WO2022163367A1 - 電力変換装置、モータ装置、および車両 - Google Patents
電力変換装置、モータ装置、および車両 Download PDFInfo
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- WO2022163367A1 WO2022163367A1 PCT/JP2022/000956 JP2022000956W WO2022163367A1 WO 2022163367 A1 WO2022163367 A1 WO 2022163367A1 JP 2022000956 W JP2022000956 W JP 2022000956W WO 2022163367 A1 WO2022163367 A1 WO 2022163367A1
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- power
- reactor
- control board
- converter
- board
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Classifications
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/14—Mounting supporting structure in casing or on frame or rack
- H05K7/1422—Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
- H05K7/1427—Housings
- H05K7/1432—Housings specially adapted for power drive units or power converters
- H05K7/14322—Housings specially adapted for power drive units or power converters wherein the control and power circuits of a power converter are arranged within the same casing
-
- 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
- H02M1/44—Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
-
- 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
- H02M3/003—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
- 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
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20927—Liquid coolant without phase change
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- 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
- H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
- H02M1/008—Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators
-
- 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
Definitions
- the present invention relates to power converters, motor devices, and vehicles.
- Patent Literature 1 discloses a configuration in which a reactor case is provided to cover the entire reactor, and the reactor case shields electromagnetic noise generated from the reactor.
- a power conversion device of the present invention is a power conversion device having an inverter circuit and a converter circuit.
- a power conversion device includes a power module having the inverter circuit, a reactor that smoothes the DC current supplied to the converter circuit, and a control board that controls at least one of the inverter circuit and the converter circuit.
- the control board is arranged on one side in the first direction with respect to the power module, with the first direction being the plate thickness direction.
- the reactor has a coil portion wound around a central axis along the first direction, and is arranged on one side of the power module in a second direction perpendicular to the first direction.
- the power module and the control board are positioned radially outside the reactor when viewed from the first direction.
- the control board is located on one side of the reactor in the first direction.
- One aspect of the motor device of the present invention has the power conversion device described above.
- One aspect of the vehicle of the present invention has the motor device described above.
- a power conversion device for conversion of a power to generate electromagnetic noise generated from a reactor hardly affects other members.
- FIG. 1 is a circuit block diagram of a motor device according to one embodiment.
- FIG. 2 is a schematic diagram showing a longitudinal section of the power conversion device of one embodiment.
- FIG. 3 is a perspective view of the reactor of one embodiment.
- a power conversion device 10, a motor device 1, and a vehicle 9 will be described below with reference to the drawings.
- the actual structure and the scale, number, etc. of each structure may be different in order to make each structure easier to understand.
- the gravitational direction is defined based on the positional relationship when the power conversion device 10 is mounted on a vehicle positioned on a horizontal road surface.
- the posture of the power conversion device 10 in this specification is an example, and does not limit the posture in which the power conversion device 10 is actually attached.
- FIG. 1 is a circuit block diagram of the motor device 1.
- FIG. A motor device 1 of the present embodiment is mounted in a vehicle 9 such as a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or the like, which uses an engine and a motor as power sources.
- the motor device 1 may be mounted in an electric vehicle (EV) that does not have an engine.
- EV electric vehicle
- a vehicle 9 of this embodiment includes a motor device 1, an engine (not shown), and drive wheels (not shown).
- the motor device 1 includes a generator 3 driven by an engine (not shown), a battery 4 as a DC power source charged by the generator 3, and at least one of the battery 4 and the generator 3 as power sources (not shown).
- the power conversion device 10 boosts the DC voltage supplied from the battery 4, converts it to AC voltage, supplies the converted AC voltage to the motor 2 to drive the motor 2, and regenerates the motor 2. is converted to a DC voltage, the voltage is stepped down, and the voltage is supplied to the battery 4 .
- the power converter 10 converts the voltage generated by the generator 3 into a DC voltage, steps it down, and supplies it to the battery 4 , or drives the motor 2 with the voltage generated by the generator 3 .
- Each configuration of the power converter 10 will be specifically described below.
- the motor 2 is mechanically connected to a reduction mechanism (not shown).
- the motor 2 drives drive wheels of the vehicle 9 via a speed reduction mechanism.
- the generator 3 is mechanically connected to the reduction mechanism.
- the generator 3 functions as a regenerative brake for driving the vehicle 9, and generates power based on energy during deceleration.
- the motor 2 and generator 3 of this embodiment are three-phase motors, but may be multi-phase motors having four or more phases.
- Motor 2 and generator 3 are each connected to power converter 10 .
- Battery 4 is, for example, a secondary battery or an electric double layer capacitor.
- the battery 4 is connected to the power converter 10 .
- the battery 4 supplies power to the motor 2 via the power converter 10 . Electric power is supplied from the generator 3 to the battery 4 via the power converter 10 .
- the power converter 10 has a converter circuit 13 , a motor inverter circuit (inverter circuit) 11 , and a generator inverter circuit (inverter circuit) 12 .
- the converter circuit 13 is a so-called DC/DC converter.
- the converter circuit 13 converts the voltage of the direct current supplied from the battery 4 .
