WO2021001048A1 - Système de module de puissance électrique - Google Patents

Système de module de puissance électrique Download PDF

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Publication number
WO2021001048A1
WO2021001048A1 PCT/EP2019/068026 EP2019068026W WO2021001048A1 WO 2021001048 A1 WO2021001048 A1 WO 2021001048A1 EP 2019068026 W EP2019068026 W EP 2019068026W WO 2021001048 A1 WO2021001048 A1 WO 2021001048A1
Authority
WO
WIPO (PCT)
Prior art keywords
module
add
electric power
base module
base
Prior art date
Application number
PCT/EP2019/068026
Other languages
English (en)
Inventor
Christoffer WEDDING
Andreas STOCKMAN
Emil SJUNNESSON
Original Assignee
Volvo Truck Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Volvo Truck Corporation filed Critical Volvo Truck Corporation
Priority to PCT/EP2019/068026 priority Critical patent/WO2021001048A1/fr
Publication of WO2021001048A1 publication Critical patent/WO2021001048A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/20927—Liquid coolant without phase change
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0063—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with circuits adapted for supplying loads from the battery
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/14—Mounting supporting structure in casing or on frame or rack
    • H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
    • H05K7/1427—Housings
    • H05K7/1432—Housings specially adapted for power drive units or power converters
    • H05K7/14327—Housings specially adapted for power drive units or power converters having supplementary functional units, e.g. data transfer modules or displays or user interfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2210/00—Converter types
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2207/00—Indexing scheme relating to details of circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J2207/20—Charging or discharging characterised by the power electronics converter
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2310/00—The network for supplying or distributing electric power characterised by its spatial reach or by the load
    • H02J2310/40—The network being an on-board power network, i.e. within a vehicle
    • H02J2310/48—The network being an on-board power network, i.e. within a vehicle for electric vehicles [EV] or hybrid vehicles [HEV]
    • 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
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H02M1/327—Means for protecting converters other than automatic disconnection against abnormal temperatures
    • 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 invention relates to an electric power module system for use in an electrically operated vehicle. It further relates to a power system of a vehicle, to an on-board battery charger of a vehicle, and to a vehicle comprising an electric power module system.
  • the invention can be applied in heavy-duty vehicles, such as trucks, buses and construction equipment. Although the invention will be described with respect to a bus, the invention is not restricted to this particular vehicle, but may also be used in other vehicles such as trucks and passenger cars.
  • a vehicle can be operated by means of an electric machine solely (all-electric vehicle), or by means of an arrangement comprising both an electric machine and an internal combustion engine.
  • the latter alternative is often referred to as a hybrid vehicle (HEV), and can for example be utilised in a manner in which an internal combustion engine is used for operating the vehicle while driving outside urban areas whereas the electric machine can be used in urban areas or in environments in which there is a need to limit the discharge of harmful pollutants such as carbon monoxide and oxides of nitrogen.
  • a vehicle being operated by means of an internal combustion engine and an electric machine supplied with power from a rechargeable energy storage system is often referred to as a plug-in hybrid electric vehicle (PHEV).
  • PHEV plug-in hybrid electric vehicle
  • a plug-in hybrid electric vehicle uses an energy storage system with rechargeable batteries or another suitable energy source which can be restored into a condition involving a full charge through a connection to an external electric power supply.
  • a powertrain of an electrically operated vehicle comprises on one hand an energy storage system (ESS) including batteries, and on the other hand one or more electric motors for propulsion of the vehicle.
  • the powertrain typically comprises power converter modules for converting direct current (DC) to alternating current (AC), such as inverters, for converting AC to DC, such as rectifiers, and for AC to AC conversion, such as transformers.
  • DC direct current
  • AC alternating current
  • modules used in vehicles are e.g. traction inverters, static converters, auxiliary converters, energy storage converters, generator converters, bidirectional inverters, and static inverters. In order not to overheat the power converter modules, efficient cooling is needed.
  • Power converters are also used in on-board battery charging of electrically operated vehicles, in which they are used to convert and control AC from an external electric power supply to DC suitable for battery charging. Furthermore, power converters are used to convert power for use in auxiliary systems of the vehicle or in other systems powered via a power system of the vehicle, such as in various systems provided on a trailer of a truck. An example of such a system is a cooling system of a cooling trailer, powered via a power system provided in the truck.
  • US201 1168476 discloses a power module system for a hybrid drive system.
  • the power module system comprises a basic converter module configured to be connected to a first electric machine, and a supplementary converter module configured to be mounted to the basic module and connected to a second electric machine.
  • the basic module further comprises cooling connections for supplying liquid coolant to a cooling channel provided in the basic module.
  • the supplementary module may be cooled via the basic module.
  • An object of the invention is to provide an electric power module system for an electrically operated vehicle, which is in at least some aspect improved in comparison with prior art systems and which is suitable both for use in on-board chargers and in a powertrain of the vehicle.
  • it is an object to provide a scalable electric power module system having a compact design.
  • Another object is to provide an in at least some aspect improved powertrain of an electrically operated vehicle.
  • at least one of the objects is achieved by an electric power module system for use in an electrically operated vehicle according to claim 1.
  • the electric power module system comprises: a base module in the form of a first power conversion module comprising at least one external electrical connection for power input to and/or power output from the electric power module system,
