WO2023002623A1 - Dispositif de conversion d'énergie électrique et procédé de fabrication de dispositif de conversion d'énergie électrique - Google Patents

Dispositif de conversion d'énergie électrique et procédé de fabrication de dispositif de conversion d'énergie électrique Download PDF

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Publication number
WO2023002623A1
WO2023002623A1 PCT/JP2021/027382 JP2021027382W WO2023002623A1 WO 2023002623 A1 WO2023002623 A1 WO 2023002623A1 JP 2021027382 W JP2021027382 W JP 2021027382W WO 2023002623 A1 WO2023002623 A1 WO 2023002623A1
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WO
WIPO (PCT)
Prior art keywords
bus bar
capacitor
negative
electrode bus
positive
Prior art date
Application number
PCT/JP2021/027382
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English (en)
Japanese (ja)
Inventor
ガネシュワラ ラオ ガンタ
晃 松下
成久 大和田
慎也 加藤
Original Assignee
日立Astemo株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 日立Astemo株式会社 filed Critical 日立Astemo株式会社
Priority to JP2023536308A priority Critical patent/JPWO2023002623A1/ja
Priority to PCT/JP2021/027382 priority patent/WO2023002623A1/fr
Publication of WO2023002623A1 publication Critical patent/WO2023002623A1/fr

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    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