- the motor inverter circuit 11 converts the DC current supplied from the converter circuit 13 into AC current and supplies the AC current to the motor 2 .
- the generator inverter circuit 12 converts the electric power generated by the generator 3 from alternating current to direct current, and charges the battery 4 .
- inverter circuits 11 and 12 are simply referred to as inverter circuits 11 and 12 .
- FIG. 2 is a schematic diagram of a longitudinal section of the power converter 10. As shown in FIG. FIG. 2 illustrates a first direction D1, a second direction D2, and a third direction D3.
- the first direction D1 is the vertical direction
- one side of the first direction D1 is the upper side
- the other side of the first direction D1 is the lower side.
- the second direction D2 is a direction perpendicular to the first direction D1.
- the second direction D2 is one direction along the horizontal plane.
- One side in the second direction D2 is the right side in FIG. 2, and the other side in the second direction D2 is the left side in FIG.
- the third direction D3 is a direction along the horizontal direction and a direction orthogonal to the first direction D1 and the second direction D2. That is, the first direction D1, the second direction D2, and the third direction D3 are directions orthogonal to each other.
- the power converter 10 includes an inverter control board (control board) 41, a converter control board (control board) 42, a power board 43, a first drive board 45, a second drive board 46, and a motor power module 21.
- the flow path forming body 60 has a first cooling plate 61 , a second cooling plate 62 , a third cooling plate 63 and a connecting pipe 64 .
- the housing 19 includes an inverter control board 41, a converter control board 42, a power board 43, a first drive board 45, a second drive board 46, a motor power module 21, a generator power module 22, a reactor 30, a reactor base 35,
- the capacitor module 15, the shield plate 50, the heat transfer plate 55, and the flow path forming body 60 are accommodated.
- the motor power module 21 has a motor inverter circuit 11 .
- the generator power module 22 has the generator inverter circuit 12 .
- the motor inverter circuit 11 and the generator inverter circuit 12 convert a DC voltage into an AC voltage or an AC voltage into a DC voltage.
- the motor power module 21 and the generator power module 22 are simply referred to as power modules 21 and 22 .
- the motor power module 21 and the generator power module 22 each have six first switching elements (switching elements) 16 .
- the first switching element 16 is an insulated gate bipolar transistor (IGBT) in this embodiment. That is, the power modules 21 and 22 have insulated gate bipolar transistors. By adopting an insulated gate bipolar transistor as the first switching element 16, the power modules 21 and 22 can be configured at relatively low cost.
- the inverter circuits 11 and 12 are PWM inverters by pulse width modulation (PWM) having a bridge circuit in which the first switching elements 16 are bridge-connected.
- the motor power module 21 and the generator power module 22 are arranged along a horizontal plane (a plane perpendicular to the first direction D1).
- the generator power module 22 is stacked above the motor power module 21 with a third cooling plate 63 interposed therebetween. That is, the third cooling plate 63 is sandwiched between the motor power module 21 and the generator power module 22 .
- the third cooling plate 63 cools the motor power module 21 and the generator power module 22 with the coolant L flowing therein.
- a first drive board 45 is arranged below the motor power module 21 .
- a second drive board 46 is arranged above the generator power module 22 .
- the substrate bodies 45a and 46a of the first drive substrate 45 and the second drive substrate 46 are arranged along a horizontal plane (a plane orthogonal to the first direction D1).
- the first drive board 45 is connected to the motor power module 21 and the inverter control board 41 .
- the second drive board 46 is connected to the generator power module 22 and the inverter control board 41 .
- the first drive board 45 and the second drive board 46 generate driving power for the first switching element 16 based on the control signal for controlling the first switching element 16 generated by the inverter control board 41 .
- the power board 43 has a converter circuit 13.
- the converter circuit 13 steps up the voltage supplied from the battery 4 or steps down the voltage supplied to the battery 4 .
- a reactor 30 is connected in series between the converter circuit 13 and the battery 4 .
- a capacitor module 15 is connected in parallel to the downstream side of the converter circuit 13 .
- the power board 43 has two second switching elements (switching elements) 17 and a board body (not shown in FIG. 1) on which the second switching elements 17 are mounted.
- the second switching element 17 is a transistor containing silicon carbide (SiC) in this embodiment. That is, the power substrate 43 has transistors containing silicon carbide.
- the converter circuit 13 has a chopper circuit to which the second switching element 17 is connected.
- the board body 43a of the power board 43 is arranged along a horizontal plane (a plane orthogonal to the first direction D1). That is, the power board 43 is arranged with the vertical direction (the first direction D1) as the board thickness direction.
- a first cooling plate 61 is arranged below the power board 43 (the other side in the first direction D1) with a heat transfer plate 55 interposed therebetween.
- the heat transfer plate 55 is made of a highly heat conductive metal material.
- the material forming the heat transfer plate 55 include an aluminum alloy and a copper alloy. It is more preferable to employ a material that shields magnetism (for example, an aluminum alloy) as the material forming the heat transfer plate 55 .
- the heat transfer plate 55 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the heat transfer plate 55 is arranged with the vertical direction (the first direction D1) as the plate thickness direction. Also, the heat transfer plate 55 is arranged to be stacked on the power substrate 43 along the vertical direction (first direction D1).
