JP4997056B2 - Bus bar structure and power converter using the same - Google Patents

Description

  The present invention relates to a power conversion device, for example, a power conversion device suitable for use in a vehicle.

  The power conversion device includes an inverter, a smoothing capacitor connected in parallel to the DC power supply terminal of the inverter, and a control circuit that controls the inverter. The inverter is composed of a plurality of power semiconductors, and the plurality of power semiconductors are handled as a power module in units of a predetermined number. Therefore, the inverter is one or a plurality of power modules including a plurality of power semiconductors. Composed.

  And in what constitutes such a power converter as a unit, for example, a plurality of power modules are arranged so that their input / output terminals are aligned in the vertical direction and arranged without stacking output conductor bus bars Are known.

  A power conversion device having such a configuration is disclosed in detail, for example, in Patent Document 1 below.

JP 2003-199363 A

  In pure electric vehicles that are driven by the output of a motor without using an internal combustion engine, or hybrid type electric vehicles that are used in combination with an internal combustion engine, the ratio of the interior of the vehicle to the entire volume of the vehicle is increased as much as possible to improve the comfort. It is hoped to improve. Therefore, it is desired to reduce the volume of the entire vehicle by further downsizing the control device. It is also desired to reduce the size of a power converter electrically connected to a vehicular rotating electrical machine. However, rotating electrical machines mounted on vehicles tend to have higher power, and the amount of heat generated by the power conversion device is larger than that in the early stages of development. In addition, the power to be handled increases due to the tendency to increase the power, and for example, in the output conductor bus bar, the one having a larger cross-sectional area tends to be used. As a solution to this, it is conceivable to increase the thickness and width of the bus bar. In this case, however, the entire apparatus tends to increase in size.

  An object of the present invention is to provide an output conductor bus bar structure capable of increasing power while suppressing increase in size and deterioration in assemblability, and a power converter using the output conductor bus bar structure.

  The representative invention disclosed in the present application has at least one of the following features. Next, features will be briefly described.

(1) One feature of the present invention is that the bus bar structure includes at least a metal bus bar, and a sheet-like insulating member attached to and fixed to the bus bar. The bus bar has a protruding shape on the end surface, and the insulating member is fixed. Each has a folded shape for
The fixing shape of the insulating member is pasted and fixed in accordance with the protruding shape of the bus bar.

(2) Another feature of the present invention is that the bus bar structure includes at least a plurality of metal bus bars, a plurality of sheet-like insulating members attached to and fixed to the bus bars, and a bracket for fixing the plurality of bus bars. The bus bar has a protruding shape on the end surface, and the insulating member has a folded shape for fixing.
The fixing shape of the insulating member is attached and fixed according to the protruding shape of the bus bar, and the insulating member is arranged so as to be positioned between the bus bars, and the fixing bracket is aligned with the protruding shape of the bus bar. is there.

(3) Still another feature of the present invention is that the power conversion device includes at least a metal housing, a water channel forming body disposed in the housing, a plurality of power modules, and an output conductor laminated via an insulating member. With a bus bar,
The plurality of power modules are arranged on the side of the water channel forming body, and the DC terminals of the respective power modules are arranged at the center of the housing, and the AC terminals of the respective power modules are arranged on the side of the housing. The AC terminal of the power module disposed on the side portion of the housing and the output conductor bus bar are electrically connected at the side portion of the housing.

  (4) Further features of the present invention will be further described in the embodiments described below.

  The effect of the present invention is that the power of the output conductor bus bar can be increased without enlarging the power conversion device and degrading the assemblability.

  Hereinafter, embodiments of a power conversion device according to the present invention will be described with reference to the drawings.

<< Electric Vehicle 100 >>
FIG. 1 is a schematic configuration diagram showing an embodiment of a hybrid electric vehicle equipped with a power conversion device according to the present invention. The power conversion device 200 according to the present invention can be applied to a pure electric vehicle, and the basic configuration and basic operation are very common between a hybrid electric vehicle and a pure electric vehicle. Therefore, an embodiment of a hybrid electric vehicle will be described below as a representative.

  The hybrid electric vehicle 100 including the front wheels 110 and the rear wheels 114 includes an engine 120, a first rotating electric machine 130, a second rotating electric machine 140, the first rotating electric machine 130, and the second rotating electric machine 140. A battery 180 for supplying high-voltage DC power is mounted. In practice, a battery for supplying low-voltage power (14-volt system power) is further mounted, and power serving as a power source for a control circuit described below is supplied, but the illustration is omitted. The rotational torque based on the engine 120, the first rotating electrical machine 130, and the second rotating electrical machine 140 is transmitted to the transmission 150 and the differential gear 160, and is transmitted to the front wheel 110 via the axle 112.

  A transmission control device 154 that controls the transmission 150, an engine control device 124 that controls the engine 120, a battery that controls the rotating electrical machine control circuit of the rotating electrical machine control circuit board 700 that controls the power converter 200, and a battery 180. The control device 184 is connected to the general control device 170 by an in-vehicle local area network 174 that is a communication line.

