WO2021210202A1

WO2021210202A1 - Power control device and current detection substrate

Info

Publication number: WO2021210202A1
Application number: PCT/JP2020/040723
Authority: WO
Inventors: 正憲桃木; 俊史岡野; 聡司柳田
Original assignee: 新電元工業株式会社
Priority date: 2020-04-14
Filing date: 2020-10-29
Publication date: 2021-10-21
Also published as: CN115380463A; JP7242963B2; DE112020007077T5; JPWO2021210202A1

Abstract

This power control device comprises: a switching substrate comprising a wiring pattern that electrically connects a battery and a three-phase AC motor and a plurality of switching elements connected to the wiring pattern; a control substrate that comprises a first through hole that passes therethrough in the thickness direction thereof and a Rogowski coil formed around the first through hole; and a power-supply-side terminal member that electrically connects the battery and the wiring pattern of the switching substrate. The control substrate is disposed at a prescribed interval from the switching substrate, and the power-supply-side terminal member is inserted into the first through hole.

Description

Power control device and current detection board

The present disclosure relates to a power control device and a current detection board.

Japanese Patent No. 6570797 discloses a power control device (rotary machine control device) that controls power supplied from a power source to a power supply target (motor). In this power control device, the control circuit controls the switching of the switching element based on the value of the output current detected by the shunt resistor, and converts the direct current on the power supply side into an alternating current.

In the apparatus described in Japanese Patent No. 6570797, when a large current flows in the control circuit, the calorific value of the shunt resistor increases and the resistance value changes significantly, so that there is a problem that the current detection accuracy by the shunt resistor decreases. be. Further, in the device, the switching element generates a larger amount of heat than other electronic elements, but since the shunt resistor is also mounted on the substrate on which the switching element is mounted, the shunt resistance affects the heat generation of the switching element. It is easily received, and there is a problem that the current detection accuracy is lowered due to this.

The present disclosure has been made to solve the above problems, and an object of the present disclosure is to improve the current detection accuracy in a power control device provided with a current detection means and a current detection substrate used in the power control device. ..

The power control device according to the present disclosure includes a wiring pattern that electrically connects a power source and a power supply target, a switch board having a plurality of switching elements connected to the wiring pattern, and a through hole penetrating in the plate thickness direction. A coil substrate having a Rogowski coil pattern formed around the through hole, and a power supply side terminal member for electrically connecting the power supply and the wiring pattern of the switch substrate. The coil boards are arranged at predetermined intervals with respect to the switch board, and the power supply side terminal members are arranged in a state of being inserted into the through holes of the coil board.

The current detection substrate according to the present disclosure includes a wiring pattern that electrically connects a power source and a power supply target, a switch board having a plurality of switching elements connected to the wiring pattern, and the power supply and the switch board. A current detection substrate used in a power control device including a power supply side terminal member that electrically connects the wiring pattern, has a through hole penetrating in the plate thickness direction, and has a logo around the through hole. The pattern of the ski coil is formed, and the switch substrate is arranged at a predetermined interval and the power supply side terminal member is inserted into the through hole.

According to the current control device and the current detection substrate according to the present disclosure, the current flowing between the power supply and the power supply target is detected by using the Rogoski coil, and the current detects the Rogoski coil itself. Since it does not flow, the amount of heat generated by the Rogoski coil does not increase due to the current. Therefore, for example, even when a large current flows between the power supply and the power supply target, the large current can be detected with high accuracy by using the Rogoski coil. Further, since the coil substrate on which the pattern of the Rogoski coil is formed is arranged at a predetermined interval with respect to the switch substrate having a plurality of switching elements, the Rogoski coil is less susceptible to the influence of heat generated by the switching element. .. From the above, the current detection accuracy can be improved.

It is a perspective view of the electric power control device which concerns on 1st Embodiment. It is an exploded perspective view of the power control device which concerns on 1st Embodiment. It is a top view of the switch board which concerns on 1st Embodiment. It is a top view of the control board which concerns on 1st Embodiment. It is an enlarged plan view which enlarges and shows the pattern of the Rogoski coil formed on the control board which concerns on 1st Embodiment. FIG. 5 is an enlarged cross-sectional view showing an enlarged cut surface along the VI-VI line of FIG. It is a partial perspective view which shows the partial structure of the switch board and the control board which concerns on 1st Embodiment. It is a circuit diagram of the power control device which concerns on 1st Embodiment. It is a block diagram which shows the structure of the detection processing part shown in FIG. It is a top view which shows the modification 1 of the power-source side terminal member and the 3rd terminal member which concerns on 1st Embodiment. It is a side view of the power supply side terminal member and the 3rd terminal member which concerns on modification 1. FIG. It is a perspective view which shows the modification 2 of the power-source side terminal member and the 3rd terminal member which concerns on 1st Embodiment. It is a perspective view which shows the modification 3 of the power-source side terminal member and the 3rd terminal member which concerns on 1st Embodiment. It is a perspective view which shows the structure of the coil substrate provided with the electric power control device which concerns on 2nd Embodiment, and its periphery. It is a side view for demonstrating the modification of the structure of the coil substrate and its surroundings which concerns on 2nd Embodiment.

Hereinafter, the first embodiment of the present disclosure will be described with reference to FIGS. 1 to 9. In the present embodiment, for convenience of explanation, the directions indicated by the arrows on the left and front are defined as above, to the left, and front of the power control device, respectively.

In the present embodiment, as an example of the power control device according to the present disclosure, the power control device 1 that controls the power supply between the battery 2 (power supply) and the three-phase AC motor 4 (power supply target) mounted on the vehicle. Will be described. As shown in FIG. 1, the power control device 1 includes a case 10 formed in a rectangular box shape, a switch board 50 housed inside the case 10, and a control board 60 in which a current detection board is integrated. Have.