  • an add-on module in the form of a second power conversion module configured to be mounted to and electrically connected to the base module, so that the add-on module, when mounted, can be powered via the base module,
  • the base module comprises a cooling passage for fluid coolant and coolant connections for supplying fluid coolant to the cooling passage, wherein the cooling passage is provided on a side of the base module configured to face the add-on module when mounted, so that the add-on module can be cooled via said cooling passage, and wherein the add-on module is configured to, when mounted to the base module, increase a power conversion capacity of the electric power module system, so that a maximum amount of converted power available via the at least one external electrical connection of the base module is increased.
  • the add-on module Since an external electrical connection of the electric power module system is only provided on the base module, the add-on module has the function of adding power conversion capacity to the base module, i.e. increasing the maximum amount of power that may be made available via the external electrical connection of the base module, thanks to the connection between the base module and the add-on module.
  • the add-on module may purely be added for increasing a power conversion capacity of the system.
  • the base module and the add-on module are thus not used in the powering of separate machines, but in the powering of the same machine, or in the same process (e.g. in a battery charging process).
  • the electric power module system may be used in a power system of an electrically operated vehicle, such as in a powertrain of such a vehicle, or in connection with e.g. an on-board battery charger of such a vehicle.
  • the power conversion modules may be configured for DC to DC power conversion, for AC to AC power conversion, for AC to DC power conversion, or for DC to AC power conversion.
  • the power conversion modules may e.g. be traction inverters, static converters, auxiliary converters, energy storage converters, generator converters, bidirectional inverters, or static inverters.
  • both modules may be power conversion modules of the same type.
  • the electric power module system further comprises power connection means for electrically connecting the modules to each other via mutually facing and connected sides of the modules.
  • the connection between the modules may thereby be hidden when the modules are mounted together, so that the electric power module system becomes more easy to handle and so that the connection is better protected when in use.
  • a sealing member may preferably be provided to separate the connection from the cooling passage, such as a sealing member extending around and outlining the cooling passage.
  • the electric power module system further comprises signal connection means for communicating signals between the modules via mutually facing and connected sides of the modules, wherein the base module comprises at least one external signal connection.
  • the base module comprises at least one external signal connection.
  • the add-on module may thus comprise electrical and signal connections only on its side configured to face the base module.
  • the base module further comprises a removable first lid configured to be removed prior to mounting the add-on module to the base module. This makes it possible to hide e.g. connection means for electrically connecting to the add-on module under the lid, and thereby protect such connection means when the base module is to be used independently of the add-on module.
  • a first connection interface for electrically and/or communicatively connecting the base module to the add-on module is covered by the removable first lid.
  • the first connection interface is thereby protected when the base module is used without the add on module.
  • the add-on module further comprises a removable second lid configured to be removed before mounting the add-on module to the base module. This makes the add-on module easier to handle when not mounted.
  • a second connection interface for electrically and/or communicatively connecting the add-on module to the base module is covered by the removable second lid. The connections are thereby efficiently protected by the lid.
  • the cooling passage is delimited by at least a first delimiting surface provided on the base module and a second delimiting surface provided on the add-on module, so that fluid coolant supplied via the coolant connections of the base module comes into contact with both of said delimiting surfaces.
  • fluid coolant e.g. liquid coolant
  • the cooling passage is only delimited by surfaces provided on the base module.
  • a more compact and space efficient design can be achieved.
  • the cooling passage is delimited by at least the first delimiting surface provided on the base module and a third delimiting surface provided on the removable first lid. This makes it possible to delimit and define the otherwise open cooling passage when the base module is to be used on its own, separately from the add-on module.
  • the electric power module system further comprises at least one sealing member for sealing the cooling passage.
  • the sealing member may e.g. be a rubber sealing or a gasket configured to seal off the cooling passage when either the add-on module or the first removable lid is mounted on the base module, thereby preventing leakage of fluid coolant from the cooling passage.
  • a power system of a vehicle comprising:
  • an electric power module system wherein the base module is electrically connected to the energy storage system and to the at least one electric machine, and wherein the add-on module is mounted to and electrically connected to the base module and configured to increase a power conversion capacity of the electric power module system, so that a maximum amount of converted power available via the at least one external electrical connection of the base module is increased.
  • the power system may e.g. be a powertrain of the vehicle, or a power system for powering auxiliary systems or devices. Advantages and advantageous embodiments of such a power system appear from the above description of the electric power module system.
  • an on-board battery charger of an electrically operated vehicle comprising the proposed electric power module system
  • the base module is configured to be electrically connected to an energy storage system and to an external alternating current power supply
  • the add-on module is mounted to and electrically connected to the base module and configured to increase a power conversion capacity of the electric power module system, so that a maximum amount of converted power available via the at least one external electrical connection of the base module is increased.