- the heat transfer plate 55 contacts the power board 43 . More specifically, the heat transfer plate 55 contacts the second switching element 17 (not shown in FIG. 2) mounted on the power board 43 .
- the heat transfer plate 55 is cooled by the coolant L flowing inside the first cooling plate 61 .
- the power board 43 is cooled by the coolant L through the heat transfer plate 55 .
- the heat transfer plate 55 may be configured to have radiation fins on the surface in contact with the coolant L. As shown in FIG.
- the capacitor module 15 is connected in parallel between the converter circuit 13 and the inverter circuits 11 and 12.
- the capacitor module 15 smoothes the DC current supplied from the converter circuit 13 to the motor inverter circuit 11 in the capacitor element 15a.
- the capacitor module 15 has a capacitor element 15a and a capacitor case 15b that accommodates the capacitor element 15a.
- the capacitor module 15 is arranged on one side (the right side in FIG. 2) in the second direction D2 with respect to the motor power module 21, the generator power module 22, and the third cooling plate 63. As shown in FIG. Also, the capacitor module 15 is arranged on the other side in the second direction D2 (left side in FIG. 2) with respect to the second cooling plate 62 .
- the capacitor module 15 contacts the second cooling plate 62 and the third cooling plate 63 .
- the second cooling plate 62 and the third cooling plate 63 are cooled by the coolant L flowing therein.
- the capacitor module 15 contacts both sides in the second direction D2 by contacting the second cooling plate 62 and the third cooling plate 63 arranged on one side and the other side in the second direction D2, respectively. efficiently cooled from As a result, the temperature of the capacitor module 15 is suppressed, and the reliability of the capacitor element 15a is enhanced.
- reactor 30 is connected in series between battery 4 and converter circuit 13 .
- Reactor 30 smoothes the DC current supplied from battery 4 to converter circuit 13 .
- the reactor 30 is arranged on one side (right side in FIG. 2) in the second direction D2 with respect to the power modules 21, 22 and the third cooling plate 63. Between reactor 30 and power modules 21 and 22 and third cooling plate 63, capacitor module 15, third cooling plate 63, and reactor pedestal 35 are arranged.
- the reactor 30 is supported by a reactor pedestal 35 .
- the reactor pedestal 35 has a plate-like portion whose plate thickness direction is the second direction D2.
- the reactor pedestal 35 is made of a highly heat-conductive metal material. Examples of the material forming the reactor pedestal 35 include materials with excellent heat conductivity, such as aluminum alloys and copper alloys. Furthermore, it is more preferable to employ a material that shields magnetism (for example, an aluminum alloy) as the material that constitutes the reactor pedestal 35 .
- the reactor pedestal 35 contacts the reactor 30 .
- the reactor pedestal 35 is cooled by the coolant L flowing inside the second cooling plate 62 .
- Reactor 30 is cooled by coolant L via reactor pedestal 35 .
- the reactor pedestal 35 may have heat radiation fins on the contact surface with the refrigerant L.
- FIG. 3 is a perspective view of the reactor 30.
- the reactor 30 has three coil portions 30a and a reactor case 30b.
- the coil portion 30a is composed of a conductive wire wound around a central axis J extending in the vertical direction (first direction D1).
- the reactor case 30b is made of, for example, a resin material.
- the reactor case 30b accommodates the three coil portions 30a.
- Coil portion 30a and reactor case 30b are positioned on one side (right side in FIG. 2) of reactor base 35 in second direction D2.
- the three coil portions 30 a are arranged along the surface direction of the reactor base 35 .
- a part of the reactor pedestal 35 may protrude in the thickness direction to support the periphery of the reactor case 30b.
- inverter control board 41 and converter control board 42 are arranged above power modules 21 and 22 (one side in first direction D1).
- control boards 41 and 42 are simply referred to as control boards 41 and 42 .
- the inverter control board 41 is electrically connected to the motor power module 21 and the generator power module 22 via the first drive board 45 and the second drive board 46 .
- the inverter control board 41 controls the inverter circuits 11 and 12 .
- the inverter control board 41 generates a control signal for controlling the first switching element 16 of the motor power module 21 and the first switching element 16 of the generator power module 22 .
- the converter control board 42 is electrically connected to the power board 43 .
- the converter control board 42 controls the converter circuit 13 of the power board 43 .
- Converter control board 42 generates a control signal for controlling second switching element 17 of power board 43 .
- the board bodies 45a, 46a of the control boards 41, 42 are arranged along a horizontal plane (a plane perpendicular to the first direction D1). That is, the control boards 41 and 42 are arranged with the vertical direction (the first direction D1) as the plate thickness direction. Inverter control board 41 is arranged above converter control board 42 (one side in first direction D1).
- the control boards 41 and 42 are relatively susceptible to high-frequency electromagnetic wave noise.
- the inventors have found that high-frequency electromagnetic noise generated from the reactor 30 propagates radially outward of the central axis J of the reactor 30 .
