not necessary to separately provide a terminal for the power conversion module 60 and a terminal for the battery 18, and the cost can be reduced.

As mentioned above, although this invention was demonstrated using suitable embodiment, the technical scope of this invention is not limited to the range as described in the said embodiment. It will be apparent to those skilled in the art that various modifications or improvements can be added to the above embodiment. It is apparent from the scope of the claims that the embodiments added with such changes or improvements can be included in the technical scope of the present invention.

Claims

In the power control unit (30) mounted on the vehicle (10),
A power conversion module (60) for converting DC power of the battery (18) into AC power;
A capacitor module (80) for smoothing power from the battery (18);
With
The capacitor module (80) includes power supply terminals (112a, 112b) for connection to the battery (18), and module terminals (112a, 112b) for connection to the power conversion module (60). Electrical device terminals (110a, 110b, 114a, 114b) for connecting to electrical devices (62, 82, 84, 98a, 98b) other than the power conversion module (60);
The power supply terminals (112a, 112b), the module terminals (112a, 112b), and the electrical device terminals (110a, 110b, 114a, 114b) are electrically connected to each other. Power control unit (30).
In the power control unit (30) according to claim 1,
The power conversion module (60) has connection terminals (117a, 117b) connected to the module terminals (112a, 112b) of the capacitor module (80),
The power control unit (30), wherein the power terminals (112a, 112b) also serve as the module terminals (112a, 112b).
In the power control unit (30) according to claim 1 or 2,
The power conversion module (60), the capacitor module (80), and the electric device (62, 82, 84, 98a, 98b) are housed in the same casing,
The electrical devices (62, 82, 84, 98a, 98b) include a charger (82), a device for quick charging (62), a fuse (98a, 98b), a DC / DC converter (84), and a contactor (102, 104) A power control unit (30), characterized in that at least one of them.
In the power control unit (30) according to claim 2,
On the upper surface side of the heat sink (50), the power conversion module (60), the device (62) for quick charging and / or the fuse (98a, 98b) which are the electric devices (62, 82, 84, 98a, 98b), A charger (82) which is the electrical device (62, 82, 84, 98a, 98b) and a DC / DC converter (84) are provided on the lower surface side of the heat sink (50),
The capacitor module (80) is fixed on the power conversion module (60) so as to be suspended from the inner wall of the casing of the power control unit (30).
The power cables (94a, 94b) connected to the battery (18) are inserted into the power control unit (30) from below through the through holes (50a, 50b) of the heat sink (50), and the power source Connected to the terminals (112a, 112b),
The electrical device terminals (110a, 110b, 114a, 114b) are a first electrical device terminal (110a, 110b) and a second electrical device terminal (sandwiched between the power supply terminals (112a, 112b)). 114a, 114b)
The through holes (50a, 50b) are formed closer to the power supply terminals (112a, 112b) than the first electric device terminals (110a, 110b) and the second electric device terminals (114a, 114b). And
The first electrical device terminals (110a, 110b) and the second electrical device terminals (114a, 114b) are connected to different electrical devices (62, 82, 84, 98a, 98b). Power control unit (30) to do.