  • the invention also relates to a vehicle comprising an electric power module system according to the first aspect of the invention.
  • the vehicle may preferably be a heavy-duty vehicle, such as a truck or a bus.
  • the vehicle may preferably be an electrically operated heavy-duty vehicle.
  • the vehicle may comprise the proposed power system and/or the proposed on-board battery charger. Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims.
  • Fig. 1 is a perspective view of an electric power module system according to an embodiment of the invention
  • Fig. 2 is a top view of a base module of the electric power module system in fig. 1
  • Fig. 3 is a bottom view of an add-on module of the electric power module system in fig.
  • Fig. 4 is a sectional view of a part of the electric power module system in fig. 1 ,
  • Fig. 5 is a schematic view of a power system comprising the electric power module system according to an embodiment of the invention
  • Fig. 6 schematically shows a vehicle comprising the electric power module system according to an embodiment of the invention. It is to be noted that all drawings are schematic. Details may thus be omitted and the various features may not be drawn to scale.
  • the electric power module system 1 comprises a base module 2 in the form of a power converter and an add-on module 3, also in the form of a power converter.
  • the electric power module system 1 is intended to be mounted in a power system 13 of an electrically operated vehicle and connected to on one hand an energy storage system (ESS) 14, comprising one or more battery packs providing input power to the base module 2, and on the other hand an electric machine 15 powered by the ESS 14 via the base module 2.
  • ESS energy storage system
  • the electric power module system 1 may alternatively be configured for use in or in connection with an on board charger, in which case it is configured to be connected to an external AC power supply and to an energy storage system, e.g. a battery pack, and for AC-DC power conversion.
  • a cooling passage 5 for fluid coolant, a coolant input connection 6 and a coolant output connection 7 for connection to a fluid coolant supply system are provided on the base module 2.
  • the base module 2 further comprises an external electrical connection 4 (see fig. 1 ) for power input to and power output from the electric power module system 1.
  • the external connection 4 may be configured e.g. for AC input and output, and for DC input and output, i.e. for independently connecting to different power sources and power consumers.
  • Both modules 2,3, have basic shapes of rectangular cuboids.
  • the cooling passage 5 is herein provided on an upper side 16 of the base module configured to face a lower side 17 of the add-on module 3, shown in fig. 3, while the electrical connection 4 and the coolant connections 6, 7 are provided on a side face 18 of the base module 2.
  • An external signal connection 12 for communicating signals to the electric power module system 1 is further provided on the side face 18 of the base module 2.
  • a first connection interface 8 is provided on the base module 2, and a second connection interface 9 is provided on the add-on module 3, for signal communication between and for electrical connection of the modules 2, 3.
  • more than one external electrical connection may be provided on the base module.
  • the add-on module 3 is in fig. 1 mounted to and electrically connected to the base module 2 via the connection interfaces 8, 9.
  • the add-on module 3, when mounted, can thereby be cooled and powered via the base module 2.
  • the cooling passage 5 is delimited by a first delimiting surface 10 provided on the upper side 16 of the base module 2 and a second delimiting surface 1 1 provided on the lower side 17 of the add-on module 3.
  • the delimiting surfaces 10, 1 1 are formed as channels in the respective upper side 16 and lower side 17.
  • the sealing member 19 is shown as being provided on the add-on module 3, but it may also be mounted on the base module, or on each of the base module and the add-on module.
  • the cooling passage may instead be completely delimited by surfaces provided on the base module, so that fluid coolant does not come into direct contact with any surface of the add-on module.
  • the cooling passage should be located sufficiently close to the add-on module such that cooling of the add-on module may still be achieved.
  • the base module 2 further comprises a removable first lid (not shown) configured to be mounted to the base module 2 instead of the add-on module 3 so that, when the removable first lid is mounted, the cooling passage 5 is delimited by the first delimiting surface 10 provided on the base module 2 and a third delimiting surface (not shown) provided on the removable first lid.
  • the removable first lid may be configured so that the cooling passage 5 has the same configuration regardless of whether the first lid or the add-on module 3 is mounted to the base module 2.
  • the removable first lid may also be configured to, when mounted, cover and hide the first connection interface 8.
  • the add-on module 3 may also comprise a removable second lid (not shown) configured to be mounted to the add-on module 3 instead of the base module 2.
  • the second lid covers the second delimiting surface 11 of the add-on module 3, and also the second connection interface 9 for electrically and communicatively connecting the add-on module 3 to the base module 2.
  • Means for mechanically connecting the add-on module to the base module may be provided, e.g. female and male fastening members. In the shown embodiment, purely by way of example, this is illustrated by a plurality of holes 20 provided on the base module 2 on the add-on module 3, configured to receive plugs, screws, pins or similar to connect the modules.
  • Fig. 6 schematically shows an electrically operated vehicle 21 in which the electric power module system 1 may be used.
  • the vehicle 21 is propelled by a schematically illustrated powertrain 13 comprising an energy storage system 14 with a plurality of battery units, an electric power module system 1 , and an electric machine 15 for propelling drive wheels 22 of the vehicle 21.
  • a schematically illustrated powertrain 13 comprising an energy storage system 14 with a plurality of battery units, an electric power module system 1 , and an electric machine 15 for propelling drive wheels 22 of the vehicle 21.
  • this is merely an example serving to illustrate how the electric power module system 1 may be used in a vehicle. It may also be used in connection with e.g. on-board charging of an energy storage system of the vehicle, or in the conversion of power used by other systems or devices on the vehicle or on e.g. trailers connected to the vehicle, such as various auxiliary systems and devices.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Human Computer Interaction (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)