Definitions

  • the present invention relates to a power conversion device and a method for manufacturing a power conversion device.
  • Patent Document 1 discloses an anode bus bar, a cathode bus bar, a first capacitive element connected between the anode bus bar and a ground connection body connected to the ground, and a connection between the cathode bus bar and the ground connection body.
  • a high voltage filter in which a cathode terminal of a capacitive element is arranged adjacently, and a cathode terminal of the second capacitive element and an anode terminal of the third capacitive element are arranged adjacently.
  • a power conversion device includes a first magnetic core having a through hole, a positive electrode bus bar and a negative electrode bus bar that are inserted into the through hole of the first magnetic core, and the positive electrode bus bar or the a filter unit having a capacitor connected to a negative bus bar; and a metal base on which the filter unit is mounted on a mounting surface.
  • Each of the positive electrode bus bar and the negative electrode bus bar has a vertical surface extending along the mounting surface and along the longitudinal direction, and one terminal of the capacitor extends along the positive electrode bus bar. It is directly connected to a vertical plane or said vertical plane of said negative bus bar.
  • a method for manufacturing a power conversion device is a method for manufacturing a power conversion device including a magnetic core having a through hole, an elongated bus bar elongated in the longitudinal direction, and a capacitor, wherein the through hole is an inserting step of inserting the bus bar in the longitudinal direction by using a squeegee; and a connecting step of directly connecting the connecting terminal of the capacitor to the side surface of the bus bar in the longitudinal direction after the inserting step.
  • the power conversion device can be downsized.
  • FIG. 1 A first embodiment of an inverter, which is a power converter, will be described below with reference to FIGS. 1 to 7.
  • FIG. 1 A first embodiment of an inverter, which is a power converter, will be described below with reference to FIGS. 1 to 7.
  • FIG. 1 A first embodiment of an inverter, which is a power converter, will be described below with reference to FIGS. 1 to 7.
  • FIG. 1 A first embodiment of an inverter, which is a power converter
  • FIG. 1 is an exploded perspective view of the inverter 100.
  • FIG. 1 to 4 show common X, Y and Z axes for clarity of correlation between the figures.
  • Inverter 100 converts, for example, DC power obtained from a high-voltage battery mounted on a vehicle into AC power for driving a main motor and a plurality of motors of an electric vehicle.
  • Inverter 100 may further include functions such as boosting, switch protection, and regenerative braking.
  • the inverter 100 includes a housing 1 , a DC connector 2 , a filter unit 3 , a DC link capacitor 4 , a power module 5 , a control board 6 and an AC connector 7 .
  • Housing 1 is a metal case that houses components of inverter 100 including DC connector 2 , filter unit 3 , DC link capacitor 4 , power module 5 , control board 6 , and AC connector 7 .
  • a DC connector 2 is an interface that receives DC power from a battery (not shown).
  • a DC power cable (not shown) is connected to the DC connector 2 on the outside of the inverter 100 .
  • a filter unit 3 is connected to the DC connector 2 on the inner side of the inverter 100 .
  • the filter unit 3 limits the unintended generation, propagation and reception of electromagnetic energy that can cause undesirable effects such as electromagnetic interference (EMI) and physical damage to operating equipment.
  • a surface which is a part of the housing 1 and which is a projection of the filter unit 3 on the negative side in the Z direction is referred to as a "mounting surface” 1B.
  • the filter unit 3 is fixed to the mounting surface 1B.
  • the DC link capacitor 4 is used for the purpose of adjusting the DC link voltage and absorbing switching ripple current.
  • the DC link capacitor 4 is also called a "smoothing capacitor".
  • the power module 5 is a power semiconductor device with multiple chips for controlling the torque and speed of the motor by pulse width modulation.
  • a control board 6 controls the power module 5 .
  • the AC connector 7 is an interface that supplies AC power from the inverter 100 to a motor (not shown).
  • FIG. 2 is an exploded perspective view of the filter unit 3.
  • FIG. 2 has a posture in which the filter unit 3 shown in FIG. 1 is turned upside down so that the Z-axis faces in the opposite direction and rotated within the XY plane.
  • Filter unit 3 includes P bus bar 11 , N bus bar 12 , first magnetic core 21 , second magnetic core 22 , X capacitor 30 and Y capacitor 40 .
  • X capacitor 30 includes a first X capacitor 31 , a second X capacitor 32 and a third X capacitor 33 .
  • Y capacitor 40 includes a first Y capacitor 41 , a second Y capacitor 42 , a third Y capacitor 43 , a fourth Y capacitor 44 , a fifth Y capacitor 45 and a sixth Y capacitor 46 .
  • the number of capacitors constituting the X capacitor 30 and the Y capacitor 40 and the arrangement of each capacitor can be changed according to EMC requirements and performance.
  • the P busbar 11 and the N busbar 12 may be collectively referred to as the "busbar" 10, and the first magnetic core 21 and the second magnetic core 22 may be collectively referred to as the "core” 20.
  • P bus bar 11 and N bus bar 12 extend longitudinally along the Y-axis and electrically connect DC connector 2 and DC link capacitor 4 .
  • the busbar 10 has a shape obtained by processing an elongated plate-like member.
  • the busbar 10 has a wide surface parallel to the YZ plane, except for the portion connected to the DC connector 2, and the thickness dimension in the X-axis direction is shorter than not only the Y-axis dimension in the extending direction but also the Z-axis dimension. .
  • the X capacitor 30 is connected between the P busbar 11 and the N busbar 12 to filter differential mode noise.
  • a Y capacitor 40 is connected between either busbar and ground to remove common mode noise.
  • Y capacitor 40 is arranged so that two terminals are aligned in the X-axis direction in order to shorten the length of P bus bar 11 and N bus bar 12 .
  • Core 20 functions as a common mode choke to suppress noise.
  • the core 20 has a through hole through which the busbar 10 is inserted.
  • the bus bar 10 releases heat to the mounting surface 1B and the housing 1 via any TIM (Thermal Interface Material).