  The general control device 170 transmits information representing the respective states from the transmission control device 154, the engine control device 124, the power conversion device 200, and the battery control device 184, which are subordinate control devices, to the in-vehicle local area network 174. Receive through. These pieces of information are used for integrated control of the vehicle from the viewpoint of vehicle drivability and safety. The integrated control of the vehicle is a control achieved by the cooperative operation of the respective control devices, and a control command to each control device for realizing the integrated control of the vehicle is integrated control via the in-vehicle local area network 174. It is transmitted from the device 170 to each control device. For example, the battery control device 184 reports the discharge status of the battery 180 and the status of each cell battery constituting the battery 180 to the general control device 170. When it is determined from the above report that the battery 180 needs to be charged, the integrated control device 170 issues a power generation instruction to the power conversion device 200. The integrated controller 170 also manages the output torque of the engine 120 and the first and second rotating electrical machines 130 and 140, and the total torque or torque distribution of the output torque of the engine and the first and second rotating electrical machines 130 and 140. The ratio is obtained by arithmetic processing, and a control command based on the processing result is transmitted to the transmission control device 154, the engine control device 124, and the power conversion device 200. Based on the torque command, the power conversion device 200 controls the first rotating electric machine 130 and the second rotating electric machine 140, and generates either of these rotating electric machines or both of the rotating electric machines to generate the command torque output. Control the rotating electrical machine.

  The first rotating electrical machine 130 and the second rotating electrical machine 140 have a structure that can operate as an electric motor or a generator. For example, when the first rotating electrical machine 130 operates as an electric motor, the second rotating electrical machine 140 can be operated as an electric motor or a generator. As described above, based on the driving state of the vehicle, the overall control device 170 determines the target torque by calculating the distribution between the engine output torque and the output torque of the rotating electrical machine, and uses the target torque of the rotating electrical machine as a torque command. To the power conversion device 200 via the local area network 174. Based on the command, the power conversion device 200 determines whether the first rotating electric machine 130 and the second rotating electric machine 140 are each operated as an electric motor or a generator by an arithmetic process, and the first rotating electric machine 130 is operated. And the 2nd rotary electric machine 140 is controlled.

  However, as another embodiment, whether the first rotating electrical machine 130 and the second rotating electrical machine 140 are operated as electric motors or as generators may be determined by the above-described overall control device 170 by calculation. In this method, when the first rotating electrical machine 130 or the second rotating electrical machine 140 is operated by a motor, the generated torque is determined by the integrated controller 170, and when the generator is operated, the generated power is determined by the general controller 170. Is sent to the power converter 200 via the in-vehicle local area network 174 as a command.

  In either method, the power conversion device 200 switches the power semiconductor that constitutes the inverter to operate the first rotating electrical machine 130 and the second rotating electrical machine 140 based on a command from the general control device 170. Control the behavior. By the switching operation of these power semiconductors, the first rotating electrical machine 130 and the second rotating electrical machine 140 are operated as an electric motor or a generator. When operating as an electric motor, DC power from the high-voltage battery 180 is applied to the inverter of the power converter 200, and the DC power is converted into a three-phase AC current by controlling the switching operation of the power semiconductor constituting the inverter. The rotating electrical machine 130 or 140 is supplied to the rotating electrical machine 130 or 140, and the rotating electrical machine 130 or 140 generates a rotational torque as an electric motor. On the other hand, when operated as a generator, the rotor of the rotating electrical machine 130 or 140 rotates with external rotational torque, and three-phase AC power is generated in the stator winding of the rotating electrical machine based on this rotational torque. The generated three-phase AC power is converted into DC power by the power converter 200 and supplied to the high-voltage battery 180, and the battery 180 is charged with DC power.

  The engine 120 shown in FIG. 1 and the first and second rotating electrical machines 130 and 140 may be mechanically directly connected by a rotating shaft, or may be connected via a gear or a clutch. When the engine 120, the first rotating electrical machine 130, and the second rotating electrical machine 140 are directly connected, the first rotating electrical machine 130 and the second rotating electrical machine 140 rotate in direct proportion to the rotational speed of the engine. Since the first rotating electrical machine 130 and the second rotating electrical machine 140 vary in rotational speed over a wide range from the rotation stopped state to the high speed rotating state, the rotating electrical machine can withstand high speed rotation and requires mechanical strength. Further, when the first rotating electric machine 130 and the second rotating electric machine 140 are always rotating, the iron loss of the rotating electric machine is always generated, and there is a problem that the iron loss is large particularly in a high speed rotation state. On the other hand, this method has an advantage that the structure is simple and inexpensive.

  In addition, the method in which the first rotating electrical machine 130 and the second rotating electrical machine 140 are connected to the vehicle drive mechanism via a clutch or a transmission gear is a variation range of the rotational speeds of the first rotating electrical machine 130 and the second rotating electrical machine 140. There is an advantage that can be reduced. In addition, the first rotating electrical machine 130 and the second rotating electrical machine 140 can be separated from the drive mechanism of the vehicle as necessary, and there is an effect that reduction in operating efficiency due to iron loss of the rotating electrical machine can be suppressed. On the other hand, this system is complicated in structure and the system becomes expensive.

  As shown in FIG. 1, the power conversion device 200 controls a capacitor module 300 having a plurality of smoothing capacitors that suppresses voltage fluctuations of a DC power supply, a power module 500 incorporating a plurality of power semiconductors, and a switching operation of the power module 500. A substrate having a switching drive circuit (hereinafter referred to as a switching drive circuit substrate) 600 and a substrate having a rotating electrical machine control circuit for generating a PWM signal for controlling a signal for determining a time width of the switching operation, that is, a pulse-wide modulation. (Hereinafter referred to as a rotating electrical machine control circuit board) 700).

  By electrically connecting the power module 500, power semiconductors included in the power module 500 are electrically connected to form an inverter circuit. A signal for controlling the power semiconductor constituting the inverter circuit is generated by the rotating electrical machine control circuit board 700 and sent to the switching drive circuit board 600. The switching drive circuit board 600 is a so-called power semiconductor gate drive circuit, generates a gate drive signal to be supplied to the gate of each power semiconductor, and sends the gate drive signal to the gate of each power semiconductor. Based on this, each power semiconductor performs a switching operation.