As shown in FIG. 2, the case 10 is composed of a box-shaped case body 12 and a lid 14 that closes the opening of the case body 12. The case body 12 is a metal rectangular box-shaped member having an opening 13 that opens upward. The case body 12 includes a front wall portion 12A, a rear wall portion 12B, a left wall portion 12C, a right wall portion 12D, and a bottom wall portion 12E. Further, on the lower surface of the bottom wall portion 12E, a heat sink 12F for radiating the heat of the switch substrate 50, which will be described later, to the outside of the case body 12 is provided.

One connector mounting portion 16 is formed on the front wall portion 12A of the case body 12. The connector mounting portion 16 is formed by a notch cut in a rectangular concave shape from the opening 13 side of the case main body 12. A power supply side connector 18 is mounted on the connector mounting portion 16. The power supply side connector 18 has a housing 18A mounted on the connector mounting portion 16 and two

terminal members

20P and 20N protruding rearward from the rear surface of the housing 18A. When the power supply side connector 18 is mounted on the connector mounting portion 16, the two

terminal members

20P and 20N project to the inside of the case 10. The two

terminal members

20P and 20N form the first terminal member 20, and are electrically connected to the positive electrode and the negative electrode of the battery 2 (see FIG. 8), respectively. Hereinafter, the terminal member 20P on the positive electrode side will be referred to as the first terminal member 20P, and the terminal member 20N on the negative electrode side will be referred to as the first terminal member 20N. These

first terminal members

20P and 20N are flat plate-shaped members arranged with the left-right direction as the plate thickness direction, and extend along the front-rear direction.

On the rear surface (side surface facing the inside of the case) side of the housing 18A of the power supply side connector 18, a columnar capacitor 3 is provided connected to two

first terminal members

20P and 20N. The capacitor 3 is connected in parallel with the battery 2.

The rear wall portion 12B of the case body 12 is provided with three connector mounting portions 22 at predetermined intervals in the left-right direction. Similar to the connector mounting portion 16 described above, these connector mounting portions 22 are formed by notches cut out in a rectangular concave shape from the opening 13 side of the case body 12. A motor-side connector 24 is mounted on each of these connector mounting portions 22. Each of the three motor-side connectors 24 corresponds to each phase (U phase, V phase, W phase) of the three-phase AC motor 4 (see FIG. 8), and the housing mounted on the connector mounting portion 22 and the corresponding. It has one terminal member 26 that projects forward from the front surface of the housing. When each motor-side connector 24 is mounted on the connector mounting portion 22, the terminal member 26 projects inward of the case 10. The terminal member 26 electrically connects the coils of each phase of the stator of the three-phase AC motor 4 and the wiring pattern 52 of the switch board 50, which will be described later. Hereinafter, the terminal member 26 will be referred to as a second terminal member 26. The second terminal member 26 is a flat plate-shaped member arranged with the left-right direction as the plate thickness direction, and extends along the front-rear direction.

One connector mounting portion 28 is provided on the left wall portion 12C of the case body 12. Similar to the connector mounting portion 16 described above, the connector mounting portion 28 is formed by a notch cut in a rectangular concave shape from the opening 13 side of the case body 12. A sensor-side connector 30 is mounted on the connector mounting portion 28. The sensor-side connector 30 has a housing mounted on the connector mounting portion 28 and a plurality of connection terminals (not shown) provided in the housing. When the sensor-side connector 30 is mounted on the connector mounting portion 28, one end side of each of the plurality of connection terminals protrudes from the housing and extends inside the case 10 so as to be connected to the control board 60. A harness (cable) that connects to an electric device such as various sensors mounted on a vehicle is connected to the sensor-side connector 30 via a connector (not shown).

The opening 13 of the case body 12 is closed from above by the lid body 14. The lid body 14 is a metal rectangular plate-shaped member. The lid 14 is fixed to the case body 12 with an adhesive applied to the upper ends of the front, rear, left and right wall portions 12A to 12D of the case body 12. By fixing the lid body 14 to the case body 12, a storage space is formed inside the case 10.

Three capacitor modules 40 are arranged along the front wall portion 12A of the case main body 12 in the front portion of the accommodation space in the case 10. Each capacitor module 40 corresponds to each phase of the three-phase AC motor 4, and includes a holding member 44 for holding the two capacitors 3 and two third terminal members 46 provided on the holding member 44. There is. The holding member 44 is composed of a block-shaped member formed of an insulating material. Two capacitors 3 are held side by side on the lower surface side of the holding member 44. The two third terminal members 46 are plate-shaped terminal members extending in the front-rear direction with the left-right direction as the plate thickness direction. These third terminal members 46 are held by the holding member 44 in a state of being connected to the two capacitors 3 and arranged in parallel.

In the accommodation space between the power supply side connector 18 mounted on the case body 12 and the three capacitor modules 40 arranged in the case 10, the power supplied from the battery 2 is applied to each phase of the three-phase AC motor 4. A bus bar module (not shown) to be distributed to is arranged. In each capacitor module 40, one end of the third terminal member 46 on one side is electrically connected to the first terminal member 20P on the positive electrode side of the power supply side connector 18 via the bus bar module. One end of the third terminal member 46 on the other side is electrically connected to the first terminal member 20N on the negative electrode side of the power supply side connector 18 via the bus bar module. The other ends of the two third terminal members 46 are electrically connected to the wiring pattern 52 of the switch board 50 corresponding to each phase of the three-phase AC motor 4. Hereinafter, the terminal member 46 on the positive electrode side will be referred to as a third terminal member 46P, and the terminal member 46 on the negative electrode side will be referred to as a third terminal member 46N.

In each capacitor module 40, the two capacitors 3 are connected to the

third terminal members

46P and 46N on the positive electrode side and the negative electrode side, and are connected in parallel with the battery 2. As described above, in the power control device 1, a plurality of (seven) capacitors 3 held by the power supply side connector 18 and the three holding members 44 described above are connected in parallel to the battery 2. Each capacitor 3 is an element for alleviating noise generated in an inverter circuit 5 (see FIG. 8) described later.