- the control boards 41 and 42 are positioned radially outside the reactor 30 when viewed in the vertical direction (first direction D1). Further, the control boards 41 and 42 are positioned above the reactor 30 (on one side in the first direction D1). Therefore, according to the present embodiment, it becomes difficult for high-frequency electromagnetic wave noise propagating radially outward from the reactor 30 to reach the control substrates 41 and 42 .
- the control boards 41 and 42 are less likely to be affected by high-frequency electromagnetic wave noise, and the reliability of the control boards 41 and 42 can be enhanced.
- the reactor pedestal 35 is arranged between the reactor 30 and the control boards 41 and 42 and the power modules 21 and 22 when viewed in the vertical direction (first direction D1). Moreover, it is preferable to employ a magnetic shielding material (for example, an aluminum alloy) as a material constituting the reactor pedestal 35 . In this case, the reactor pedestal 35 shields electromagnetic noise that propagates from the reactor 30 to the outside in the radial direction of the central axis J and travels toward the control boards 41 and 42 and the power modules 21 and 22 . It should be noted that the effect of shielding electromagnetic waves by the reactor pedestal 35 is merely an auxiliary one. Therefore, it is not necessary to increase the thickness of the reactor pedestal 35 in order to enhance the shielding effect.
- a magnetic shielding material for example, an aluminum alloy
- a second cooling plate 62 is arranged between the power modules 21 and 22 and the reactor 30 to extend along the vertical direction (first direction D1). Moreover, it is preferable to adopt a magnetic shielding material (for example, an aluminum alloy) as the material constituting the second cooling plate 62 . In this case, the second cooling plate 62 shields electromagnetic noise that propagates from the reactor 30 to the outside in the radial direction of the center axis J and travels toward the control boards 41 and 42 and the power modules 21 and 22 .
- a magnetic shielding material for example, an aluminum alloy
- the capacitor module 15 is arranged between the power modules 21 , 22 and the second cooling plate 62 . Therefore, the capacitor module 15 shields electromagnetic noise that propagates from the reactor 30 to the outside in the radial direction of the center axis J and travels toward the control boards 41 and 42 and the power modules 21 and 22 .
- the power modules 21 and 22 are positioned radially outside the reactor 30 when viewed in the vertical direction (first direction D1).
- the power modules 21 and 22 are relatively large components among the members that configure the power converter 10 .
- the central axis J of the coil portion 30a extends along the first direction D1.
- the phrase “along the first direction D1” means that the central axis J is not only strictly parallel to the first direction D1, but also within a range of ⁇ 45° with respect to the first direction D1. , including the case of being inclined in at least one of the second direction D2 and the third direction D3. According to the present embodiment, even if the central axis J of the coil portion 30a is arranged in a posture inclined within a range of ⁇ 45° with respect to the vertical direction (the first direction D1), the above-described certain effects can be obtained. Obtainable.
- control boards 41 and 42 and the power board 43 are stacked in the vertical direction (first direction D1). That is, the power board 43 is arranged in a layered manner with the control boards 41 and 42 .
- the control boards 41 and 42 and the power board 43 can be easily arranged close to each other, and a harness (not shown) connecting the boards can be shortened. As a result, electromagnetic noise generated from the harness can be reduced.
- the shielding plate 50 is arranged between the inverter control board 41 and the converter control board 42 .
- the shield plate 50 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the shield plate 50 is arranged with the vertical direction (the first direction D1) as the plate thickness direction.
- the shield plate 50 supports the control boards 41 and 42 . That is, inverter control board 41 is fixed to the upper surface of shielding plate 50 , and converter control board 42 is fixed to the upper surface of shielding plate 50 . Also, the shielding plate 50 is fixed to the inner surface of the housing 19 .
- the shield plate 50 shields magnetism between the inverter control board 41 and the converter control board 42 . Therefore, shield plate 50 prevents electromagnetic wave noise generated in one of inverter control board 41 and converter control board 42 from reaching and affecting the other.
- the shield plate 50 is made of, for example, an aluminum alloy. However, the shielding plate 50 may be made of an iron-based alloy for the purpose of enhancing the magnetic shielding effect.
- the converter control board 42 of the present embodiment is provided with both a high voltage region through which high voltage current flows and a low voltage region through which low voltage current flows.
- the inverter control board 41 is provided with only a low voltage region through which a low voltage current flows. According to the present embodiment, electromagnetic wave noise generated in the high voltage region of converter control board 42 can be suppressed from affecting inverter control board 41 .
- the shielding plate 50 covers the entire lower surface of the inverter control board 41 . That is, the shield plate 50 overlaps the entire inverter control board 41 when viewed in the vertical direction (first direction D1). Thereby, the shielding plate 50 effectively suppresses electromagnetic noise from reaching the inverter control board 41 from below.
- the inverter control board 41 is arranged above the shielding plate 50 (one side in the first direction D1), and the converter control board 42 is arranged below the shielding plate 50 .
- Inverter control board 41 is more susceptible to high-frequency electromagnetic wave noise from reactor 30 than converter control board 42 .
- by arranging the inverter control board 41 above the shielding plate 50 it is possible to suppress the electromagnetic wave noise of the reactor 30 positioned below the shielding plate 50 from reaching the inverter control board 41 . , the reliability of the power converter 10 can be enhanced.
