WO2021199804A1 - 電力変換装置 - Google Patents

電力変換装置 Download PDF

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Publication number
WO2021199804A1
WO2021199804A1 PCT/JP2021/007125 JP2021007125W WO2021199804A1 WO 2021199804 A1 WO2021199804 A1 WO 2021199804A1 JP 2021007125 W JP2021007125 W JP 2021007125W WO 2021199804 A1 WO2021199804 A1 WO 2021199804A1
Authority
WO
WIPO (PCT)
Prior art keywords
converter
sensor
electric
bus bar
power conversion
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/JP2021/007125
Other languages
English (en)
French (fr)
Japanese (ja)
Inventor
侑也 橋本
優 山平
俊幸 甲埜
弘洋 一条
和哉 竹内
村上　達也
哲矢 松岡
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Denso Corp
Original Assignee
Denso Corp
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 Denso Corp filed Critical Denso Corp
Priority to CN202180024591.4A priority Critical patent/CN115336160A/zh
Priority to DE112021002009.9T priority patent/DE112021002009T5/de
Publication of WO2021199804A1 publication Critical patent/WO2021199804A1/ja
Priority to US17/954,593 priority patent/US12081137B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • 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
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007—Plural converter units in cascade
    • 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
    • H02M3/00—Conversion of DC power input into DC power output
    • H02M3/02—Conversion of DC power input into DC power output without intermediate conversion into AC
    • H02M3/04—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters
    • H02M3/10—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M3/145—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M3/155—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/156—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators
    • H02M3/158—Conversion of DC power input into DC power output without intermediate conversion into AC by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of output voltage or current, e.g. switching regulators including plural semiconductor devices as final control devices for a single load
    • 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
    • H02M7/42—Conversion of DC power input into AC power output without possibility of reversal
    • H02M7/44—Conversion of DC power input into AC power output without possibility of reversal by static converters
    • H02M7/48—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H02M7/5387—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
    • H02M7/53871—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration with automatic control of output voltage or current
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/04—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
    • H02P27/06—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters
    • H02P27/08—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters with pulse width modulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/04—Arrangements for controlling or regulating the speed or torque of more than one motor

Definitions

  • the present disclosure relates to a power conversion device including a coreless current sensor.
  • Patent Document 1 discloses a power converter used in a vehicle.
  • the power converter in Patent Document 1 converts a DC voltage from a DC power source into a three-phase AC and supplies it to a motor.
  • the power converter includes a converter that boosts the DC voltage from the DC power supply and an inverter that converts the DC voltage into a three-phase AC.
  • the power converter of Patent Document 1 includes a current sensor used for detecting the current of each phase supplied from the inverter to the motor and the current flowing through the converter.
  • the current sensor is provided by a resin terminal unit incorporating a plurality of bus bars for passing a current to be detected and a plurality of sensor elements corresponding to each bus bar. That is, the terminal unit in the power converter of Patent Document 1 functions as a housing that integrally supports all of the bus bar and the sensor element.
  • the components of the converter may include members that generate a large amount of heat, such as reactors. Therefore, the temperature of the converter bus bar that allows the current flowing through the converter to flow as a detection target is more likely to rise than other bus bars due to the connection with the components of the converter that generate a large amount of heat.
  • the bus bar and the sensor element are integrally supported in one housing. Therefore, in Patent Document 1, the temperature of the electric sensor that detects the current to the rotating electric machine may rise excessively as the temperature of the converter bus bar rises due to heat transfer through the housing. Excessive temperature rise of the electric sensor may reduce the accuracy of detecting the current to the rotating electric machine.
  • An object of the present disclosure is to provide a power conversion device capable of suppressing a temperature rise of an electric sensor due to a temperature rise of a converter bus bar.
  • the power converter of the present disclosure for achieving the above object is an inverter that provides a three-phase AC to a rotary electric machine, a converter that converts a voltage between a DC power supply and the inverter, and an inverter and a rotary electric machine.
  • An electric bus bar that allows current to flow a coreless electric sensor that detects the current flowing through the electric bus bar based on a magnetic field, an electric sensor housing that houses the electric sensor integrally with the electric bus bar, and a converter bus bar that allows current to flow through the converter.
  • a coreless converter sensor that detects the current flowing through the converter bus bar based on a magnetic field, and a converter sensor housing that is separated from the electric sensor housing and houses the converter sensor integrally with the converter bus bar.