  • a non-split core is used as the core 20 because the non-split core has much higher EMC performance than the split core.
  • the P bus bar 11, the N bus bar 12, the X capacitor 30, and the Y capacitor 40 symmetrically, the stray inductance and stray capacitance can be reduced and the electrical characteristics can be improved by a well-balanced layout. can.
  • the components of the filter unit 3 including the P busbar 11 and the N busbar 12 can also be arranged in an L shape according to package requirements.
  • FIG. 3 is a perspective view of the filter unit 3.
  • FIG. The view of FIG. 3 is the same as that of FIG.
  • the filter unit 3 shown in FIG. 3 shows a state before the ground bus bar 60 is attached.
  • the ground busbars 60 include a first ground busbar 61 , a second ground busbar 62 , a third ground busbar 63 , a fourth ground busbar 64 , a fifth ground busbar 65 and a sixth ground busbar 66 .
  • the first ground bus bar 61 to sixth ground bus bar 66 are connected to the first Y capacitor 41 to sixth Y capacitor 46, respectively.
  • Y capacitor 40 has one terminal connected to ground bus bar 60 and the other terminal connected to P bus bar 11 or N bus bar 12 .
  • the ground bus bar 60 is connected to the ground potential via the mounting surface 1B (not shown in FIG. 3).
  • FIG. 4 is a rear view of the filter unit 3.
  • the leftward direction in the drawing is the positive side of the Y-axis
  • the downward direction in the drawing is the positive side of the X-axis.
  • the plus side of the Z axis is the depth direction.
  • the ground bus bar 60 is not shown in FIG. 4 for convenience of drawing. The configuration of the filter unit 3 will be described in detail with reference to FIGS. 3 and 4.
  • a total of nine capacitors included in the filter unit 3 can be classified into three according to the arranged X-axis coordinates.
  • the first group is the first Y-capacitor 41, the third Y-capacitor 43, and the fifth Y-capacitor 45 whose X-coordinate value is "x1".
  • the second group is three X-capacitors 30 with an X-coordinate value of "x2".
  • the third group is the second Y capacitor 42, the fourth Y capacitor 44, and the sixth Y capacitor 46, whose X coordinate value is "x3".
  • Each X capacitor 30 is connected to the P busbar 11 and the N busbar 12 . All the capacitors forming the filter unit 3 have two terminals arranged in the X-axis direction.
  • the relatively wide interval between the P bus bar 11 and the N bus bar 12 at the position in contact with the X capacitor 30 is also referred to as "first distance”.
  • the relatively narrow interval between the P bus bar 11 and the N bus bar 12 at the position in contact with the Y capacitor 40 is also called a "second distance”.
  • a region in which the distance between the P bus bar 11 and the N bus bar 12 is the first distance is also referred to as a "first region”
  • a region in which the distance between the two is the second distance is also referred to as a "second region”.
  • the X capacitor 30 and the Y capacitor 40 are in direct contact with the busbar 10. More specifically, the X capacitor 30 and the Y capacitor 40 have connection terminals extending in the Z direction and directly contact wall surfaces of the bus bar 10 parallel to the YZ plane. Details will be described later with reference to another drawing.
  • the terminals of each capacitor are in contact with the P bus bar 11 from the negative side of the X axis. may contact from the positive side of the X-axis.
  • the terminals of each capacitor are in contact with the N bus bar 12 from the plus side of the X axis, but some of the capacitor terminals may be in contact with the minus side of the X axis. , the terminals of all the capacitors may contact from the minus side of the X-axis.
  • FIG. 5 is an external view of the housing 1, viewed from a position higher than that of FIG.
  • the mounting surface 1B of the housing 1 is provided with connection bosses 71-76.
  • the connection bosses 71 to 76 of the housing 1 shown in FIG. 5 and the ground bus bar 60 are connected with the filter unit 3 shown in FIG. 3 turned upside down.
  • a partition member SP shown in the center of FIG. 5 is a partition that separates the area in which the filter unit 3 is stored from other areas.
  • the partition member SP is connected to the bottom of the housing 1 on the negative side in the Z direction and forms a bathtub-shaped space in which the filter unit 3 is arranged.
  • FIG. 6 is a circuit diagram of the inverter 100.
  • FIG. Housing 1 serves as electrical ground.
  • FIG. 6 shows the DC connector 2, the filter unit 3, the DC link capacitor 4, the power module 5, and the AC connector 7 in order from the left.
  • FIG. 6 does not show the control board 6 that controls the power module 5 .
  • straight lines extending laterally from DC connector 2 correspond to P bus bar 11 and N bus bar 12 .
  • the three capacitors connecting the P busbar 11 and the N busbar 12 are the first X capacitor 31, the second X capacitor 32, and the third X capacitor 33.
  • Ground busbar 60 shown in FIG. 3 and connecting bosses 71 to 76 shown in FIG. Y capacitors 40 are six capacitors that connect either one of the P bus bar 11 and the N bus bar 12 to the ground.
  • FIG. 7 is a schematic diagram explaining the connection between the bus bar 10 and the capacitor.
  • the N bus bar 12 is shown as a representative of the bus bar 10
  • the second Y capacitor 42 is shown as a representative of the X capacitor 30 and the Y capacitor 40.
  • the mounting surface 1B is a surface parallel to the XY plane.
  • the longitudinal direction of the N busbar 12 extends parallel to the Y-axis along the mounting surface 1B.
  • the N bus bar 12 has a vertical surface 12S along the Y-axis direction which is vertical and longitudinal to the mounting surface 1B.
  • the vertical surface 12S can also be said to be a surface of the outer wall surface of the busbar 10 that is not parallel to the mounting surface 1B and is not a surface that exists at both ends of the busbar 10 in the longitudinal direction.
  • the N bus bar 12 does not meander in the X-axis direction in FIG. 7 because it is a simplified illustration, the vertical plane 12S also includes a region that meanders in the X-axis direction.
  • the second Y capacitor 42 has two connection terminals extending in the Z direction, and at least one connection terminal has a side surface in direct contact with the vertical surface 12S of the N bus bar 12 .