- the coolant L flows through the passage forming body 60 .
- the flow path forming body 60 is a separate member from the housing 19 .
- the channel forming body 60 forms a channel for the coolant L inside the housing 19 .
- the coolant L flowing through the channel of the channel forming body 60 cools the components arranged inside the housing 19 .
- the flow path forming body 60 has a first flow path forming portion 60A and a second flow path forming portion 60B which are separable from each other.
- the first flow path forming portion 60A has a first cooling plate 61 and a second cooling plate 62 .
- the second flow path forming portion 60B has a third cooling plate 63 and a connecting pipe 64 .
- the second flow path forming portion 60B is connected to the first flow path forming portion 60A by connecting the connecting pipe 64 to the first cooling plate 61 . That is, the first flow path forming portion 60A and the second flow path forming portion 60B are connected to each other.
- a plurality of cooling plates 61, 62, 63 are provided inside the housing 19, and these cooling plates 61, 62, 63 are connected to each other. Therefore, a plurality of cooling plates 61, 62, 63 can be arranged in a complicated manner inside the housing 19, and the constituent members inside the housing 19 can be efficiently cooled.
- the first flow path forming portion 60A and the second flow path forming portion 60B are made of a metal material with high heat conductivity.
- materials forming the first flow path forming portion 60A and the second flow path forming portion 60B include an aluminum alloy and a copper alloy. It is more preferable to employ a material that shields magnetism (for example, an aluminum alloy) as the material forming the first flow path forming portion 60A and the second flow path forming portion 60B.
- the coolant L flows inside the passage forming body 60 in the order of the third cooling plate 63 , the connecting pipe 64 , the first cooling plate 61 and the second cooling plate 62 .
- Each part of the flow path forming body 60 will be described below along the flow of the coolant L.
- the third cooling plate 63 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the third cooling plate 63 is arranged with the vertical direction (the first direction D1) as the plate thickness direction.
- the third cooling plate 63 is arranged between the motor power module 21 and the generator power module 22 .
- the third cooling plate 63 cools the motor power module 21 and the generator power module 22 with the coolant L flowing therein.
- the third cooling plate 63 is provided with a first connection hole 63c, a third recess 63a, a first communication hole 63d, and a fourth recess 63b.
- the coolant L flows into the flow path forming body 60 through the first connection hole 63c.
- the first connection hole 63c opens in the second direction D2.
- An inflow port 69 for the coolant L is connected to the opening of the first connection hole 63c.
- the first connection hole 63c opens to the inner side surface of the third recess 63a.
- the third recess 63a is provided on the lower surface of the third cooling plate 63.
- the third recess 63a opens downward. That is, the third concave portion 63a opens toward the motor power module 21 side.
- the third recess 63a is covered with the motor power module 21 .
- a heat radiation fin 21p is directed to the upper surface of the motor power module 21 .
- the radiation fins 21p are arranged inside the third recesses 63a. Inside the third concave portion 63a, the coolant L flows between the radiation fins 21p.
- the first communication hole 63d penetrates the third cooling plate 63 in the vertical direction (first direction D1).
- the first communication hole 63d opens to the bottom surface of the third recess 63a and the bottom surface of the fourth recess 63b.
- 63 d of 1st communication holes mutually connect the 3rd recessed part 63a and the 4th recessed part 63b.
- the fourth recess 63b is provided on the upper surface of the third cooling plate 63.
- the fourth recess 63b opens upward. That is, the fourth concave portion 63b opens toward the generator power module 22 side.
- the fourth recess 63b is covered with the generator power module 22 .
- a radiation fin 22p is directed to the lower surface of the generator power module 22 .
- the radiation fins 22p are arranged inside the fourth concave portions 63b. Inside the fourth concave portion 63b, the coolant L flows between the radiation fins 22p.
- the coolant L passes through the first connection hole 63c, the third recess 63a, the first communication hole 63d, and the fourth recess 63b in this order.
- the coolant L cools the motor power module 21 when passing through the third recess 63a, and cools the generator power module 22 when passing through the fourth recess 63b.
- the power modules 21 and 22 are provided with the heat radiation fins 21p and 22p, a wide contact area between the power modules 21 and 22 and the coolant L can be ensured.
- the cooling medium L can be used for efficient cooling.
- the surface of the third cooling plate 63 facing one side in the second direction D2 contacts the capacitor module 15 . Thereby, the third cooling plate 63 cools the capacitor module 15 .
- the connecting pipe 64 extends along the vertical direction (first direction D1).
- the connecting pipe 64 connects the third cooling plate 63 and the first cooling plate 61 .
- the coolant L moves from inside the third cooling plate 63 to inside the first cooling plate 61 via the connecting pipe 64 .
- the first cooling plate 61 is arranged along a horizontal plane (a plane orthogonal to the first direction D1) and has a plate shape. That is, the first cooling plate 61 is arranged with the vertical direction (the first direction D1) as the plate thickness direction.
- the first cooling plate 61 is arranged along the lower surface of the power board 43 .