  The high-voltage battery 180 is a secondary battery such as a nickel metal hydride battery or a lithium ion battery, and outputs high-voltage DC power of 300 volts, 600 volts, or more.

<< Overall configuration of power conversion device >>
2, 3, and 4 are exploded perspective views of the power conversion device 200 described above, and schematically show the overall configuration of the power conversion device 200. 2, 3 and 4 are exploded perspective views of the power converter 200 as seen from different directions.

  The power conversion device 200 includes a housing 210 having a box shape, and a water channel forming body 220 having a cooling water channel 216 in which cooling water circulates is provided at the bottom of the housing 210. A cooling water inlet pipe 212 and a cooling water outlet pipe 214 for supplying cooling water to the cooling water passage 216 are fixed to the bottom of the housing 210 so as to protrude to the outside of the housing 210.

  The power module 500 described with reference to FIG. 1 includes a first power module 502 and a second power module 504 arranged in parallel in the housing 210. The first power module 502 and the second power module 504 are provided with heat radiation fins 506 and 507 for cooling, respectively. On the other hand, the water channel forming body 220 is provided with openings 218 and 219 connected to the water channel. By fixing the first and second power modules 502 and 504 on the cooling passage 216, the cooling fins 506 and 507 for the cooling are respectively passed from the openings 218 and 219 provided in the water passage forming body 220. 216 projects into the interior. The openings 218 and 219 are closed by metal walls around the heat dissipating fins 506 and 507 so that cooling water does not leak and a cooling water channel is formed. The first power module 502 and the second power module 504 are arranged on the left and right sides of a virtual line segment orthogonal to the side wall surface of the housing 210 where the cooling water inlet pipe 212 and the cooling water outlet pipe 214 are formed. Are arranged in each. The cooling water channel formed inside the water channel forming body 220 extends from the cooling water inlet pipe 212 to the other end along the longitudinal direction of the bottom of the housing, and is folded back into a U-shape at the other end. Extending to the outlet tube 214 along the longitudinal direction of the tube. Two sets of parallel water channels along the longitudinal direction are formed in the water channel forming body 220, and the water channel forming body 220 is formed with the openings 218 and 219 having a shape penetrating each water channel. A first power module 502 and a second power module 504 are fixed to the water channel formation body 220 along the passage. The heat radiation fins provided in the first and second power modules 502 and 504 project into the water channel so that efficient cooling is achieved, and the metal water channel forming body 220 has the first and second powers. An efficient heat dissipation structure can be realized by closely contacting the heat dissipation surfaces of the modules 502 and 504. Further, since the openings 218 and 219 are respectively closed by the heat radiation surfaces of the first and second power modules 502 and 504, the structure is reduced in size and the cooling effect is improved.

  The first power circuit board 602 and the second power circuit board 604 are provided in a state where they are stacked on the first power module 502 and the second power module 504, respectively. The first drive circuit board 602 and the second drive circuit board 604 constitute the switching drive circuit board 600 described with reference to FIG.

  The first drive circuit board 602 disposed above the first power module 502 is formed slightly smaller than the first power module 502 when viewed in a plan view, and is shown in FIGS. Only the terminals arranged in parallel on both sides of the first power module 502 are exposed and visually observed, and most of the terminals are hidden behind the first drive circuit board 602 and cannot be visually observed. Similarly, when viewed in plan, the second drive circuit board 604 disposed above the second power module 504 is formed slightly smaller than the second power module 504. In FIG. 4, the terminals arranged in parallel on both sides of the second power module 504 are only exposed and visually observed, and most of the terminals are hidden by the second drive circuit board 604 and cannot be visually observed. ing.

  An inlet pipe 212 and an outlet pipe 214 for the cooling water are provided on the side surface of the housing 210, and a hole 260 is further formed on the side surface. A signal connector 282 is disposed in the hole 260. A noise removal board 560 and a second discharge board 520 that are fixed in the vicinity of the signal connector 282 are disposed inside the housing 210 at a position where the connector 282 is attached. These are attached so that the attachment surfaces of the noise removal substrate 560 and the second discharge substrate 520 are parallel to the attachment surfaces of the first power module 502, the second power module 504, and the like. .

  The noise removal substrate 560 is disposed so as to overlap the lower side of the second discharge substrate 520. For example, in FIG. 2, FIG. 3 and FIG. 4, the noise removal substrate 560 is hidden by the second discharge substrate 520 and cannot be seen. Yes. The noise removing substrate 560 and the second discharge substrate 520 are arranged in a state of being sufficiently separated from the switching drive circuit substrate 600 including the power module 500 and the switching drive circuit in the height direction of the housing 210. Has been. The switching drive circuit board 600 is composed of a plurality of boards including a first drive circuit board 602 and a second drive circuit board 604.

A capacitor module 300 having a plurality of smoothing capacitors is disposed above the plurality of drive circuit boards 602 and 604. The capacitor module 300 actually includes a first capacitor module 302 and a second capacitor module 304. Each of the first capacitor module 302 and the second capacitor module 304 is disposed above the first drive circuit board 602 and the second drive circuit board 604, respectively. Each of the first capacitor module 302 and the second capacitor module 304 is fixed to a holding plate 320 which will be described later, and its electrodes are configured to be connected to the power module 500.