  • the converter sensor housing that houses the converter bus bar and the converter sensor is separated from the inverter sensor housing that houses the inverter sensor.
  • Heat transfer is less likely to occur between the converter sensor housing and the inverter sensor housing, which are separated from each other, as compared with the case where they are configured as an integral housing. Therefore, heat transfer from the converter bus bar to the inverter sensor is suppressed as compared with the case where each bus bar and each sensor are held in an integral housing. Therefore, even when the temperature of the converter bus bar rises, the temperature rise of the inverter sensor is suppressed.
  • the power conversion device 100 according to the embodiment of the present disclosure will be described with reference to the drawings. First, the circuit configuration of the power conversion device 100 will be described with reference to FIG.
  • the power conversion device 100 is used in a vehicle such as an electric vehicle or a hybrid vehicle equipped with a rotating electric machine used as a traveling drive source.
  • the power conversion device 100 is a device that converts electric power between the rotary electric machine 1 and the DC power supply 2.
  • the rotary electric machine 1 is a three-phase AC type rotary electric machine.
  • the vehicle is provided with, for example, two rotary electric machines 1 including a first rotary electric machine 1a and a second rotary electric machine 1b.
  • the first rotary electric machine 1a is mainly used as a traveling drive source for a vehicle.
  • the second rotary electric machine 1b is mainly used as a generator that generates electricity by utilizing the rotational driving force of the internal combustion engine of the vehicle.
  • the DC power supply 2 is a power supply unit that outputs a DC power supply, including a rechargeable secondary battery such as a lithium ion battery.
  • the power conversion device 100 converts the DC voltage from the DC power supply 2 into a three-phase AC to the first rotary electric machine 1a. As a result, the power conversion device 100 causes the first rotary electric machine 1a to drive the vehicle with the electric power charged in the DC power supply 2. As another example, the power conversion device 100 converts the three-phase alternating current from the second rotating electric machine 1b, which generates electricity by the rotational driving force of the internal combustion engine, into three-phase alternating current having a different frequency and the like, and converts the first rotating electric machine into three-phase alternating current. Output to 1a.
  • the applications of the first rotary electric machine 1a and the second rotary electric machine 1b in the vehicle are not limited to those described above, and can be appropriately changed, added, or replaced according to the design of the vehicle to be used. Therefore, the operation of the power conversion device 100 is not limited to that described above, and can be appropriately changed, added, or replaced.
  • the power conversion device 100 includes a filter capacitor 110, a converter 120, a smoothing capacitor 130, an inverter 140, a first sensor unit 150, a second sensor unit 160, and a control circuit unit 170.
  • the filter capacitor 110 is a capacitor provided between the positive electrode line 3P connected to the positive electrode of the DC power supply 2 and the negative electrode line 3N connected to the negative electrode.
  • the filter capacitor 110 functions as a filter for removing noise of the DC voltage supplied from the DC power supply 2 to the converter 120.
  • the converter 120 is a conversion circuit unit that converts a DC voltage into a DC voltage having a different value, including a plurality of semiconductor switching elements and reactors. In this embodiment, a reverse conduction insulated gate bipolar transistor is used as the semiconductor switching element.
  • the converter 120 is used for converting a DC voltage between the DC power supply 2 and the inverter 140. As an example, the converter 120 operates to boost the DC voltage provided as the voltage between the positive electrode line 3P and the negative electrode line 3N from the DC power supply 2.
  • the converter 120 has a function of providing the boosted voltage to the inverter 140 as the voltage of the high potential line 4H and the low potential line 4L.
  • the converter 120 has upper and lower arms arranged to connect between the high potential line 4H and the low potential line 4L, which are mainly composed of two semiconductor switching elements connected in series. Further, the converter 120 has a reactor 121 arranged to connect a connection point between semiconductor switching elements and a positive electrode line 3P. That is, one end of the reactor 121 is connected to the connection point between the semiconductor switching elements, and the other end is connected to the positive electrode of the DC power supply 2 and one end of the filter capacitor 110.
  • the converter 120 of the present embodiment is configured as a so-called two-phase converter including two sets of buck-boost circuits by the set of the upper and lower arms and the reactor 121 described above.
  • the smoothing capacitor 130 is a capacitor provided between the high potential line 4H and the low potential line 4L.
  • the smoothing capacitor 130 has a function of smoothing the DC voltage provided between the high potential line 4H and the low potential line 4L by the converter 120 or the like.
  • the inverter 140 is a conversion circuit unit that includes a plurality of semiconductor switching elements and performs conversion between a DC voltage and a three-phase alternating current.