  • the second Y capacitor 42 and the N bus bar 12 are in contact or very close together in the Z direction so that the connection terminal is in contact with the vertical surface 12S of the N bus bar 12 over approximately the entire length.
  • the second Y capacitor 42 may be in contact with the N bus bar 12 from the plus side or the minus side of the X coordinate.
  • the P bus bar 11 not shown in FIG. 7 also has a vertical surface 11S.
  • the positions of the busbar 10 and the capacitor may be reversed in the Z direction.
  • a method of manufacturing filter unit 3 included in inverter 100 will be described.
  • the bus bar 10 is processed into the shape shown in FIG.
  • the core 20 is passed through one of the busbars 10 and laterally offset at the required position.
  • the other busbar 10 is inserted through the offset core 20 .
  • the X capacitor 30 and the Y capacitor 40 are ultrasonically bonded to the vertical surface of the busbar 10 .
  • Other welding methods such as laser welding and TIG welding may be used.
  • the X capacitors 30 and the Y capacitors 40 may be connected to the inner vertical surface or the outer vertical surface of the busbar 10 .
  • the ground bus bar 60 is welded to the ground terminal of the Y capacitor 40.
  • Connection bosses 71 to 76 are fixed in advance to the mounting surface 1B, and the ground bus bar 60 is connected to the connection bosses 71 to 76 using screws. Thereby, the bus bar 10 is sandwiched between the housing 1 and each capacitor. Note that the ground terminal of the Y capacitor 40 may be directly welded to the housing 1 without using the ground bus bar 60 and screws.
  • the housing 1 has a bathtub-shaped space in which the filter unit 3 is arranged, and the potting material is injected into the space after the filter unit 3 is arranged.
  • This potting material acts as fixing, cooling and insulating.
  • the filter unit 3 may be molded in resin and fixed to the housing 1 with screws via a cooling TIM such as a heat conductive sheet, potting, or grease.
  • a cooling TIM such as a heat conductive sheet, potting, or grease.
  • mold sealing, outsert molding, an insulating sheet, or the like may be used.
  • the inverter 100 which is a power conversion device, includes a first magnetic core 21 having a through hole, a positive bus bar 11 and a negative bus bar 12 inserted through the through hole of the first magnetic core 21, and a positive bus bar 11 or a filter unit 3 having a capacitor connected to a negative bus bar 12;
  • the longitudinal direction of each of positive electrode bus bar 11 and negative electrode bus bar 12 extends in the Y-axis direction along mounting surface 1B.
  • Each of the positive electrode busbar 11 and the negative electrode busbar 12 has a vertical surface 11S and a vertical surface 12S that are perpendicular to the mounting surface 1B and extend along the longitudinal direction.
  • One terminal of X capacitor 30 and Y capacitor 40 is directly connected to vertical surface 11S or vertical surface 12S. Therefore, X capacitor 30 and Y capacitor 40 are directly connected to bus bar 10, and filter unit 3 can be miniaturized.
  • terminals for connecting to the respective capacitors are provided on the sides of the bus bar 10 .
  • the terminals cannot pass through the through holes of the core 20, so the bus bar 10 must be divided into a plurality of parts. Therefore, there is a problem that the size of the busbar 10 increases because it is necessary to provide a connecting portion for the busbar 10 .
  • the inverter 100 according to the present embodiment does not have such a problem, so it can be miniaturized.
  • the overall length of the bus bar 10 is short, effects such as reduction in power loss, reduction in inductance, and reduction in ripple voltage and surge voltage can be obtained.
  • Filter unit 3 of inverter 100 includes second magnetic core 22 having a through hole.
  • the positive bus bar 11 and the negative bus bar 12 are inserted through the through holes of the first magnetic core 21 and through the through holes of the second magnetic core 22 .
  • Second X capacitor 32 , third Y capacitor 43 , and fourth Y capacitor 44 are connected to positive bus bar 11 or negative bus bar 12 between first magnetic core 21 and second magnetic core 22 . Therefore, even the inverter 100 including a plurality of cores 20 can be miniaturized.
  • the capacitor includes an X capacitor 30 having one terminal connected to the positive bus bar 11 and the other terminal connected to the negative bus bar 12, and one terminal connected to either the positive bus bar 11 or the negative bus bar 12.
  • Y capacitor 40 connected to the housing 1 and having the other terminal connected to the housing 1 . Therefore, inverter 100 including X capacitor 30 and Y capacitor 40 can be miniaturized.
  • the positive bus bar 11 and the negative bus bar 12 have a first region with a first distance and a second region with a second distance smaller than the first distance.
  • the X capacitor 30 is connected to the first region of the positive busbar 11 and the negative busbar 12
  • the Y capacitor 40 is connected to the second region of the positive busbar 11 or the negative busbar 12 .
  • the housing 1 is formed with a bathtub-shaped accommodation space having a mounting surface 1B as a bottom surface and accommodating at least the positive electrode bus bar 11 and the negative electrode bus bar 12 .
  • This accommodation space is filled with an electrically insulating resin member. Therefore, the resin member can fix the filter unit 3, improve the heat conductivity, and provide insulation.
  • the method of manufacturing inverter 100 includes an inserting step of longitudinally inserting busbar 10 into a through-hole of core 20, and after the inserting step, capacitors are formed on vertical surfaces existing on longitudinal side surfaces of busbar 10. and a connecting step of directly connecting the connection terminals. Therefore, coupling processing of the bus bar 10 is unnecessary, and the size of the inverter 100 can be reduced.
  • inverter 100 After the connecting step, core 20, bus bar 10, and capacitors are arranged in a housing space of housing 1 having a bathtub-shaped housing space, and an electrically insulating resin member is filled. Including the filling process.
  • Filter unit 3 of inverter 100 includes two cores 20 . However, providing two cores 20 is not an essential configuration, and at least one may be provided. Inverter 100 may not include X capacitor 30 and may not include Y capacitor 40 . According to Modification 1, the present invention can be applied to various configurations.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)