- a heat transfer plate 55 is provided between the first cooling plate 61 and the power board 43 .
- the first cooling plate 61 cools the power board 43 with the coolant L flowing inside. That is, the power board 43 is arranged on one side of the first cooling plate 61 and cooled by the coolant L. As shown in FIG.
- the first cooling plate 61 is provided with a second connection hole 61b, a first recess 61a, and a second communication hole 61c.
- the coolant L passes through the second connection hole 61b, the first recess 61a, and the second communication hole 61c in this order.
- the second connection hole 61b penetrates in the vertical direction (first direction D1).
- the second connection hole 61b opens downward.
- a connecting pipe 64 is connected to the opening of the second connecting hole 61b.
- the second connection hole 61b opens to the bottom surface 61f of the first recess 61a.
- the first concave portion 61a is provided on the lower surface of the first cooling plate 61.
- the first recess 61a opens upward. That is, the first concave portion 61a opens toward the power substrate 43 side.
- the coolant L flows through the first concave portion 61a.
- the first recess 61 a is covered with the heat transfer plate 55 .
- the coolant L in the first recess 61 a cools the power board 43 via the heat transfer plate 55 .
- the first concave portion 61a has a bottom surface 61f facing the opening side.
- the bottom surface 61f has an inclined surface 61s.
- 61 s of inclined surfaces deepen the opening depth toward the downstream of the refrigerant
- 61 s of inclined surfaces are provided in a part of 61 f of bottom surfaces.
- the bottom surface 61f as a whole may be an inclined surface in which the depth of the opening increases toward the downstream side of the coolant L.
- the second communication hole 61c extends along the second direction D2.
- the second communication hole 61c opens to the bottom surface 61f of the first recess 61a.
- the second communication hole 61c opens to the bottom surface 62f of the second recess 62a.
- the second communication hole 61c allows the first recess 61a and the second recess 62a to communicate with each other.
- the second cooling plate 62 is arranged along the vertical direction (first direction D1) and has a plate shape. Also, the second cooling plate 62 is arranged with the second direction D2 as the plate thickness direction.
- the second cooling plate 62 is arranged along the reactor 30 .
- a reactor pedestal 35 is provided between the second cooling plate 62 and the reactor 30 .
- the second cooling plate 62 cools the reactor 30 with the coolant L flowing inside. That is, the reactor 30 is arranged on one side of the second cooling plate 62 and cooled by the coolant L. As shown in FIG.
- the second cooling plate 62 is provided with a second concave portion 62a and a discharge hole 62b.
- the coolant L passes through the second recesses 62a and the discharge holes 62b in this order.
- the second concave portion 62a is provided on the surface of the second cooling plate 62 facing one side (right side in FIG. 2) in the second direction D2.
- the second recess 62a opens on one side in the second direction D2. That is, the second recessed portion 62a opens toward the reactor 30 side.
- the second recess 62a has a bottom surface 62f facing the opening side.
- a second communication hole 61c extending from the first cooling plate 61 opens in the bottom surface 62f.
- the coolant L flows into the second recess 62a through the second communication hole 61c.
- the coolant L flows through the second concave portion 62a.
- the second recess 62 a is covered with the reactor base 35 .
- the coolant L in the second recess 62 a cools the power board 43 via the reactor base 35 .
- the surface of the second cooling plate 62 facing the other side in the second direction D2 contacts the capacitor module 15. Thereby, the second cooling plate 62 cools the capacitor module 15 .
- the discharge hole 62b extends vertically (first direction D1) from the inner wall surface of the second recess 62a. That is, the discharge hole 62b opens to the inner wall surface of the second recess 62a. Also, the discharge hole 62 b opens at the lower end of the second cooling plate 62 .
- the discharge hole 62 b is disposed on the most downstream side of the flow path forming body 60 and discharges the coolant L inside the flow path forming body 60 . In addition, you may arrange
- the first flow path forming portion 60A of this embodiment has a first cooling plate 61 and a second cooling plate 62 that intersect each other. That is, the second cooling plate 62 crosses the first cooling plate 61 and is connected to the first cooling plate 61 .
- the first cooling plate 61 and the second cooling plate 62 “intersect” means that the first cooling plate 61 and the second cooling plate 62 are arranged along planes that are not parallel to each other and connected to each other. means to be
- the first cooling plate 61 and the second cooling plate 62 are arranged in the housing 19 so as to cross each other.
- the degree of freedom in arranging each component within the housing 19 is increased compared to the case where the housing itself is provided with a flow path and the heating element is arranged along the housing for cooling.
- the flow path forming body 60 can be efficiently arranged in the gap between each component of the power conversion device 10. can be placed in
- the larger one of the two crossing angles formed by the first cooling plate 61 and the second cooling plate 62 is assumed to be the dominant angle ⁇ , and the smaller one is assumed to be the minor angle ⁇ .
- the dominant angle ⁇ is an angle greater than 180°.
- Each beta is an angle of less than 180°.
- the first cooling plate 61 and the second cooling plate 62 are orthogonal to each other. The dominant angle ⁇ is therefore 270° and the minor angle ⁇ is 90°.