  • the inverter 140 converts a DC voltage and a three-phase alternating current between the high-potential line 4H and the low-potential line 4L and the rotating electric machine 1 corresponding to the inverter 140.
  • the power conversion device 100 of the present embodiment includes two inverters 140, a first inverter 140a and a second inverter 140b.
  • the first inverter 140a is connected to the first rotary electric machine 1a.
  • the first inverter 140a converts, for example, the DC voltage between the high potential line 4H and the low potential line 4L into three-phase alternating current and outputs it to the first rotary electric machine 1a.
  • the second inverter 140b is connected to the second rotary electric machine 1b.
  • the second inverter 140b rectifies the three-phase alternating current from the second rotary electric machine 1b and outputs it as a DC voltage between the high potential line 4H and the low potential line 4L.
  • the inverter 140 has three upper and lower arms corresponding to three phases one-to-one in an arrangement that connects the high-potential line 4H and the low-potential line 4L in parallel with each other.
  • the circuit configuration of the upper and lower arms of the inverter 140 in this embodiment has the same circuit configuration as the upper and lower arms of the converter 120.
  • the connection points between the semiconductor switchings in the upper and lower arms of each phase are connected to the corresponding phase of the rotary electric machine 1 corresponding to the inverter 140.
  • the first sensor unit 150 is used to detect the current flowing between the inverter 140 and the rotary electric machine 1.
  • the first sensor unit 150 of the present embodiment individually detects the magnitude and direction of the three-phase current flowing between the first inverter 140a and the first rotary electric machine 1a. Further, the first sensor unit 150 individually and sequentially detects the magnitude and direction of the three-phase current flowing between the second inverter 140b and the second rotary electric machine 1b.
  • the second sensor unit 160 is used to detect the current flowing through the converter 120. Specifically, the second sensor unit 160 individually and sequentially detects the magnitude and direction of the current flowing through the two reactors 121 of the converter 120. The second sensor unit 160 of the present embodiment detects the current flowing between each reactor 121 and the upper and lower arms. The second sensor unit 160 transmits a detection signal indicating the current flowing through each detected reactor 121 to the control circuit unit 17 Output to 0.
  • the control circuit unit 170 is a group of circuits that exert a function of controlling the operation of the semiconductor switching elements of the converter 120 and the inverter 140.
  • the control circuit unit 170 is mainly composed of, for example, a memory as a substantive storage medium in which control software is recorded non-transitionally, and a microcomputer including a processor that executes the software.
  • the control circuit unit 170 controls the operation of each semiconductor switching element based on the current detected by the second sensor unit 160 and the first sensor unit 150. By controlling each semiconductor switching element, power conversion by a power conversion device is realized.
  • control circuit unit 170 sets a target fluctuation pattern of the current flowing through each phase of the first rotary electric machine 1a based on the output torque request of the first rotary electric machine 1a from the upper ECU of the vehicle.
  • the control circuit unit 170 feedback-controls the first inverter 140a so that the output current to the first rotary electric machine 1a fluctuates along the target fluctuation pattern. That is, the control circuit unit 170 drives each semiconductor switching element of the first inverter 140a based on the output current from the first inverter 140a detected by the first sensor unit 150.
  • the power conversion device 100 includes a conversion device housing 10, a semiconductor device 30, a cooler 20, a reactor unit 40, a first capacitor unit 50, a second capacitor unit 60, a first sensor unit 70, and a first power conversion device 100.
  • the two sensor units 80 are provided.
  • the conversion device housing 10 is a housing that houses each member constituting the power conversion device 100.
  • the conversion device housing 10 is formed of, for example, a metal material in a substantially rectangular parallelepiped shape having an accommodation space inside.
  • An output terminal opening 11 is formed on the outer wall of the conversion device housing 10. It can be said that the output terminal opening 11 corresponds to a connector for connecting the rotary electric machine 1 to the power conversion device 100.
  • the output terminal opening 11 exposes the first sensor unit 70 to the outside of the conversion device housing 10.
  • the cooler 20 is a device that cools the semiconductor device 30 by, for example, circulating water as a refrigerant inside. Water that has been cooled by the radiator and supplied to the power converter 100 flows through the cooler 20.
  • the cooler 20 has a plurality of refrigerant flow paths 21 that branch and flow the supplied water in an arrangement arranged in the Y direction. Each refrigerant flow path 21 extends along the X direction.
  • a semiconductor device 30 is arranged between the refrigerant flow paths 21.