  A flat holding plate 320 is disposed above the first capacitor module 302 and the second capacitor module 304 so that the periphery thereof is in close contact with the inner wall surface of the housing 210. The holding plate 320 supports and fixes the first capacitor module 302 and the second capacitor module 304 on the surfaces of the first and second power modules, and controls the rotating electrical machine on the opposite surface. The circuit board 700 is held and fixed. The holding plate 320 is made of, for example, a metal material like the housing 210, and the heat generated by the first capacitor module 302, the second capacitor module 304, and the rotating electrical machine control circuit board 700 is caused to flow to the housing 210. The structure is designed to dissipate heat.

  As described above, the power module 500, the switching drive circuit board 600, the noise removal board 560, the second discharge board 520, the capacitor module 300, the holding plate 320, and the rotating electrical machine control circuit board 700 are accommodated in the housing 210. The upper opening of the housing 210 is closed by a metal cover 290.

  Further, when the side wall of the housing 210 where the cooling water inlet pipe 212 and outlet pipe 214 are provided is the front, for example, the terminal box 800 is attached to the right side wall. The terminal box 800 includes a DC power terminal 812 for supplying DC power from the battery 180, a DC power terminal block 810 provided therein, a first rotating electrical machine 130, and a second power terminal. An AC power terminal 822 connected to the rotating electrical machine 140 and an AC terminal block 820 provided therein are provided.

  The DC power terminal block 810 is electrically connected to the electrodes of the first capacitor module 302 and the second capacitor module 304 via a bus bar, and the AC terminal block 820 includes a plurality of components constituting the power module 500. The power modules 502 and 504 are electrically connected to the AC terminals via bus bars, respectively.

  The terminal box 800 is configured by attaching a bottom plate portion 844 and a cover portion 846 in which the DC power terminal block 810 is disposed on the main body 840. This is to facilitate the assembly of the terminal box 800.

  The power conversion device 200 assembled in this way is configured as an extremely compact shape as shown in FIG.

  The DC power terminal block 810, the DC power terminal 812, the AC terminal block 820, and the AC power terminal 822 are, for example, made by operating the first rotating electrical machine 130 as a generator and obtaining the three Depending on the operation mode of the hybrid vehicle in which phase AC power (regenerative energy) is converted into DC power by the power converter 200 and supplied to the battery 180, each functions as an AC terminal, an AC terminal block, and an input terminal and a DC terminal block. To do.

《Electric circuit diagram of power conversion device》
Prior to detailed description of the above-described components of the power conversion device 200, the power module 500, the switching drive circuit board 600, the noise removal board 560, the second discharge board 520, and the rotating electrical machine control circuit board 700 are described. 6 and FIG. 7 will be described together with other components. 6 and 7 show partial diagrams obtained by dividing the circuit diagram into left and right, and the circuit diagram is completed by combining FIG. 6 and FIG.

<Noise removal substrate 560>
First, each signal that is input to or output from the power conversion device 200 through the signal connector 282 passes through the noise removal board 560. These signals include each signal from the rotational position sensor 132 of the rotor incorporated in the first rotating electrical machine 130, the signal from the temperature sensor 134 incorporated in the first rotating electrical machine 130, and the general control device 170. Signals transmitted / received to / from the control device via the vehicle-mounted local area network 174, the start signal 192 sent from the general control device 170, and the rotational position of the rotor incorporated in the second rotating electrical machine 140 These are a signal from the sensor 142, a signal from the temperature sensor 144 incorporated in the second rotating electrical machine 140, and an abnormality processing signal 194 sent from the general controller 170. The signal transmitted via the in-vehicle local area network 174 includes an engine speed signal and an accelerator opening signal.

  Further, the low voltage current sent from the low voltage battery is also configured to pass through the noise removal board 560, and the + electrode power supply from the 12V power supply 176 is connected to the other side from the one side of the noise removal board 560. Is output through the electrode, the filter circuit 570, and the electrode, and the negative electrode power source from the 12V power source 176 is output through the electrode, the wiring layer, and the electrode. ing.

  Each of the signals excluding the 12V power source 176 is output from one side of the noise removing substrate 560 to the other side via the electrode, the bypass capacitor 562, and the electrode. The bypass capacitor 562 is configured to be interposed between a wiring layer to which each signal is transmitted and a wiring layer to which a negative electrode power source from the 12V power source is supplied.

  The noise removing board 560 configured as described above is designed to remove noise superimposed on each signal by the bypass capacitor 162 and to input the noise to the rotating electrical machine control circuit board 700 described later.

  The noise removing board 560 is formed differently from the rotating electrical machine control circuit board 700 and is physically separated from the rotating electrical machine control circuit board 700. This is because the noise removing board 560 is arranged at a free place without being restricted by the place where the rotating electrical machine control circuit board 700 is placed.

  To physically separate a circuit (corresponding to a circuit on the noise removal board 560 of this embodiment) of a part that removes noise of an input signal from the rotating electrical machine control circuit board 700 having a relatively large area is the rotation. The electric control circuit board 700 can be reduced in size. Furthermore, the noise removal board 560 can be freely arranged such as being positioned in a plane parallel to or perpendicular to the rotating electrical machine control circuit board 700. Therefore, it is very convenient when the power converter 200 is to be miniaturized.

<Rotating electrical machine control circuit board 700>
Each signal from the rotational position sensor 132 and the temperature sensor 134 of the rotor input via the noise removal board 560 is input to the first microcomputer 702 via the interface circuit 732 on the rotating electrical machine control circuit board 700. It has come to be.

  Similarly, each signal from the rotational position sensor 142 and the temperature sensor 144 of the rotor input via the noise removing board 560 is sent to the second microcomputer 704 via the interface circuit 742 in the rotating electrical machine control circuit board 700. Is input.