As shown in FIGS. 2 and 3, in the accommodation space inside the case 10, three switch boards 50 corresponding to each phase of the three-phase AC motor 4 are arranged behind the three capacitor modules 40. .. Each switch board 50 has a plate thickness direction in the vertical direction and is formed in a rectangular plate shape in a plan view. As an example, for heat dissipation, a metal circuit board such as copper or aluminum is joined to a ceramic board. It is composed of an insulating substrate. Further, each switch board 50 is mounted on the bottom wall portion 12E of the case body 12, and the heat of each switch board 50 is transferred to the heat sink 12F via the bottom wall portion 12E.

A wiring pattern 52 (only a part of which is shown) is provided on the mounting surface 50A which is the upper surface of the switch board 50. The wiring pattern 52 is a wiring pattern that electrically connects the battery 2 and the three-phase AC motor 4. A plurality of switching elements 54 and a plurality of

terminal members

56 and 58 are connected to the wiring pattern 52. These wiring patterns 52, switching elements 54, and the like form a part of an inverter circuit 5 (see FIG. 8) that converts a direct current on the battery 2 side into an alternating current. Specifically, six switching elements 54 are mounted on the mounting surface 50A of each switch board 50. These six switching elements 54 are composed of an nMOSFET (n-type MOS field effect transistor) as an example, and switch the power supplied to one of the phases of the three-phase AC motor 4. As an example, FIG. 3 shows a switch board 50U corresponding to the U phase of the three-phase AC motor 4 in a plan view.

On the mounting surface 50A of the switch board 50U, the three switching elements 54UH1, 54UH2, 54UH3 mounted on the right side portion are on the side where the U-phase voltage level is high (electrically connected to the positive electrode side of the battery 2). It constitutes a switching element 54UH. These three switching elements 54UH1, 54UH2, 54UH3 are connected in parallel with each other, and each drain is electrically connected to the positive electrode side of the battery 2. On the other hand, on the mounting surface 50A of the switch board 50U, the three switching elements 54UL1, 54UL2, 54UL3 mounted on the left side are electrically connected to the side where the U-phase voltage level is low (the negative electrode side of the battery 2). The switching element 54UL is configured. These three switching elements 54UL1, 54UL2, 54UL3 are connected in parallel with each other, and each source is electrically connected to the negative electrode side of the battery 2. Further, the thermistor 55 is mounted near the switching element 54 on the mounting surface 50A of the switch board 50U. The thermistor 55 is a temperature sensor that senses the temperature related to the heat generated by the inverter circuit 5.

On the mounting surface 50A of the switch board 50U, two power supply side terminal members 56 are provided on both the left and right sides at a position closer to the front end portion 50B than the switching elements 54UH and 54UL. Each power supply side terminal member 56 is a long flat plate-shaped member whose plate thickness direction is substantially left and right, and extends upward from the mounting surface 50A. A curved portion 56A (reference numeral omitted in FIG. 2) curved in a U shape is provided below each power supply side terminal member 56. The lower surface of the curved portion 56A is connected to the wiring pattern 52 by being placed on the mounting surface 50A and soldered. Each power supply side terminal member 56 extends linearly upward from the upper end of the curved portion 56A. When the switch board 50U is arranged in the case 10, the rear end side of the two

third terminal members

46P and 46N of the capacitor module 40 arranged in the case 10 and the upper end side of the two power supply side terminal members 56. Are arranged side by side in the left-right direction. The upper end side of these power supply side terminal members 56 and the rear end side of the

third terminal members

46P and 46N are joined by resistance welding or the like, respectively. As a result, the battery 2 and the wiring pattern 52 are electrically connected via the two

third terminal members

46P and 46N and the two power supply side terminal members 56. Hereinafter, the power supply side terminal member 56 on the positive electrode side will be referred to as a power supply side terminal member 56P, and the power supply side terminal member 56 on the negative electrode side will be referred to as a power supply side terminal member 56N.

On the mounting surface 50A of the switch board 50U, one motor-side terminal member 58 is provided at a position closer to the rear end portion 50C than the switching elements 54UH and 54UL. The basic structure of the motor side terminal member 58 is the same as that of the power supply side terminal member 56. The lower surface of the curved portion 58A of the motor-side terminal member 58 is soldered to the mounting surface 50A, so that the motor-side terminal member 58 is connected to the wiring pattern 52. The motor-side terminal member 58 extends linearly upward from the upper end of the curved portion 58A. When the switch board 50U is arranged in the case 10, the end side of the second terminal member 26 of the motor side connector 24 mounted on the case 10 and the upper end side of the motor side terminal member 58 are aligned in the left-right direction. It is designed to be arranged with. The upper end side of the motor side terminal member 58 and the end side of the second terminal member 24 are joined by resistance welding or the like. As a result, the three-phase AC motor 4 and the wiring pattern 52 are electrically connected via the second terminal member 24 and the motor side terminal member 58.

So far, the switch board 50U corresponding to the U phase of the three-phase AC motor 4 has been described, but the

switch boards

50V and 50W corresponding to the V phase and the W phase are basically configured in the same manner. The six switching elements 54 mounted on the switch board 50V corresponding to the V phase include three switching elements 54VH (electrically connected to the positive side of the battery 2) on the side where the voltage level of the V phase is high and V. It is composed of three switching elements 54VL on the side where the voltage level of the phase is low (electrically connected to the negative side of the battery 2). The power supply side terminal member 56 of the switch board 50V includes a power supply side terminal member 56P joined to the third terminal member 46P on the positive electrode side and a power supply side terminal member 56N joined to the third terminal member 46N on the negative electrode side. It is composed of. The motor-side terminal member 58 of the switch board 50V is joined to the second terminal member 26 of the motor-side connector 24 corresponding to the V phase.