  • the semiconductor device 30 is a device in which a semiconductor switching element and a connecting member used for electrical connection of the semiconductor switching element are integrally packaged by resin sealing or the like.
  • Each semiconductor device 30 of the present embodiment includes a semiconductor switching element corresponding to one upper and lower arm, and a connecting member thereof.
  • Each semiconductor device 30 has a substantially rectangular plate shape with its main surface facing the Y direction. The semiconductor devices 30 are stacked along the Y direction with the refrigerant flow path 21 interposed therebetween.
  • Each semiconductor device 30 includes three main terminals, a high potential side terminal 31H, a low potential side terminal 31L, and a connection point terminal 31M.
  • the high-potential side terminal 31H corresponds to a connection point of the upper and lower arms with the high-potential line 4H.
  • the low-potential side terminal 31L corresponds to a connection point of the upper and lower arms with the low-potential line 4L.
  • the connection point terminal 31M corresponds to a connection point between the semiconductor switching elements of the upper and lower arms.
  • the three main terminals included in each semiconductor device 30 project from the surface of the semiconductor device 30 facing the Z direction in an arrangement arranged along the X direction. Of the three main terminals arranged along the X direction, the main terminal located at the end on the first sensor unit 70 side corresponds to the connection point terminal 31M.
  • the power conversion device 100 of this embodiment includes eight semiconductor devices 30. Specifically, the power conversion device 100 includes three first electric devices 30a, three second electric devices 30b, and two converter devices 30c as semiconductor devices 30.
  • the first electric device 30a is a semiconductor device 30 constituting the first inverter 140a. That is, the three first electric devices 30a individually correspond to the three-phase upper and lower arms of the first inverter 140a. Of the eight semiconductor devices 30 arranged in the Y direction, the three on the side farther from the reactor unit 40 correspond to the first electric device 30a.
  • the second electric device 30b is a semiconductor device 30 that constitutes the second inverter 140b. That is, the three second electric devices 30b individually correspond to the three-phase upper and lower arms of the second inverter 140b. Of the eight semiconductor devices 30 arranged in the Y direction, the third to fifth devices 30 from the reactor unit 40 side correspond to the second electric device 30b.
  • the converter device 30c is a semiconductor device 30 that constitutes the converter 120. That is, the two converter devices 30c individually correspond to the two-phase upper and lower arms of the converter 120. Of the eight semiconductor devices 30 arranged in the Y direction, two on the reactor unit 40 side correspond to the converter device 30c.
  • the reactor unit 40 is a device in which the reactor 121 is integrally packaged together with an accessory member such as a core and a connecting member made of a magnetic material. Inside the reactor unit 40 of the present embodiment, two reactors 121 used in the two-phase converter 120 are resin-sealed so as to be insulated from each other. One end of each reactor 121 is pulled out from the reactor unit 40 and is connected to the second condenser unit 60, respectively. The other end of each reactor 121 is pulled out from the reactor unit 40 and is connected to the second sensor unit 80, respectively.
  • the reactor unit 40 of the present embodiment is arranged so as to be aligned with the semiconductor device 30 housed in the cooler 20 in the Y direction.
  • the first capacitor unit 50 is a device in which a capacitor corresponding to a smoothing capacitor 130 is integrally packaged together with an accessory member such as a connecting member. In the first capacitor unit 50, both ends of the built-in smoothing capacitor 130 are connected to the high potential side terminal 31H and the low potential side terminal 31L of each semiconductor device 30.
  • the first capacitor unit 50 of the present embodiment is arranged so as to be aligned with the semiconductor device 30 housed in the cooler 20 in the X direction.
  • the second capacitor unit 60 is a device in which a capacitor corresponding to the filter capacitor 110 is integrally packaged together with an accessory member such as a connecting member.
  • the second capacitor unit 60 connects one end of the built-in filter capacitor 110 to one end of each reactor 121 built in the reactor unit 40.
  • the second capacitor unit 60 of the present embodiment is arranged so as to line up with the reactor unit 40 in the Y direction.
  • the second condenser unit 60 is arranged so as to partially overlap the cooler 20 in the projection view in the Z direction.
  • the first sensor unit 70 is a device in which members for realizing the function as the first sensor unit 150 are integrally packaged.
  • the first sensor unit 70 is arranged so as to line up with the semiconductor device 30 housed in the cooler 20 in the X direction. Specifically, the first sensor unit 70 is located on the side opposite to the first condenser unit 50 with respect to the cooler 20 in the X direction.