  Information from the in-vehicle local area network 174 is sent to the first microcomputer 702 and the second microcomputer 704 via the communication driver circuit 720. Information representing the operating state is sent from the first microcomputer 702 and the second microcomputer 704 to the in-vehicle local area network 174 through the communication driver circuit 720 and the noise removal board 560, and a predetermined device, for example, a total It is sent to the control device 170. This general control device 170 determines the operation mode, for example, each mode when the vehicle starts or runs at low speed, during normal travel (medium speed, during high speed travel), acceleration, deceleration or braking. The general control device 170 that has determined the operation mode transmits a determination result to the first microcomputer 702 and the second microcomputer 704, and based on this result, the first microcomputer 702 and the second microcomputer 704 respectively The first rotating electrical machine 130 and the second rotating electrical machine 140 are controlled.

The control content corresponding to the operation mode is, for example, that the first rotating electrical machine 130 is mainly operated as an electric motor when the vehicle starts or runs at a low speed. During normal traveling of the vehicle, the engine 120 and the first rotating electrical machine 130 are used in combination, and the vehicle travels with both torques. During sudden acceleration of the vehicle or during high load operation, in addition to the operation during normal running, the output power from the battery 180 is converted into three-phase AC power and supplied to the second rotating electrical machine 140. The rotating electric machine is operated as an electric motor, and the output torque is used for driving the vehicle, and the operation is further performed by adding the output of the engine. When the vehicle is decelerated or braked, the first rotating electric machine 130 and the second rotating electric machine 140 are operated as generators, and the three-phase AC power obtained thereby is converted into DC power by an inverter described later. The battery 180 is supplied and charged.

  The first microcomputer 702 and the second microcomputer 704 that have received the operation mode information from the general controller 170 obtain the operation timings of the power semiconductor elements that constitute the inverter, respectively, by arithmetic processing. A timing signal based on the calculation result of the first microcomputer 702 is sent to the first drive circuit board 602 via the interface circuit 734. Further, the timing signal generated and calculated by the second microcomputer 704 is sent to the second drive circuit board 604 via the interface circuit 744.

  The output of the first current sensor 536 for detecting the current value flowing through each phase of the stator winding of the first rotating electrical machine 130 and the output of the first temperature sensor 532 incorporated in the first power module 502. Are taken into the first microcomputer 702 via the interface circuit 736. The first microcomputer 702 uses the output of the first current sensor 536 that has been taken in, so that the control based on the command value of the integrated control device 170 is performed. And feedback control. The output of the temperature sensor 532 is used for diagnosing abnormal operation.

  Similarly, the output of the second current sensor 538 that detects the current value flowing through each phase of the stator winding of the second rotating electrical machine 140 and the second temperature sensor 534 incorporated in the second power module 504. Are output to the second microcomputer 704 via the interface circuit 746. The second microcomputer 704 uses the output of the second current sensor 536 that has been taken in, so that the control based on the command value of the general control device 170 is performed. And feedback control. The output of the second temperature sensor 534 is used for diagnosing abnormal operation.

  The first current sensor 536 and the second current sensor 538 are provided on an AC terminal block 820 described later.

  The rotating electrical machine control circuit board 700 has an abnormality monitoring circuit 760. The abnormality monitoring circuit 760 receives an abnormality processing signal from the general controller 170 which is a host controller obtained through the noise removing substrate 560 and the second discharge substrate 520. The abnormality processing signal is, for example, a signal that is issued when the high-level control device 170 determines that there is a danger in the high voltage portion, and when the abnormality monitoring circuit 760 receives this signal, the first micro An abnormal state signal is sent to the computer 702 as a monitoring result. Based on this signal, the operation of the first rotating electrical machine 130 is stopped by the first microcomputer 702. In this state, the vehicle is driven with the output torque of engine 120.

  DC power is supplied to the power supply circuit 750 from the 12V power supply 176 via the noise removal substrate 560, and a stabilized constant voltage is output from the power supply circuit 750. The output of the power supply circuit 750 is supplied to the first microcomputer 702, the second microcomputer 704, the interface circuit 732, and other circuits on the rotating electrical machine control circuit board 700 on the rotating electrical machine control circuit board 700.

<Switching drive circuit board 600>
The switching drive circuit board 600 includes a first drive circuit board 602 and a second drive circuit board 604. A switching timing signal generated by the first microcomputer 702 is input to the first drive circuit board 602 via the interface circuit 734 of the rotating electrical machine control circuit board 700. These timing signals are input to a U-phase driver circuit 632, a V-phase driver circuit 634, and a W-phase driver circuit 636, respectively, via an insulating circuit 622 made of, for example, a photocoupler. The outputs from the driver circuits 632, 634, and 636 are used as drive signals for controlling the switching operation of each power semiconductor element in the first power module 502 described later.

  The first drive circuit board 602 is provided with a voltage sensor circuit 638 that detects voltages in the driver circuits 632, 634, and 636. The output of the voltage sensor circuit 638 is sent to the first microcomputer 702 via the insulation circuit 622 and the interface circuit 736 of the rotating electrical machine control circuit board 700 as described above.

  The driver circuits 632, 634, and 636 are driven by a constant voltage from a power supply circuit 612 provided on the first drive circuit board 602. The power supply circuit 612 is supplied with 12V DC power from the signal connector 282 via the noise removal board 560 and the rotating electrical machine control circuit board 700.

  A switching timing signal generated by the second microcomputer 704 is input to the second drive circuit board 604 via the interface circuit 744 of the rotating electrical machine control circuit board 700. These signals are input to the U-phase driver circuit 642, the V-phase driver circuit 644, and the W-phase driver circuit 646 through the insulating circuit 624. The outputs from the drivers 642, 644, and 646 are used as signals for controlling the switching operation of each power semiconductor element in the second power module 504 described later.