In the switch board 50W corresponding to the W phase of the three-phase AC motor 4, the six switching elements 54 in the switch board 50W are on the side where the voltage level of the W phase is high (electrically connected to the positive electrode side of the battery 2). It is composed of three switching elements 54WH and three switching elements 54WL on the side where the voltage level of the W phase is low (electrically connected to the negative electrode side of the battery 2). The power supply side terminal member 56 of the switch board 50W includes a power supply side terminal member 56P joined to the third terminal member 46P on the positive electrode side and a power supply side terminal member 56N joined to the third terminal member 46N on the negative electrode side. It is composed of. The motor-side terminal member 58 of the switch board 50W is joined to the second terminal member 26 of the motor-side connector 24 corresponding to the W phase.

As shown in FIGS. 1 and 2, the control board 60 is arranged on the upper side of the three switch boards 50 at a predetermined interval with respect to the switch board 50 in the accommodation space inside the case 10. .. The control board 60 is a rectangular plate-shaped printed wiring board having a predetermined width in the front-rear direction and the left-right direction and having a plate thickness direction in the vertical direction. The dimensions of the control board 60 in the front-rear direction are substantially the same as the dimensions of the switch board 50 in the front-rear direction. The horizontal dimension of the control board 60 is set to be sufficiently large to cover the three switch boards 50 arranged on the lower side, and in the present embodiment, it is three times the horizontal dimension of the switch board 50. It is said to be a degree.

As shown in FIG. 4, six first through holes 62 are formed side by side in the left-right direction on the mounting surface 60C, which is the upper surface of the control board 60, at a position close to the front end portion 60A of the control board 60. .. These first through holes 62 penetrate the control substrate 60 in the plate thickness direction, and are formed in an oval shape having a longitudinal direction in the front-rear direction in a plan view. Further, on the mounting surface 60C of the control board 60, three second through holes 63 are formed side by side in the left-right direction at a position close to the rear end portion 60B of the control board 60. Similar to the first through hole 62, these second through holes 63 penetrate the control substrate 60 in the plate thickness direction, and are formed in an oval shape having a longitudinal direction in the front-rear direction in a plan view.

As shown in FIGS. 4 and 7, a pattern 70 of the Rogoski coil forming a part of the current detection sensor is formed around each of the six first through holes 62 in the control board 60. The pattern 70 of the Rogoski coil is formed on the control board 60 as a wiring pattern, and is integrally formed with the control board 60. Hereinafter, these patterns 70 will be referred to as ROGOVSKI coils 70. When the control board 60 is arranged above the three switch boards 50 in the accommodation space inside the case 10, the power supply of the switch board 50 is provided in each of the first through holes 62 formed around the Rogoski coil 70. The side terminal member 56 is inserted in a non-contact state with respect to the edge of the first through hole 62. On the upper side of the control board 60, the upper end side of the power supply side terminal member 56 extending to the upper side of the control board 60 through the first through hole 62 extends parallel to the control board 60. It is designed to be joined to the 3-terminal member 46. As a result, the current flowing through the power supply side terminal member 56 is sensed by using the Rogoski coil 70. The six power supply side terminal members 56 through which the six first through holes 62 are inserted are arranged in parallel with each other, and the inclination and distance of the Rogoski coil 70 with respect to each power supply side terminal member 56 are set to be the same. There is.

When the control board 60 is arranged on the upper side of the three switch boards 50 in the accommodation space in the case 10, the switch board is formed in each of the second through holes 63 formed on the rear end portion 60B side of the control board 60. The motor-side terminal member 58 of the 50 is inserted in a non-contact state with respect to the edge of the second through hole 63. On the upper side of the control board 60, the upper end side of the motor side terminal member 58 extending to the upper side of the control board 60 through the second through hole 63 of the motor side connector 24 extending parallel to the control board 60. It is designed to be joined to the second terminal member 26.

Next, the Rogoski coil 70 formed on the control board 60 will be described with reference to FIGS. 5 and 6. The Rogoski coil 70 is formed on the control board 60 and is arranged in an annular region surrounding the first through hole 62, separated from the first through hole 62. One end of the Rogoski coil 70 is connected to the electrode connection piece 75, and the Rogoski coil 70 has a spiral shape (a spiral shape that swirls clockwise in the traveling direction) along the circumference of the first through hole 62. A coil having a diameter of the control substrate 60 is formed therein. Then, the other end of the Rogoski coil 70 is connected to the return wire 71 at a position substantially around the circumference of the first through hole 62.

In the Rogoski coil 70, a plurality of

conductor films

72 and 73 formed on both sides of the control board 60 are connected via a plurality of vias 74 formed so as to penetrate the control board 60 in the plate thickness direction. (See the lower right figure of FIG. 5). As described above, since the Rogoski coil 70 is an air-core coil, the impedance is small and the power loss due to the current measurement is small. Further, in the Rogoski coil 70, the magnetic flux is not saturated and it is possible to measure a large current.

One end of the return wire 71 is connected to the Rogoski coil 70, and is formed so as to surround the Rogoski coil 70 when viewed from the axial direction of the first through hole 62. The other end of the return wire 71 is connected to an electrode connection piece 76 arranged side by side with the electrode connection piece 75. Therefore, the Rogoski coil 70 substantially goes around the electrode connection piece 75 so as to surround the first through hole 62, and the return wire 71 so as to fold back from the electrode connection piece 75 substantially reverses the outer position of the Rogoski coil 70. It goes around and enters the inner position of the Rogoski coil 70 at a position past the outer position of the electrode connection piece 75, and is connected to the electrode connection piece 76. When a current flows through the conductor to be measured of the Rogoski coil 70 (the terminal member 56 on the power supply side in this embodiment), an induced electromotive force is generated in the

electrode connection pieces

75 and 76 at both ends of the coil. This induced electromotive force is output to the detection processing unit 7, which will be described later, as a signal output from the Rogoski coil 70. The detection processing unit 7 calculates the current value flowing through the power supply side terminal member 56 based on the signal output from the Rogoski coil 70.