  • the first sensor unit 70 includes an electric sensor housing 71, an electric bus bar 72, an electric sensor 73, an electric sensor board 74, and an electric sensor shield 75.
  • the electric sensor housing 71 is a member formed of an insulating material such as resin for integrally supporting each member constituting the first sensor unit 70.
  • the electric sensor housing 71 has a rectangular parallelepiped shape with the longitudinal direction in the Y direction.
  • An electric bus bar 72 and an electric sensor shield 75 are embedded in the electric sensor housing 71 by insert molding.
  • the electric sensor board 74 on which the electric sensor 73 is mounted is housed in the accommodation space formed inside the electric sensor housing 71.
  • the electric sensor housing 71 integrally accommodates each electric sensor 73 so that the position with respect to the electric bus bar 72 is maintained.
  • Fastening portions for fixing the first sensor unit 70 are provided at both ends of the electric sensor housing 71 in the Y direction.
  • the electric bus bar 72 is a conductive member that allows a current flowing between the inverter 140 and the rotary electric machine 1, which is the detection target current of the first sensor unit 70, to flow.
  • the electric bus bar 72 is formed in a strip shape that is partially bent by a conductive material such as copper.
  • the first sensor unit 70 of the present embodiment has six electric bus bars that correspond one-to-one to each of the first electric device 30a and the second electric device 30b.
  • each electric bus bar 72 is connected to the connection point terminal 31M of the corresponding first electric device 30a or the second electric device 30b by welding or the like.
  • Each electric bus bar 72 extends along the X direction as a whole and penetrates the electric sensor housing 71. Therefore, the X direction corresponds to the stretching direction of the electric bus bar 72.
  • the portion of each electric bus bar 72 located inside the electric sensor housing 71 has a strip-like shape in which the main surface extends in the X direction toward the Z direction.
  • a connector terminal portion 72a is formed in a portion of each electric bus bar 72 that is exposed from the side opposite to the semiconductor device 30 of the electric sensor housing 71.
  • Each connector terminal portion 72a has a plate shape with its main surface facing in the X direction, and is formed with a through hole for fastening a connection cable with the rotary electric machine 1. That is, the first sensor unit 70 also functions as an output terminal block for the rotary electric machine 1.
  • the electric sensor 73 is a device for detecting the current flowing through the electric bus bar 72.
  • the electric sensor 73 detects the flowing current by detecting the strength of the magnetic field generated by the flowing current.
  • the electric sensor 73 is a sensor package including a semiconductor chip on which a magnetoelectric conversion element such as a magnetoresistive effect element is formed.
  • the electric sensor 73 outputs, for example, a detection value indicating the strength and direction of the magnetic field along the detection axis in a predetermined direction at its own position as an electric signal corresponding to the magnitude of the current.
  • the first sensor unit 70 of the present embodiment has two electric sensors 73 that correspond one-to-one to the six electric bus bars 72.
  • Each electric sensor 73 is arranged so as to face the corresponding electric bus bar 72 along the Z direction in a posture in which the detection axis is in the Y direction. That is, the electric sensor 73 detects the magnetic field in the Y direction generated at the position in the Z direction with respect to the electric bus bar 72 by the current along the X direction.
  • the six electric sensors 73 are arranged along the Y direction at a pitch that matches the pitch of the electric bus bar 72 in the Y direction.
  • a member made of a magnetic material is not provided in the middle of the electric sensor 73 in the Y direction. That is, each electric sensor 73 is configured as a coreless current sensor without a magnetic collecting core surrounding the electric bus bar 72.
  • the electric sensor board 74 is a circuit board in which wiring made of copper or the like is provided on a flat plate-shaped base material made of, for example, epoxy resin.
  • the electric sensor substrate 74 is formed in a rectangular plate shape with the main surface facing in the Z direction and the longitudinal direction in the Y direction.
  • a connector for electrical connection with the control circuit unit 170 and the like are mounted on the electric sensor board 74.
  • the electric sensor board 74 on which each electric sensor 73 is mounted is housed inside the electric sensor housing 71.
  • the electric sensor shield 75 is a magnetic shield member formed in a rectangular plate shape by a magnetic material.
  • the electric sensor shield 75 is in a posture in which the main surface is directed in the Z direction and the longitudinal direction is the Y direction.
  • the first sensor unit 70 has two electric sensor shields 75 arranged so as to sandwich the electric sensor 73 and the electric bus bar 72 in the Z direction.