Abstract

La présente invention concerne un dispositif de conversion d'énergie électrique comprenant une unité de filtre incluant un premier noyau de corps magnétique ayant un trou traversant, une barre omnibus d'électrode positive et une barre omnibus d'électrode négative qui sont insérées à travers le trou traversant dans le premier noyau de corps magnétique, un condensateur connecté à la barre omnibus d'électrode positive ou à la barre omnibus d'électrode négative, et une base métallique ayant une surface de placement sur laquelle l'unité de filtre est placée : les directions longitudinales de la barre omnibus d'électrode positive et de la barre omnibus d'électrode négative s'étendant le long de la surface de placement ; la barre omnibus d'électrode positive et la barre omnibus d'électrode négative ayant chacune une surface perpendiculaire qui est perpendiculaire à la surface de placement et qui s'étend dans la direction longitudinale ; et une borne du condensateur étant connectée directement à la surface perpendiculaire de la barre omnibus d'électrode positive ou à la surface perpendiculaire de la barre omnibus d'électrode négative.
PCT/JP2021/027382 2021-07-21 2021-07-21 Dispositif de conversion d'énergie électrique et procédé de fabrication de dispositif de conversion d'énergie électrique WO2023002623A1 (fr)

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JP2023536308A JPWO2023002623A1 (fr) 2021-07-21 2021-07-21
PCT/JP2021/027382 WO2023002623A1 (fr) 2021-07-21 2021-07-21 Dispositif de conversion d'énergie électrique et procédé de fabrication de dispositif de conversion d'énergie électrique

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PCT/JP2021/027382 WO2023002623A1 (fr) 2021-07-21 2021-07-21 Dispositif de conversion d'énergie électrique et procédé de fabrication de dispositif de conversion d'énergie électrique

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002204580A (ja) * 2000-10-31 2002-07-19 Fuji Electric Co Ltd 電力変換装置
WO2019150859A1 (fr) * 2018-02-02 2019-08-08 日立オートモティブシステムズ株式会社 Dispositif de circuit de filtre et appareil de conversion de puissance le comportant
JP2020054059A (ja) * 2018-09-25 2020-04-02 日立オートモティブシステムズ株式会社 高電圧フィルタおよび電力変換装置
JP2020088888A (ja) * 2018-11-15 2020-06-04 株式会社日立製作所 電圧フィルタおよび電力変換装置
JP2020102913A (ja) * 2018-12-20 2020-07-02 株式会社日立製作所 電力変換装置、及び高電圧ノイズフィルタ

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002204580A (ja) * 2000-10-31 2002-07-19 Fuji Electric Co Ltd 電力変換装置
WO2019150859A1 (fr) * 2018-02-02 2019-08-08 日立オートモティブシステムズ株式会社 Dispositif de circuit de filtre et appareil de conversion de puissance le comportant
JP2020054059A (ja) * 2018-09-25 2020-04-02 日立オートモティブシステムズ株式会社 高電圧フィルタおよび電力変換装置
JP2020088888A (ja) * 2018-11-15 2020-06-04 株式会社日立製作所 電圧フィルタおよび電力変換装置
JP2020102913A (ja) * 2018-12-20 2020-07-02 株式会社日立製作所 電力変換装置、及び高電圧ノイズフィルタ

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