Due to the characteristics of the Rogowski coil 70, an induced current corresponding to the magnetic flux penetrating the area surrounded by the Rogowski coil 70 is generated, but the return wire 71 causes a reverse magnetic flux penetrating the area surrounded by the return wire 71. Since the induced currents of the opposite-direction components corresponding to the above are generated and canceled each other, the current flowing through the power supply side terminal member 56 inserted through the first through hole 62 can be accurately detected.

Further, since the current to be detected does not flow through the Rogoski coil 70 itself, the amount of heat generated by the Rogoski coil 70 does not increase due to energization. The suppression of heat generation of the Rogoski coil 70 contributes to the improvement of the current detection accuracy by the Rogoski coil 70 and the detection processing unit 7 (see FIG. 8) described later.

Further, due to the characteristics of the Rogoski coil 70, a correction for correcting (calibrating) the error between the current value actually flowing through the conductor and the calculated value calculated by the calculation due to the inclination of the Rogoski coil 70 with respect to the conductor. The values will be different. Therefore, at the stage after the product is assembled, the initial value correction for correcting the error due to the inclination of the Rogoski coil 70 mounted on each power control device 1 is performed. This initial value correction is calculated based on the inspection current, for example, by connecting an inspection board having a diagnostic function to the control board 60, initializing the correction value stored in advance in the memory mounted on the control board 60, and calculating the initial value correction. This is performed by newly storing the corrected correction value. Therefore, when a plurality of Rogoski coils 70 are mounted on the power control device 1, if the structure is such that the inclination of each Rogoski coil 70 varies, the initial stage as described above is provided for each single Rogoski coil 70. Value correction is required. Further, a connection terminal for connecting a substrate for inspection and a circuit for diagnosis are required for each single Rogoski coil 70.

However, according to the present embodiment, a plurality of Rogoski coils 70 are formed by a wiring pattern on one control board 60. Therefore, since the inclination of each Rogoski coil 70 does not vary, the initial value correction can be performed by using a common correction value for the plurality of Rogoski coils 70. Therefore, the man-hours associated with the initial value correction are reduced.

Further, due to the characteristics of the Rogoski coil 70 described above, it is desirable to provide a means for suppressing the tilt displacement of the control board 60 due to the external environment such as vibration after assembling the power control device 1. In the present embodiment, after assembly, the inside of the case 10 is filled with potting resin. As a result, the internal parts such as the control board 60 can be held at the position at the time of assembly, and it is possible to prevent the control board 60 from being inadvertently displaced due to vibration during traveling of the vehicle or the like.

A circuit constituting the control unit 6 and the detection processing unit 7 shown in FIG. 8 is mounted on the mounting surface 60C of the control board 60. The control unit 6 has a CPU (Central Processing Unit) 64 (see FIG. 4), and controls an on state and an off state of a plurality of switching elements 54. The various electronic components mounted on the control board 60 and the various electronic components mounted on the switch board 50 are electrically connected by a plurality of connection pins 66 extending in the vertical direction, as partly shown in FIG. .. Further, these connection pins 66 support the control board 60 with respect to the three switch boards 50 at predetermined intervals. In drawings other than FIG. 7, the connection pin 66 is not shown.

As shown in FIG. 4, a plurality of third through holes 68 that penetrate the control board 60 in the plate thickness direction are formed on the mounting surface 60C of the control board 60 at a position close to the left end portion of the control board 60. There is. The tips of the plurality of connection terminals of the sensor-side connector 30 are inserted into these third through holes 68 from below and soldered. As a result, the sensor-side connector 30 is connected to the control board 60. The signals detected by various sensors such as the vehicle speed sensor mounted on the vehicle are output to the control board 60 via the sensor-side connector 30, and are output to the CPU 64 via the wiring pattern formed on the control board 60.

In this embodiment, the current detection sensor is composed of the Rogoski coil 70 and the detection processing unit 7 (see FIG. 8). The control unit 6 calculates a current value based on the signal input from the detection processing unit 7, switches the on state and the off state of the plurality of switching elements 54, and supplies power to each phase of the three-phase AC motor 4. Is in control. Hereinafter, these functions will be described with reference to the block diagrams of FIGS. 8 and 9.

As shown in FIG. 8, the power control device 1 includes an inverter circuit 5 mounted on three switch boards 50. The inverter circuit 5 converts the direct current on the battery 2 side into an alternating current and supplies it to each phase of the three-phase alternating current motor 4. The drains of the switching elements 54UH, 54VH, and 54WH on the high voltage level side (High side) corresponding to the U phase, V phase, and W phase are connected to the positive electrode side of the battery 2. Further, the sources of the switching elements 54UL, 54VL, and 54WL on the low voltage level side (Low side) corresponding to each phase are connected to the negative electrode side of the battery 2. Further, the gates of all the switching elements 54 are connected to the signal lines of the control signals output from the control unit 6, respectively.

The six Rogowski coils 70 include three Rogowski coils 70U1, 70V1, 70W1 for measuring the current flowing between the positive side of the battery 2 and the switching elements 54UH, 54VH, 54WH on the high side of the inverter circuit 5, respectively, and the battery. It is composed of three Rogowski coils 70U2, 70V2, 70W2 for measuring the current flowing between the negative electrode of No. 2 and the switching elements 54UL, 54VL, 54WL on the Low side of the inverter circuit 5, respectively. In these six Rogoski coils 70, the current value at the moment when the switching element 54 corresponding to each phase of the three-phase AC motor 4 is switched between the on state and the off state is measured. Then, the output signal (induced electromotive force) output from each Rogoski coil 70 is input to the detection processing unit 7 mounted on the control board 60.