  • Each electric sensor shield 75 extends in the Y direction so as to straddle the six converter sensors 83 arranged in the Y direction and covers each electric sensor 73.
  • Each electric sensor shield 75 suppresses the influence of the external magnetic field of the first sensor unit 70 on the detected value of the electric sensor 73.
  • Each electric sensor shield 75 is embedded inside the electric sensor housing 71.
  • the second sensor unit 80 is a device in which members for realizing the function as the second sensor unit 160 are integrally packaged.
  • the second sensor unit 80 of the present embodiment is located between the semiconductor device 30 and the reactor unit 40 in the Y direction.
  • the second sensor unit 80 includes a converter sensor housing 81, a converter bus bar 82, a converter sensor 83, a converter sensor board 84, and a converter sensor shield 85.
  • the converter sensor housing 81 is a member for supporting each member constituting the second sensor unit 80, which is formed of the same insulating material as the electric sensor housing 71.
  • the converter housing 81 of the present embodiment has a rectangular parallelepiped shape with the longitudinal direction in the X direction.
  • a converter bus bar 82 and a converter sensor shield 85 are embedded in the converter sensor housing 81 by insert molding.
  • the converter sensor housing 81 is arranged so as to be separated from the electric sensor housing 71. That is, the converter sensor housing 81 and the electric sensor housing 71 are arranged so as not to come into contact with each other.
  • the converter sensor board 84 on which the converter sensor 83 is mounted is accommodated in the accommodation space formed inside the converter sensor housing 81.
  • the converter sensor housing 81 integrally accommodates each converter sensor 83 so that its position with respect to the converter bus bar 82 is maintained.
  • Fastening portions for fixing the second sensor unit 80 are provided at both ends of the converter sensor housing 81 in the X direction.
  • the converter bus bar 82 is a conductive member that allows the current flowing through the converter 120, which is the detection target current of the second sensor unit 80, to flow. More specifically, the converter bus bar 82 is a conductive member that allows the current flowing through the reactor 121 of the converter 120 to flow.
  • the converter bus bar 82 is formed in the shape of a partially bent strip plate by the same conductive material as the electric bus bar 72.
  • the second sensor unit 80 includes two converter buses 82 that individually correspond to the two reactors 121.
  • Each converter bus bar 82 of the present embodiment connects one end of the corresponding reactor 121 to the connection point terminal 31M of the converter device 30c corresponding to the reactor 121.
  • Each converter bus bar 82 of the present embodiment is connected to the connection point terminal 31M in an arrangement that is drawn out from the connection point terminal 31M along the X direction.
  • Each converter bus bar 82 is bent at a position closer to the semiconductor device 30 than the electric sensor 73 in the X direction, and extends toward the reactor unit 40 along the Y direction.
  • each converter bus bar 82 A part of the portion extending along the Y direction of each converter bus bar 82 is housed inside the converter sensor housing 81.
  • a detected portion 82a that is detected by the converter sensor 83.
  • the stretching direction of the detected portion 82a is along the direction intersecting the X direction. More specifically, the detected portion 82a extends along the Y direction, which is a direction orthogonal to the X direction.
  • the detected portion 82a is formed as a section having a shape in which the main surface extends in a band shape in the Y direction toward the Z direction.
  • the portion of each converter bus bar 82 exposed from the converter sensor housing 81 is arranged so as not to come into contact with the electric sensor housing 71 and to be separated from each other.
  • the converter sensor 83 is a device for detecting the current flowing through the converter bus bar 82.
  • the converter sensor 83 detects the flowing current by detecting the strength of the magnetic field generated by the flowing current.
  • a sensor package having the same configuration as the electric sensor 73 is adopted as the converter sensor 83. Therefore, like the electric sensor 73, the converter sensor 83 outputs a detection value indicating the strength and direction of the magnetic field along the detection axis in a predetermined direction at its own position as an electric signal corresponding to the magnitude of the current.
  • the second sensor unit 80 of the present embodiment has two converter sensors 83 that correspond one-to-one to the two converter bus bars 82.
  • Each converter sensor 83 is arranged so as to face the detected portion 82a of the corresponding converter bus bar 82 along the Z direction in a posture in which the detection axis is in the X direction. That is, the converter sensor 83 detects the magnetic field in the X direction generated at the position in the Z direction with respect to the detected portion 82a by the current along the Y direction.
  • the detection axis of the converter sensor 83 is in the direction along the stretching direction of the electric bus bar 72.