- the reactor 30 and the power board 43 are arranged on the side of the reflex angle ⁇ between the first cooling plate 61 and the second cooling plate 62 .
- the power modules 21 and 22 and the capacitor module 15 are arranged on the minor angle ⁇ side formed by the first cooling plate 61 and the second cooling plate 62 .
- the reactor 30 and the power board 43 which are relatively small in thickness among the heating elements, are arranged on the dominant angle ⁇ side of the first flow path forming portion 60A, so that the power conversion device 10 is Can be made smaller.
- the relatively large power modules 21 and 22 and the capacitor module 15 among the heat generating elements are arranged on the minor angle ⁇ side of the first flow path forming portion 60A, so that the first cooling plate The area surrounded by 61 and the second cooling plate 62 can be efficiently used to reduce the size of the power conversion device 10 .
- the reactor 30, the power board 43, the power modules 21 and 22, and the capacitor module 15 can be efficiently cooled.
- the area where the reactor 30 and the power board 43 are arranged and the area where the power modules 21 and 22 and the capacitor module 15 are arranged can be partitioned by the flow path forming body 60 . Thereby, the inside of the housing 19 can be efficiently utilized.
- the first cooling plate 61 is arranged between the power board 43 and the power modules 21 and 22 .
- the first cooling plate 61 separates the space for arranging the power substrate 43 and the space for arranging the power modules 21 and 22 to suppress heat exchange therebetween.
- one of the power board 43 and the power modules 21 and 22 can be prevented from being heated by the other, and the reliability of the power board 43 and the power modules 21 and 22 can be improved.
- the second cooling plate 62 is arranged between the reactor 30 and the capacitor module 15 .
- the second cooling plate 62 efficiently cools the reactor 30 and the capacitor module 15 on both sides.
- the second cooling plate 62 separates the space for arranging the reactor 30 and the space for arranging the capacitor modules 15 to suppress heat exchange therebetween. Thereby, one of reactor 30 and capacitor module 15 can be prevented from being heated by the other, and the reliability of reactor 30 and capacitor module 15 can be improved.
- the motor power module 21, the third cooling plate 63, the generator power module 22, the first cooling plate 61, and the power substrate 43 form a laminated structure. Therefore, these components can be easily arranged at high density, the internal space of the housing 19 can be effectively used, and the power conversion device 10 can be miniaturized as a whole. Moreover, the power modules 21 and 22 and the power board 43 which are heat generating bodies can be efficiently cooled by using the first cooling plate 61 and the third cooling plate 63 . In addition, a first cooling plate 61 and a third cooling plate 63 are arranged between the power modules 21 and 22 and the power board 43, which are heating elements, respectively. Therefore, even if the heating elements are arranged close to each other, the heating elements can be prevented from heating each other, and the reliability of the power modules 21 and 22 and the power board 43, which are the heating elements, can be improved.
- the coolant L cools the power modules 21 and 22, the power board 43, and the reactor 30 in this order from the upstream side to the downstream side.
- the temperature of the heating elements of the power conversion device 10 tends to increase in the order of the power modules 21 and 22, the power board 43, and the reactor 30.
- FIG. According to the present embodiment, by cooling the coolant L in this order, it is possible to supply a coolant with a lower temperature to the heating element that needs to be cooled more, and the reliability of the power conversion device 10 can be improved. can.
- the motor power module 21 is used more frequently than the generator power module 22 and tends to reach high temperatures.
- the coolant L cools the motor power module 21 and the generator power module 22 in this order. Therefore, it is possible to prevent the motor power module 21, which tends to be heated to a high temperature, from becoming hot, and improve the reliability of the power conversion device 10.
- the power conversion device 10 is provided with the motor power module 21 connected to the motor 2 and the generator power module 22 connected to the generator 3 as the power modules.
- the power converter 10 may have only one of the motor power module 21 and the generator power module 22 .
- the inclined surface 61s is provided on the bottom surface of the first concave portion 61a.
- the inclined surface may be provided on the bottom surface of the second recess 62a. That is, the inclined surface may have the bottom surface of at least one of the first recess 61a and the second recess 62a.
- the shape of the fins is not limited as long as the heat radiation area can be increased.
- a plurality of pin fins or plate-like fins may be used.