As shown in FIG. 9, the detection processing unit 7 includes six integrator circuits 80 (A to F) corresponding to the six Rogoski coils 70 and three adders corresponding to each phase of the three-phase AC motor 4. It is configured to have 82 (U to W). In the detection processing unit 7, the output signals of the six Rogoski coils 70 are input to the six integrating circuits 80 (A to F), respectively. Each integrating circuit 80 includes, for example, an operational amplifier, a resistor, and a capacitor. The integrating circuit 80 integrates the output signal from the Rogoski coil 70 and outputs a signal corresponding to a voltage waveform proportional to the measured current at each point.

The adder 82 includes an adder 82U corresponding to the U phase of the three-phase AC motor 4, an adder 82V corresponding to the V phase, and an adder 82W corresponding to the W phase. In the adder 82U, the voltage waveform obtained by integrating the output signals of the two Rogoski coils 70U1 and 70U2 corresponding to the U phase is added. As a result, the detection value on the negative electrode side is added to the detection value on the positive electrode side of the battery 2, and an output signal UC proportional to the direct current output from the battery 2 to the U phase can be obtained. Similarly, in the adder 82V, an output signal UV proportional to the direct current output from the battery 2 to the V phase can be obtained. Further, in the adder 82W, an output signal UW proportional to the direct current output from the battery 2 to the W phase can be obtained. The signals output from the

adders

82U, 82V, 82W are input to the control unit 6, and the output current output from the battery 2 to each phase of the three-phase AC motor 4 is calculated by the control unit 6. Obtainable.

(Action and effect)
Next, the operation and effect of this embodiment will be described.

According to the power control device 1 according to the present embodiment, the current flowing between the battery 2 and the three-phase AC motor 4 is detected by using the Rogowski coil 70, and the current is the Rogowski coil 70. Since it does not flow through itself, the amount of heat generated by the Rogowski coil 70 does not increase due to energization. Therefore, for example, even when a large current flows between the battery 2 and the three-phase AC motor 4, the large current can be detected with high accuracy by using the Rogoski coil 70. Further, since the control board 60 on which the pattern of the Rogoski coil 70 is formed is arranged at a predetermined interval with respect to the switch board 50 having the plurality of switching elements 54, the influence of heat generation of the switching element 54 is logoed. The ski coil 70 is difficult to receive. From the above, the current detection accuracy can be improved.

Further, since the Rogoski coil 70 is formed on the control board 60 and the coil board on which the Rogoski coil 70 is formed and the control board 60 are integrated, the control board 60 and the coil board are separated. The number of parts constituting the power control device 1 can be reduced as compared with the case where the power control device 1 is configured as.

Further, according to the present embodiment, the current flowing through the six power supply side terminal members 56 connected to the three

switch boards

50U, 50V, 50W corresponding to each phase of the three-phase AC motor 4 is controlled by one sheet. The detection is performed using six Rogoski coils 70 formed on the substrate 60. Since the plurality of Rogowski coils 70 are formed on one control board 60 (coil board) in this way, if the angles of the terminal members 56 on each power supply side with respect to the switch board 50 are the same (each power supply side). If the terminal members 56 are parallel to each other), the inclinations (distances) of the Rogowski coils 70 with respect to the terminal members 56 on the power supply side are aligned. Therefore, it is not necessary to perform the initial value correction (initialization) of the current detection for all the Rogoski coils 70, and the initial value correction is performed for one Rogoski coil 70, and the correction value is used for the other Rogoski coils. Since it can also be used for 70, the man-hours for initial value correction can be reduced.

Note that, in the first embodiment, the power supply side terminal member 560 and the third terminal member 460 as the first modification shown in FIGS. 10 and 11 can also be used. The same components as those of the above-described first embodiment are designated by the same numbers, and the description thereof will be omitted.

The power supply side terminal member 560 according to the first modification is characterized in that a comb-shaped joint portion 100 is provided on the side surface of the upper end portion in a plan view (vertical direction view). The power supply side terminal member 560 extends linearly upward from the upper end of the curved portion 560A curved in a U shape and inserts the first through hole 62 of the control board 60. The power supply side terminal member 560 is provided with a comb-shaped joint portion 100 on the side surface of the upper end portion extending above the control board 60 through the first through hole 62. In this modification 1, in order to insert the power supply side terminal member 560 into the first through hole 62, the first through hole 62 formed in the control board 60 extends to the front end portion 60A of the control board 60 and opens forward. It has a slit shape. When the first through hole 62 is not the slit shape but the first through hole 62 having an oval shape as in the first embodiment, the joint portion 100 is formed from the upper end portion of the power supply side terminal member 560. It may be formed so as to extend upward, and after the power supply side terminal member 560 is inserted into the first through hole 62, the joint portion 100 may be bent and formed with respect to the power supply side terminal member 560.

The third terminal member 460 according to the first modification is characterized in that a comb-shaped jointed portion 110 is provided at one end to be joined to the power supply side terminal member 560. The third terminal member 460 has a plate thickness direction in the vertical direction and extends in the front-rear direction. Further, on the side surface of the tip end portion of the third terminal member 460, a joint portion 110 having a comb tooth shape in a plan view (vertical direction view) is provided. The joint portion 100 of the power supply side terminal member 560 and the joint portion 110 of the third terminal member 460 are joined by soldering or the like in a state where the comb teeth are meshed with each other without a gap. By this meshing, the contact area between the power supply side terminal member 560 and the third terminal member 460 is secured.

According to the configuration of the first modification, the contact area is reduced while reducing the size of the joint portion between the power supply side terminal member 560 and the third terminal member 460 by engaging the comb-shaped joint portion 100 and the joint portion 110. It can be increased to secure the conductivity. For example, the vertical dimension of the power supply side terminal member 560 is shortened as compared with the configuration in which the side surfaces of the power supply side terminal member and the third terminal member are brought into contact with each other and joined as shown by a two-dot chain line in FIG. Therefore, the power control device 1 can be miniaturized in the vertical direction.

Further, from the same viewpoint as the first modification, the power supply side terminal member 562 and the third terminal member 462 as the second modification shown in FIG. 12 can also be used in the first embodiment. The same components as those of the above-described modification 1 are designated by the same numbers, and the description thereof will be omitted.