  • Each converter sensor 83 and each electric sensor 73 are located on substantially the same plane defined by the X direction and the Y direction.
  • the two converter sensors 83 are arranged along the Y direction at a pitch that matches the pitch of the detected portion 82a in the Y direction.
  • a member made of a magnetic material is not provided in the middle of the converter sensor 83 in the Y direction. That is, each converter sensor 83 is configured as a coreless current sensor without a magnetic collecting core surrounding the converter bus bar 82. Therefore, each current sensor included in the power conversion device 100 is configured as a coreless current sensor.
  • the distance between the converter sensor 83 and the converter device 30c is shorter than the distance between the first electric device 30a or the second electric device 30b and the electric sensor 73.
  • the converter sensor distance D2 is shorter than the electric sensor distance D1.
  • the electric sensor distance D1 is the distance between the connection point terminal 31M of the first electric device 30a or the second electric device 30b and the electric sensor 73 in the X direction.
  • the converter sensor distance D2 is the distance between the connection point terminal 31M of the converter device 30c and the converter sensor 83 in the X direction.
  • the electric sensor distance D1 is longer than the capacitor distance D3.
  • the capacitor distance D3 is the distance between the high potential side terminal 31H of the first electric device 30a or the second electric device 30b and the first capacitor unit 50 in the X direction. That is, the electric sensor 73 is arranged to be farther from the semiconductor device 30 than the smoothing capacitor 130 and the converter sensor 83 in the X direction.
  • the converter sensor board 84 is a circuit board similar to the electric sensor board 74.
  • the converter sensor substrate 84 is formed in a rectangular plate shape with the main surface facing in the Z direction and the longitudinal direction in the X direction.
  • On the converter sensor board 84 in addition to the two converter sensors 83, a connector for electrical connection with the control circuit unit 170 and the like are mounted.
  • the converter sensor board 84 on which each converter sensor 83 is mounted is housed inside the converter sensor housing 81. Therefore, the converter sensor board 84 is provided in the second sensor unit 80 as a circuit board separate from the electric sensor board 74.
  • the converter sensor shield 85 is a rectangular plate-shaped magnetic shield member formed of the same magnetic material as the electric sensor shield 75.
  • the converter sensor shield 85 is in a posture in which the main surface is directed in the Z direction and the longitudinal direction is in the X direction.
  • the second sensor unit 80 has two converter sensor shields 85 arranged so as to sandwich the converter sensor 83 and the converter bus bar 82 in the Z direction.
  • Each converter sensor shield 85 extends in the X direction so as to straddle the two converter sensors 83 arranged in the X direction and covers each converter sensor 83 in the projection view in the Z direction.
  • Each converter sensor shield 85 suppresses the influence of the external magnetic field of the second sensor unit 80 on the detected value of the converter sensor 83.
  • Each converter sensor shield 85 is embedded inside the converter sensor housing 81. Therefore, each converter sensor shield 85 is provided in the second sensor unit 80 as a magnetic shield member separate from the electric sensor shield 75.
  • the converter sensor housing 81 accommodating the converter bus bar 82 and the converter sensor 83 is separated from the electric sensor housing 71 accommodating the electric sensor 73.
  • Heat transfer is less likely to occur between the converter sensor housing 81 and the electric sensor housing 71, which are separated from each other, as compared with the case where they are configured as an integral housing. Therefore, heat transfer from the converter bus bar 82 to the electric sensor 73 is suppressed as compared with the case where each bus bar and each sensor are held in an integral housing. Therefore, even when the temperature of the converter bus bar 82 rises, the temperature rise of the electric sensor 73 is suppressed.
  • the configuration in which the electric sensor housing 71 and the converter sensor housing 81 described above are separated from each other reduces crosstalk between the first sensor unit 150 and the second sensor unit 160 in addition to the above-mentioned effects.
  • the effect of That is, the component due to the current of the converter bus bar 82 can be superimposed on the detected value of the electric sensor 73.
  • a component due to the current of the electric bus bar 72 may be superimposed on the detected value of the converter sensor 83. Since the electric sensor housing 71 and the converter sensor housing 81 are separated from each other, the superposition of such components is reduced as compared with the case of the contact arrangement.
  • the detected portion 82a of the converter bus bar 82 is stretched along a direction intersecting the stretching direction of the electric bus bar 72, specifically, a direction orthogonal to the stretching direction.
  • the components along the direction of the magnetic field by the detected unit 82a are reduced. Therefore, in the detection value of the converter sensor 83 that detects the magnetic field by the detected unit 82a, the superposition of noise due to the current flowing through the electric bus bar 72 is further suppressed.