  Similar to the first drive circuit board 602, the second drive circuit board 604 is provided with a voltage sensor circuit 648 for detecting the voltages in the driver circuits 642, 644 and 646, and the output thereof as described above. Is sent to the second microcomputer 704 via the insulation circuit 624 and the interface circuit 746 of the rotating electrical machine control circuit board 700.

  The circuit including the driver circuits 642, 644 and 646 is driven by a stable power supply from the power supply circuit 614 mounted on the second drive circuit board 604. The power supply circuit 614 is supplied with the 12V power PW from the signal connector 282 via the noise removal board 560 and the rotating electrical machine control circuit board 700.

<Insulation circuits 622 and 624>
In the present embodiment, two types of DC power sources, a low voltage battery and a high voltage battery 180, are provided as power sources. These power supplies are not only different in voltage but also different in ground potential. By providing the insulating circuits 622 and 624, normal operation can be obtained even when the ground potential is different. For example, even if the potentials of the driver circuits 632, 634, 636, the voltage sensor circuit 638, and the driver circuits 642, 644, 646, and the voltage sensor circuit 648 are different from the ground potential of the rotating electrical machine control circuit board, the insulation circuits 622 and 624 It operates normally without being affected. The same can be said for the capacitor discharge control circuit described in detail below.

<Power module 500>
The power module 500 illustrated in FIG. 1 includes a first power module 502 and a second power module 504. The first power module 502 is not illustrated, but, for example, 2 connected in series. The inverter includes a total of six power semiconductor elements, each of which constitutes a U-phase, V-phase, and W-phase bridge circuit. Both ends of each bridge circuit are configured to be supplied with a DC voltage from the battery 180. In addition, when the current supplied to the first rotating electrical machine 130 is a large current, a plurality of power semiconductor elements constituting the inverter are arranged in parallel. The same applies to the second power module 504.

  Each U-phase power semiconductor element is a signal from the driver circuit 632 of the switch drive circuit board 602 and each V-phase power semiconductor element is a signal from the driver circuit 634 of the switch drive circuit board 602. Each power semiconductor element performs a switching operation in response to a signal from the driver circuit 636 of the switch drive circuit board 602. As a result, a three-phase alternating current is output and supplied to the first rotating electrical machine 130. The current in each layer is detected by a current sensor 536.

  A temperature sensor 532 is provided in the first power module 502 and is taken into the first microcomputer 702 via the interface 736. When the temperature rise rises, the current to the first rotating electrical machine is suppressed and the power module 502 is prevented from being damaged.

  Similarly, the second power module 504 includes an inverter composed of power semiconductor elements. Each phase power semiconductor element constituting the inverter performs a switching operation in accordance with a signal from each driver circuit 642, 644 and 646 of the switch drive circuit board 604, outputs a three-phase alternating current, or performs a second rotation. The output of the electric machine 140 is converted into direct current. The current of each phase is detected by a current sensor 538. The power module 504 is provided with a temperature sensor 534, and the output of the temperature sensor 534 is input to the second microcomputer 704 via the interface 746. In accordance with the temperature rise, the control current of the inverter is suppressed to prevent the power module 504 from being damaged.

<Capacitor module 300 and first and second discharge resistors>
The capacitor module 300 of FIG. 1 has a first capacitor module 302 and a second capacitor module 304 connected in parallel. Each of the first capacitor module 302 and the second capacitor module 304 is connected in parallel between both lines of a bus bar 860 (see FIG. 7) acting as a DC power supply line. High voltage DC power is supplied. The bus bar 860 is connected to both DC terminals of the inverter circuits of the first power module 502 and the second power module 504.

  In addition, a first discharge resistor (not shown) and a second discharge resistor 524 are connected in parallel to each of the first capacitor module 302 and the second capacitor module 304. Each of these resistors is for discharging electric charges stored in the first capacitor module 302 and the second capacitor module 304, and the second discharge resistor 524 among them is quickly used for the first capacitor module 302. And a resistor used when discharging the accumulated charge of the second capacitor module 304, and is performed under the control of the second discharge substrate 520.

<Second discharge substrate 520>
An abnormal processing signal 194 is input to the second discharge board 520 from the signal connector 282 via the noise removal board 560 and stored in the first capacitor module 302 and the second capacitor module 304. A capacitor discharge control circuit 522 is provided to quickly discharge the charged electric charge.

  The capacitor discharge control circuit 522 includes a transistor which is a switching element 526 that operates in response to the input of the abnormality processing signal 194. The transistor 526 is connected in series with the second discharge resistor 524, and the transistor 526 The second discharge resistor 524 forms a closed circuit for the first capacitor module 302 and the second capacitor module 304. Due to the movement of the transistor 526, the charges stored in the first capacitor module 302 and the second capacitor module 304 are discharged through the second discharge resistor 524.

<< Each component of power converter 200 >>
Next, the detailed configuration of each component shown in FIGS. 2 to 4 will be sequentially described.

<Housing 210>
The housing 210 is made of a metal material such as aluminum, is formed of a substantially rectangular box, and has a water channel forming body having a cooling water channel at the bottom. The top is open. In consideration of the convenience of the following description, one of the four side walls of the housing 210 is referred to as a front wall 232, and the right side of the side walls adjacent to the front wall 232 is the right side wall. Is referred to as a main side wall portion 234.

  FIG. 8 shows a view of the power conversion device 200 as seen from the front wall 232 side of the housing 210.