The power supply side terminal member 562 according to the second modification is characterized in that a joint portion 100 having a comb tooth shape is formed at the upper end portion in a front view (front-back direction view). The power supply side terminal member 562 extends upward with the front-rear direction as the plate thickness direction. The third terminal member 462 according to the second modification is characterized in that a comb-shaped jointed portion 110 is provided at one end to be joined to the power supply side terminal member 562. The third terminal member 462 has a plate thickness direction in the vertical direction and extends in the front-rear direction. Further, a joint portion 110 having a comb tooth shape in a plan view (vertical view) is provided at the tip end portion of the third terminal member 462. The joint portion 100 of the power supply side terminal member 562 and the jointed portion 110 of the third terminal member 462 are joined by soldering or the like in a state where the comb teeth arranged in orthogonal positions with each other are in mesh with each other without a gap. Even when this configuration is applied, it is possible to increase the contact area and secure the conductivity while reducing the size of the joint portion between the power supply side terminal member 562 and the third terminal member 462, so that the power control device 1 can be downsized. Contribute to.

Further, in the first embodiment, the power supply side terminal member 564 and the third terminal member 464 as the modification 3 shown in FIG. 13 can also be used. The same components as those of the above-described modification 1 are designated by the same numbers, and the description thereof will be omitted.

The power supply side terminal member 564 extends linearly upward from the upper end of the curved portion (not shown) curved in a U shape. The power supply side terminal member 564 extends in the vertical direction with the front-rear direction as the plate thickness direction. The power supply side terminal member 564 has a joint portion 105 formed by bending the upper end portion side of the power supply side terminal member 564 forward at a substantially right angle. The third terminal member 464 has a plate thickness direction in the vertical direction and extends in the front-rear direction. Further, the third terminal member 464 is integrally formed with a joint piece 120 having a width narrower than that of the power supply side terminal member 564 at the tip end portion. The joint piece 120 is superposed on the joint portion 105 of the power supply side terminal member 564 from above, and is soldered in a state of being in contact with the upper surface of the joint portion 105. Even when this configuration is applied, the vertical dimension of the power supply side terminal member 564 can be shortened, so that the power control device 1 can be miniaturized in the vertical direction. Further, since the joint portion between the power supply side terminal member 564 and the third terminal member 464 can be made into a simple shape, production is easy.

Next, the power control device 200 according to the second embodiment will be described with reference to FIG. The same components as those of the above-described first embodiment are designated by the same numbers, and the description thereof will be omitted. This second embodiment is different from the power control device 1 of the first embodiment in that the control board 600 and the coil board 610 on which the Rogoski coil 70 is formed are formed separately. The coil substrate 610 corresponds to the current detection substrate in the present invention. Other configurations are the same as those in the first embodiment.

In the present embodiment, the control board 60 described in the first embodiment is a control board 600 on which the circuits constituting the control unit 6 and the detection processing unit 7 are mounted, and a coil board on which a plurality of Rogoski coils 70 are formed. It is divided into 610. In the control board 600, since a plurality of Rogoski coils 70 are not formed on the front end 600A side of the mounting surface 600C, the mounting area of various circuits can be set up to the front end 600A side of the mounting surface 600C. It is formed to be slightly smaller than the control board 60 described above.

The coil board 610 is a long printed wiring board extending in the left-right direction. The coil board 610 is provided at a position on the front end portion 600A side of the surface of the control board 600 opposite to the mounting surface 600C (the surface facing the switch board 50), and is arranged between the switch board 50 and the control board 600. ing. The coil substrate 610 has a plate thickness direction in the front-rear direction, and is arranged in an upright posture with respect to the control substrate 600. Six first through holes 62 are formed in the coil substrate 610 along the left-right direction. A Rogoski coil 70 is formed around each of the six first through holes 62.

Connection pins 620 are connected to

electrode connection pieces

75 and 76 connected to both ends of each Rogoski coil 70, respectively. These connection pins 620 extend from the upper end of the coil board 610 toward the control board 600 and are connected to a wiring pattern formed on the mounting surface 600C of the control board 600. As a result, the signal (induced electromotive force) output from each Rogoski coil 70 is output to the detection processing unit 7 formed on the control board 600. Further, the coil board 610 is attached to the control board 600 via these connection pins 620.

A third terminal member 46 protruding from the holding member 44 of the capacitor module 40 is inserted into the first through hole 62 of the coil substrate 610 in a non-contact state with respect to the edge of the first through hole 62. As described above, in the present embodiment, the third terminal member 46 constitutes the "power supply side terminal member" in the present invention. Further, the tip end side of the third terminal member 46 is joined to the tip end side of the power supply side terminal member 56 between the switch board 50 and the control board 600.

(Action and effect)
As described above, the power control device 200 according to the present embodiment includes a coil board 610 that is separate from the switch board 50 and the control board 600, and the coil board 610 includes the switch board 50 and the control board 600. It is placed in between. Therefore, the mounting area of the control board 600 can be expanded and the control board 600 can be downsized as compared with the configuration in which the coil board is integrally formed with the control board.

[supplementary explanation]
In each of the above embodiments and modifications, the power source in the present invention is the battery 2, and the power supply target in the present invention is the three-phase AC motor 4, but the present invention is not limited to this. The power supply and the power supply target can be set as appropriate. For example, the power source may be a power source that can be obtained from a generator or an outlet. Further, as the power supply target, a single-phase AC motor, an AC motor having three or more phases such as a four-phase AC or a five-phase AC, various electric devices, and the like can be appropriately adopted.

In each of the above embodiments and modifications, the case where power is supplied from the battery 2 to the three-phase AC motor 4 has been described, but the present invention controls the power supplied (charged) from the motor to the battery, such as regenerative power. Can also be used for.