- First cooling plate 61a First concave portion 61f, 62f Bottom surface 61s Inclined surface 62 Second cooling plate , 62a...Second concave portion, 63...Third cooling plate, D1...First direction, D2...Second direction, J...Center axis line, L...Refrigerant, ⁇ ...Major angle, ⁇ ...Minor angle
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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
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- Thermal Sciences (AREA)
- Electromagnetism (AREA)
- Inverter Devices (AREA)
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Abstract
Description
以下、電力変換装置10の各構成について具体的に説明する。
以下の説明において、モータ用インバータ回路11と発電機用インバータ回路12とを区別しない場合、これらを単に、インバータ回路11、12と呼ぶ。
図2には、第1方向D1と第2方向D2と第3方向D3を図示する。
本実施形態において、第1方向D1は上下方向であり、第1方向D1の一方側が上側であり、第1方向D1の他方側が下側である。
第2方向D2は、第1方向D1と直交する方向である。本実施形態において、第2方向D2は、水平面に沿う一方向である。第2方向D2の一方側が図2において右側であり、第2方向D2の他方側が図2において左側である。
第3方向D3は、水平方向に沿う方向であり、第1方向D1および第2方向D2と直交する方向である。すなわち、第1方向D1と第2方向D2と第3方向D3とは、それぞれ互いに直交する方向である。
以下の説明において、モータ用パワーモジュール21と発電機用パワーモジュール22とを区別しない場合、これらを単に、パワーモジュール21、22と呼ぶ。
リアクトル30は、3つのコイル部30aと、リアクトルケース30bと、を有する。コイル部30aは、上下方向(第1方向D1)に沿う中心軸線J周りに巻き回される導線から構成される。リアクトルケース30bは、例えば、樹脂材料から構成される。リアクトルケース30bは、3つのコイル部30aを収容する。コイル部30aおよびリアクトルケース30bは、リアクトル台座35の第2方向D2の一方側(図2中右側)に位置する。3つのコイル部30aは、リアクトル台座35の面方向に沿って並ぶ。
リアクトル台座35の一部が厚み方向に突出しており、リアクトルケース30bの周囲を支持する構成としても良い。
以下の説明において、インバータ制御基板41とコンバータ制御基板42とを区別しない場合、これらを単に、制御基板41、42と呼ぶ。
Claims (12)
- インバータ回路およびコンバータ回路を有する電力変換装置であって、
前記インバータ回路を有するパワーモジュールと、
前記コンバータ回路に供給される直流電流を平滑化するリアクトルと、
前記インバータ回路および前記コンバータ回路の少なくとも一方を制御する制御基板と、を備え、
前記制御基板は、前記パワーモジュールに対し第1方向の一方側に、第1方向を板厚方向として配置され、
前記リアクトルは、前記第1方向に沿う中心軸線周りに巻き回されるコイル部を有し、前記パワーモジュールに対し前記第1方向と直交する第2方向の一方側に配置され、
前記パワーモジュールおよび前記制御基板は、前記第1方向から見て、前記リアクトルの径方向外側に位置し、
前記制御基板は、前記リアクトルより前記第1方向の一方側に位置する、電力変換装置。 - 前記制御基板として、前記インバータ回路を制御するインバータ制御基板、および前記コンバータ回路を制御するコンバータ制御基板をそれぞれ備え、
前記インバータ制御基板と前記コンバータ制御基板との間に前記第1方向を板厚方向として配置される遮蔽板を備え、
前記遮蔽板は、前記インバータ制御基板と前記コンバータ制御基板の間で磁気をシールドする、請求項1に記載の電力変換装置。 - 前記インバータ制御基板は、前記遮蔽板より前記第1方向の一方側に配置される、請求項2に記載の電力変換装置。
- 前記コンバータ回路を有するパワー基板を備え、
前記パワー基板は、前記第1方向を板厚方向とし前記第1方向に沿って前記制御基板と積層して配置される、請求項1~3の何れか一項に記載の電力変換装置。 - 前記パワーモジュールと前記リアクトルとの間に配置され前記第1方向に沿って延びる冷却板を備え、
前記冷却板は、内部を冷媒が流れ前記リアクトルを冷却する、請求項1~4の何れか一項に記載の電力変換装置。 - 前記インバータ回路に供給される直流電流を平滑化するコンデンサモジュールを備え、
前記コンデンサモジュールは、前記パワーモジュールと前記冷却板との間に配置される、請求項5に記載の電力変換装置。 - 前記コンバータ回路を有するパワー基板と、
内部を冷媒が流れる流路形成体と、を備え、
前記冷媒は、前記パワーモジュール、前記パワー基板、および前記リアクトルを、上流側から下流側に向かってこの順に冷却する、請求項1~6の何れか一項に記載の電力変換装置。 - 前記パワーモジュールとして、モータに接続されるモータ用パワーモジュール、および発電機に接続される発電機用パワーモジュールをそれぞれ備える、請求項1~7の何れか一項に記載の電力変換装置。
- 前記コンバータ回路を有するパワー基板と、を備え、
前記パワー基板は、シリコンカーバイドを含むトランジスタを有し、
前記パワーモジュールは、絶縁ゲートバイポーラトランジスタを有する、請求項1~8の何れか一項に記載の電力変換装置。 - 前記第2方向を板厚方向とする板状のリアクトル台座を備え、
前記リアクトルは、前記リアクトル台座の前記第2方向の一方側に位置し前記リアクトル台座の面方向に沿って並ぶ3つの前記コイル部を有する、請求項1~9の何れか一項に記載の電力変換装置。 - 請求項1~10の何れか一項に記載の電力変換装置を有するモータ装置。
- 請求項11に記載のモータ装置を有する車両。
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JP2011243890A (ja) * | 2010-05-21 | 2011-12-01 | Denso Corp | 電力変換装置 |
WO2012056735A1 (ja) * | 2010-10-27 | 2012-05-03 | 三菱電機株式会社 | 電動パワーステアリング用モータ駆動制御装置 |
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JP2024072892A (ja) | 2024-05-29 |
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