  At the bottom of the housing 210, two cooling water channels are provided so as to circulate by being folded, and a water channel is formed with a double structure sandwiching a space (not shown) to which the cooling water is supplied. A body 220 is provided. The front wall 232 of the housing 210 includes a cooling water inlet pipe 212 and a cooling water outlet pipe 214 connected to the space, and the cooling water inlet pipe 212 and the cooling water outlet are connected to the space. By supplying cooling water through the pipe 214, the cooling water can be circulated to the bottom of the housing 210. That is, the housing 210 has a configuration provided with a cooling water passage 216 through which cooling water circulates at the bottom.

  Further, an upper plate of the water channel forming body 220 that forms the space portion of the housing 210 (a plate on the side facing the power module 500) is substantially the same as the main side wall portion 234 as shown in FIG. Openings 218 and 219 are formed so as to extend from one of the front wall portions 232 to the opposite side wall portion at the substantially central portion of each region divided into two by virtual parallel line segments.

  A pair of power modules including a first power module 502 and a second power module 504 are arranged at the bottom of the housing 210, and each of the first power module 502 and the second power module 504 is a water channel formation body 220. It is positioned above and arranged. The heat radiation surfaces of the first power module 502 and the second power module 504 are provided with heat radiation fins 506 and 507 made up of a large number of juxtaposed pin-like protrusions. The portions where the heat dissipating fins 506 and 507 are formed protrude into the openings 218 and 219 of the water channel forming body 220, respectively. Further, the openings are closed by the heat radiation surfaces of the power modules 504 around the radiation fins 506 and 507, respectively, thereby preventing water leakage and forming a sealed water channel 216.

  The radiating fins 506 and 507 of the first power module 502 and the second power module 504 and the openings 218 and 219 formed on the bottom surface of the housing 210 are cross-sectional views taken along line VIII-VIII in FIG. 9.

  With such a configuration, the cooling by the cooling water at the bottom of the housing 210 is efficiently performed by the heat radiation fins 506 and 507 of the first power module 502 and the second power module 504. Further, since the heat radiation fins 506 and 507 of the first power module 502 and the second power module 504 are inserted and arranged along the openings 218 and 219, the first power to the housing 210 is obtained. This has the effect of positioning the module 502 and the second power module 504.

  The front wall 232 of the housing 210 where the cooling water inlet pipe 212 and the cooling water outlet pipe 214 protrude is positioned above the cooling water inlet pipe 212 and the cooling water outlet pipe 214. A substantially rectangular hole 260 having a relatively small area is formed at a location. In the hole 260, a signal connector 282, which will be described in detail later, is arranged in a state of protruding from the inside of the housing through the hole 260.

  Further, as shown in FIG. 3, for example, as shown in FIG. 3, the front wall portion 232 from the front wall portion 232 is formed on the main side wall portion 234 of the housing 210 on the opening side of the housing 210 (the upper portion where the cover CV is disposed). A hole 262 having a relatively small area and a hole 264 having a relatively large area are formed side by side in the direction extending to the side of the other side wall portion facing the surface. A terminal box 800, which will be described in detail later, is arranged on the main side wall portion 234 of the housing 210. A terminal block 810 for DC power in the terminal box 800 is connected to the first side in the housing 210 through the hole 262. The terminal block 820 for AC in the terminal box 800 is electrically connected to the first capacitor module 302 and the second capacitor module 304, and the first power module 502 and the second power module 502 in the housing 210 are connected through the hole 264. The power module 504 is electrically connected.

  In addition, on the inner side surface of each side wall portion of the housing 210, for example, as shown in FIG. 4, a plurality of protrusions PR arranged in parallel along the circumferential direction are formed. Each protrusion PR extends from the bottom of the housing 210 toward the opening end, that is, in the height direction, and has an end surface in front of the opening end. Each end face of these projections PR is substantially parallel to the water channel formation body 220 at the bottom of the housing 210, and a screw hole is formed. As will be described in detail later, these protrusions PR support a holding plate 320 arranged at the end face thereof so as to close the opening of the housing 210 over a wide range, and the screw through the holding plate 320. The holding plate 320 is fixed by a screw SC4 (see FIG. 15) screwed into the hole.

<Power Module 500 and Switching Drive Circuit Board 600>
FIG. 10 is a plan view showing a state in which the power module 500 and the switch drive circuit board 600 are arranged inside the housing 210.

  The first and second power modules 502 and 504 constituting the power module 500 are disposed in the housing 210 so as to be positioned in a lowermost layer than other electric components described later. The first power module 502 and the second power module 504 drive the first rotating electrical machine 130 (motor or generator) and the second rotating electrical machine 140 (generator or motor), respectively.

  The first power module 502 and the second power module 504 have their longitudinal sides parallel to the main side wall portion 234 so that their short sides are parallel to the front wall portion 232 of the housing 210. So that they are arranged in parallel.

  The first power module 502 and the second power module 504 have the same geometric configuration with the DC terminals IT1 and IT2 and the AC terminals OT1 and OT2 arranged in the same direction. For example, by rotating the other second power module 504 by 180 ° with respect to one first power module 502, the DC terminals IT1 and IT2 are arranged so as to face each other. . In this case, the first power module 502 and the second power module 504 are arranged slightly shifted in the longitudinal direction in order to place the corresponding ones in the DC terminals IT1 and IT2 close to each other. As shown in FIG. 10, the DC terminals IT1 and IT2 of the first power module 502 and the second power module 504 are arranged at the center of the housing 210, and the AC terminals OT1 and OT2 are arranged at the side of the housing 210. Has been.