In each of the above embodiments and modifications, six Rogoski coils 70 corresponding to the positive electrode side terminal member 56P and the negative electrode side terminal member 56N of the power supply side terminal member 56 are formed on one substrate, but the present invention has the present invention. Not limited to this. The six Rogoski coils 70 may be formed by dividing the six Rogoski coils 70 into a plurality of substrates. For example, a first coil substrate on which three Rogoski coils 70 corresponding to the positive electrode side terminal member 56P of the power supply side terminal member 56 are formed, and three Rogoski corresponding to the negative electrode side terminal member 56N of the power supply side terminal member 56. A second coil substrate on which the coil 70 is formed may be provided.

Further, in each of the above embodiments and modifications, the currents of the positive electrode side terminal member 56P and the negative electrode side terminal member 56N of the switch substrate 50 corresponding to each phase (U, V, W) of the three-phase AC motor 4 are detected. However, the present invention is not limited to this. For example, if the current corresponding to the two phases of the three-phase AC motor can be detected, the power supplied to the remaining one phase can be calculated and controlled using the detected value of the current. In this case, the currents of the positive electrode side terminal member 56P and the negative electrode side terminal member 56N of the switch substrate 50 corresponding to any two phases of each phase of the three-phase AC motor may be detected. In this case, four Rogoski coils 70 are formed on the coil substrate.

In the

power control devices

1 and 200 in each of the above embodiments, seven capacitors 3 are connected in parallel to the battery 2, but the capacitors 3 may not be provided. In this case, the capacitor module 40 is not required, and the positive electrode and the negative electrode of the bus bar may be connected to the positive electrode side terminal member 56P and the negative electrode side terminal member 56N of the power supply side terminal member 56.

In the above modification 3, the joint piece 120 of the third terminal member 464 is joined to the upper surface of the joint portion 105 of the power supply side terminal member 564, but the present invention is not limited to this. The joint piece 120 of the third terminal member 462 may be joined to the lower surface of the joint portion 105. Further, a joining piece 120 may be formed at the tip of the joining portion 105 of the power supply side terminal member 564 and joined to one end of the third terminal member 464.

In the second embodiment, the coil board 610 is arranged in an upright position with respect to the control board 600, but the present invention is not limited to this. Even if the coil board 610 is arranged in a posture parallel to or substantially parallel to the control board 600 so that the power supply side terminal member 56 of the switch board 50 is inserted into the first through hole 62 of the coil board 610. good.

In the second embodiment, the coil board 610 is arranged between the switch board 50 and the control board 600, but the present invention is not limited to this. As shown in the coil board positions A (1 to 4) shown in FIG. 15, the coil board 610 may be arranged on the front side of the control board 600. At the coil board positions A1, A2, and A3 shown in FIG. 15, the coil board 610 is arranged in a posture parallel to or substantially parallel to the switch board 50 (and the control board 600). Then, the power supply side terminal member 56 of the switch board 50 is inserted into the first through hole 62 of the coil board 610 so that the terminal member 56 on the power supply side of the switch board 50 is inserted into the lower side (A1 position) of the control board 600 or on the same plane as the control board 600 (A2). Position) or above the control board 600 (A3 position). At the coil board position A4 shown in FIG. 15, the coil board 610 is in an upright posture with respect to the switch board 50 (and the control board 600), and is arranged apart from the front side of the control board 600. Then, the third terminal member 46 of the capacitor module 40 as the power supply side terminal member is inserted into the first through hole 62 of the coil board 610.

The disclosure of Japanese Patent Application No. 2020-072590 filed on April 14, 2020 is incorporated herein by reference in its entirety.
All documents, patent applications, and technical standards described herein are to the same extent as if the individual documents, patent applications, and technical standards were specifically and individually stated to be incorporated by reference. Incorporated herein by reference.

Claims

A wiring pattern that electrically connects the power supply and the power supply target, and a switch board having a plurality of switching elements connected to the wiring pattern.
A coil substrate having a through hole penetrating in the plate thickness direction and having a Rogoski coil pattern formed around the through hole.
A power supply side terminal member for electrically connecting the power supply and the wiring pattern of the switch board is provided.
A power control device in which the coil board is arranged at a predetermined interval with respect to the switch board, and the power supply side terminal member is arranged in a state of being inserted into the through hole of the coil board.
The power supply side terminal member includes a positive electrode side terminal member that electrically connects the positive electrode of the power supply and the wiring pattern, and a negative electrode side terminal member that electrically connects the negative electrode of the power supply and the wiring pattern. death,
The coil substrate has two through holes through which the positive electrode side terminal member and the negative electrode side terminal member are inserted, and a pattern of the Rogoski coil is formed around the two through holes. The power control device according to claim 1.
The power supply target is a three-phase AC motor,
The power supply side terminal member has three positive electrode side terminal members and three negative electrode side terminal members corresponding to each phase of the three-phase AC motor.
The coil substrate has six through holes through which the three positive electrode side terminal members and the three negative electrode side terminal members are inserted, respectively, and the pattern of the Rogoski coil is formed around the six through holes. The power control device according to claim 2, wherein the power control device is formed.
A control board for controlling the plurality of switching elements based on a current value detected by using the Rogoski coil is provided.
The power control device according to any one of claims 1 to 3, wherein the coil board is integrally formed with the control board.
A control board for controlling the plurality of switching elements based on a current value detected by using the Rogoski coil is provided.
The power control device according to any one of claims 1 to 3, wherein the coil board is arranged between the switch board and the control board.
A wiring pattern that electrically connects the power supply and the power supply target, and a switch board having a plurality of switching elements connected to the wiring pattern.
A current detection board used in a power control device including a power supply side terminal member that electrically connects the power supply and the wiring pattern of the switch board.
It has a through hole that penetrates in the plate thickness direction, and a pattern of Rogoski coil is formed around the through hole.
A current detection board arranged at a predetermined distance from the switch board and with the power supply side terminal member inserted through the through hole.