  • the distance between the electric sensor 73 and the first electric device 30a or the second electric device 30b in the X direction is larger than the distance between the converter device 30c and the converter sensor 83.
  • the length of the converter bus bar 82 may be excessively increased. That is, the length of the converter bus bar can be increased by detouring from the converter device in a direction different from that of the reactor.
  • the power conversion device can reduce the switching noise in the detection value of the electric sensor 73 while suppressing the increase in the length of the converter bus bar 82.
  • the electric bus bar 72 is formed with a connector terminal portion 72a for connecting the rotary electric machine 1 to the power conversion device 100. That is, the first sensor unit 70 also functions as an output terminal block of the power conversion device 100. Therefore, the power conversion device 100 can be connected to the rotary electric machine 1 without additionally providing an output terminal block. Therefore, the physique of the power converter 100 is further reduced in addition to the reduction by adopting the coreless current sensor.
  • the current detection position by the second sensor unit 160 is the position between the converter 120 and the filter capacitor 110. In other words, it is located on the filter capacitor 110 side with respect to the reactor 121. That is, as shown in FIG. 5, the converter bus bar 82 is arranged to connect the reactor 121 of the converter 120 and the filter capacitor 110. That is, the position to be detected by the second sensor unit 160 moves away from the semiconductor switching element and approaches the filter capacitor 110. Therefore, with such an arrangement, switching noise due to the semiconductor switching element in the current flowing through the converter bus bar 82 is suppressed.
  • the power conversion device 100 includes two inverters 140 connected to each of the two rotary electric machines 1.
  • the number of rotary electric machines 1 connected to the power conversion device 100 and the number of inverters 140 connected to them may be one or three or more. Therefore, the number of the electric bus bar 72 and the electric sensor 73 included in the first sensor unit 70 can be appropriately changed accordingly.
  • the converter 120 can adopt a configuration in which it is a single-phase converter or a three-phase or more multi-phase converter. Therefore, the number of converter bus bars 82 and converter sensors 83 included in the second sensor unit 80 can be appropriately changed accordingly.
  • the converter sensor 83 detects the magnetic field of the converter bus bar 82 by the detected portion 82a that stretches in the direction orthogonal to the stretching direction of the electric bus bar 72.
  • the converter sensor 83 may be configured to detect the magnetic field due to the portion of the converter bus bar 82 extending in parallel with the electric bus bar 72.
  • the converter sensor 83 is arranged at a position closer to the semiconductor device 30 than the electric sensor 73 in the X direction.
  • the distance from the semiconductor device 30 in the X direction may be substantially the same as the distance between the converter sensor 83 and the electric sensor 73, or the converter sensor 83 may be farther.
  • the first sensor unit 70 also functions as an output terminal block of the power conversion device 100.
  • the output terminal block may be provided separately from the first sensor unit 70.
  • the converter 120 has a circuit configuration having an upper and lower arms mainly composed of a semiconductor switching element and a reactor 121.
  • the circuit configuration of the converter 120 is not limited to the above, and can be changed as appropriate.
  • the combination of the members connected through the converter bus bar 82 is also changed as appropriate. That is, if the converter 120 is arranged so as to allow a current to flow through any part of the converter 120, the arrangement of the converter bus bar 82 is not limited to the arrangement of the above-described embodiment. In other words, the constituent members of the converter 120 that cause the temperature rise of the converter bus bar 82 are not limited to the reactor 121.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)
  • Control Of Ac Motors In General (AREA)
PCT/JP2021/007125 2020-03-31 2021-02-25 電力変換装置 Ceased WO2021199804A1 (ja)

Priority Applications (3)

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CN202180024591.4A CN115336160A (zh) 2020-03-31 2021-02-25 电力转换装置
DE112021002009.9T DE112021002009T5 (de) 2020-03-31 2021-02-25 Stromrichter
US17/954,593 US12081137B2 (en) 2020-03-31 2022-09-28 Power converter

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JP2020062637A JP2021164243A (ja) 2020-03-31 2020-03-31 電力変換装置
JP2020-062637 2020-03-31

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US12081137B2 (en) 2020-03-31 2024-09-03 Denso Corporation Power converter
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US12081137B2 (en) 2024-09-03
JP2021164243A (ja) 2021-10-11
US20230020456A1 (en) 2023-01-19
DE112021002009T5 (de) 2023-01-26

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