Abstract

L'invention concerne un système de module de puissance électrique (1) destiné à être utilisé dans un véhicule électrique (21), comprenant : un module de base comprenant un passage de refroidissement pour le liquide de refroidissement et des raccords de liquide de refroidissement pour alimenter le passage de refroidissement en liquide de refroidissement, le module de base comprenant en outre au moins une connexion électrique externe pour une entrée de puissance et/ou une sortie de puissance du système de module de puissance électrique ; et un module complémentaire conçu pour être monté sur le module de base et connecté électriquement à celui-ci, de telle sorte que le module complémentaire, lorsqu'il est monté, peut être refroidi et alimenté par l'intermédiaire du module de base. Le module complémentaire est conçu pour, lorsqu'il est monté sur le module de base, augmenter une capacité de conversion de puissance du système de module de puissance électrique, de telle sorte qu'une quantité maximale de puissance convertie disponible par l'intermédiaire de la ou des connexions électriques externes du module de base est augmentée.
PCT/EP2019/068026 2019-07-04 2019-07-04 Système de module de puissance électrique WO2021001048A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2019/068026 WO2021001048A1 (fr) 2019-07-04 2019-07-04 Système de module de puissance électrique

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2019/068026 WO2021001048A1 (fr) 2019-07-04 2019-07-04 Système de module de puissance électrique

Publications (1)

Publication Number Publication Date
WO2021001048A1 true WO2021001048A1 (fr) 2021-01-07

Family

ID=67185033

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2019/068026 WO2021001048A1 (fr) 2019-07-04 2019-07-04 Système de module de puissance électrique

Country Status (1)

Country Link
WO (1) WO2021001048A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004254358A (ja) * 2003-02-18 2004-09-09 Mitsubishi Electric Corp 電力変換装置
US20110168476A1 (en) 2010-01-11 2011-07-14 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Hybrid drive of a hybrid vehicle
US20130044434A1 (en) * 2011-08-15 2013-02-21 Lear Corporation Power module cooling system
US20130241486A1 (en) * 2010-11-22 2013-09-19 Honda Motor Co., Ltd. Power control unit for electric vehicle
US20180168075A1 (en) * 2015-05-18 2018-06-14 Calsonic Kansei Corporation Power converter
US20190023201A1 (en) * 2017-07-20 2019-01-24 NextEv USA, Inc. Integrated power systems for electric vehicles

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2004254358A (ja) * 2003-02-18 2004-09-09 Mitsubishi Electric Corp 電力変換装置
US20110168476A1 (en) 2010-01-11 2011-07-14 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Hybrid drive of a hybrid vehicle
US20130241486A1 (en) * 2010-11-22 2013-09-19 Honda Motor Co., Ltd. Power control unit for electric vehicle
US20130044434A1 (en) * 2011-08-15 2013-02-21 Lear Corporation Power module cooling system
US20180168075A1 (en) * 2015-05-18 2018-06-14 Calsonic Kansei Corporation Power converter
US20190023201A1 (en) * 2017-07-20 2019-01-24 NextEv USA, Inc. Integrated power systems for electric vehicles

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