  The first power module 502 and the second power module 504 are bonded to the conductive substrate of a thermally conductive member made of, for example, copper and the periphery of the upper surface of the conductive substrate, although not shown. A case formed of a weir, an insulating substrate soldered, for example, to a region surrounded by the case of the conductive substrate, a transistor (for example, an insulated gate bipolar transistor) and a diode mounted on the insulating substrate, and these transistors, A wiring layer for connecting a diode, and a plurality of DC terminals IT, an AC terminal OT and the like connected to these wiring layers and formed on the case. An IGBT may be used instead of the transistor.

  In FIG. 10, since the switch drive circuit boards 602 and 604 are arranged on the first power module 502 and the second power module 504 respectively, the transistors and diodes or IGBTs are mounted. The region of the center portion thus formed is not visually observed, and is drawn in a state where the DC terminal IT and the AC terminal OT formed on the case are visually observed.

As described above, the DC terminals IT1 and IT2 of the first power module 502 and the second power module 504 are sides of the first power module 502 and the second power module 504 that face each other in close proximity to each other. The AC terminals OT1 and OT2 of the first power module 502 and the second power module 504 are parallel to the side where the DC terminals IT1 and IT2 are formed, respectively. Are formed side by side on the side of each side. In other words, the DC terminal IT of the power module 500 is positioned at the center of the first power module 502 and the second power module 504 arranged in parallel, and the AC terminal OT of the power module 500 is arranged in parallel. The first power module 502 and the second power module 504 are arranged so as to be positioned outside.

  The direct current terminals IT1 and IT2 of the first power module 502 and the second power module 504 are electrically connected to terminals of the capacitor module 300, which will be described in detail later, and the first power module 502 and the second power module. The AC terminals OT1 and OT2 504 are connected to an AC terminal block 820 in a terminal box 800 described in detail later.

  That is, the AC terminal OT1 of the first power module 502 includes terminals OT1u, OT1v, and OT1w in the U-phase, V-phase, and W-phase. After being routed along one short side of each of the installed power modules 502 and 504, the housing 210 is provided via bus bars BP1u, BP1v, and BP1w that are erected on the main side wall 234 side of the housing 210. Are led out to lead terminals OL1u, OL1v, OL1w protruding through holes 264 formed in the main side wall portion 234.

  Similarly, the AC terminal OT2 of the second power module 504 includes terminals OT2u, OT2v, and OT2w in the U phase, the V phase, and the W phase. The lead wires OL2u, OL2v, OL2w projecting through the holes 264 are drawn out from the locations via bus bars BP2u, BP2v, BP2w standing on the main side wall portion 234 side of the housing 210.

  Note that heat radiation fins 506 and 507 projecting into the water channel are provided on the heat radiation surfaces of the first power module 502 and the second power module 504, and the heat radiation of the first power module 502 and the second power module 504 is performed. A screw hole is formed around the fin. The screw hole is fixed to the bottom surface of the housing 210. A switching drive circuit board 600 is disposed above the power module. This switching drive circuit board 600 is also composed of a pair of first drive circuit board 602 and second drive circuit board 604 which are separate bodies, and the first drive circuit board 602 is disposed above the power module 502, and the screw SC2 The second drive circuit board 604 is disposed above the second power module 504, and is fixed to the power module 504 with screws SC2.

  As described above, the first drive circuit board 602 and the second drive circuit board 604 are configured as circuit boards for supplying switching signals to the first power module 502 and the second power module 504, respectively. Has been.

  A harness HN is drawn out from the first drive circuit board 602 and the second drive circuit board 604 and connected via a connector CN provided on the main surface of the rotating electrical machine control circuit board 700.

  In the description of this embodiment, the power module 500 and the rotating electrical machine control circuit board 700 are treated as separate bodies, but the switch drive circuit may be integrally provided on the power module 500 board. . The present embodiment is preferable in terms of heat dissipation efficiency and downsizing of the apparatus.

<Capacitor module 300>
FIG. 11 is a plan view showing a state in which a capacitor module 300 having a smoothing capacitor is disposed inside the housing 210.

  The capacitor module 300 is positioned and disposed above the switching drive circuit board 600 inside the housing 210.

  The capacitor module 300 includes a first capacitor module 302 and a second capacitor module 304. The first capacitor module 302 and the second capacitor module 304 are formed in a rectangular parallelepiped case made of, for example, a resin material. For example, 5 or 6 film capacitors (capacitor cells) are accommodated.

  The first capacitor module 302 and the second capacitor module 304 are arranged in parallel, the first capacitor module 302 is located above the first drive circuit board 602, and the second capacitor module 304 is the second capacitor module 304. The drive circuit board 604 is disposed above.

  FIG. 12 is a diagram schematically showing the first capacitor module 302 and the second capacitor module 304, and is a cross-sectional view in a plane orthogonal to the longitudinal direction of each of the first capacitor module 302 and the second capacitor module 304. It is. FIGS. 12A and 12B are cross-sectional views of the first capacitor module 302 and the second capacitor module 304 at positions shifted in the longitudinal direction.

  Each of the first capacitor module 302 and the second capacitor module 304 is fixed to each other by, for example, electrodes ET1 and ET2 arranged so as to span the spaced-apart portion on the bottom surface side of the first capacitor module 302 and the second capacitor module 304. It has become a state. The electrodes ET1 and ET2 are connected to the DC terminals IN of the first power module 502 and the second power module 504, respectively.

  The outer surface of the electrode ET1 is bent at the bottom of the case CS1 of the first capacitor module 302 from the inside to the first power module 502 side. The connecting portion JN1 is designed to be connected to the DC terminal IN. The electrode ET1 is made of a material having a sequential three-layer structure of a first conductive plate FC1, an insulating sheet IS1, and a second conductive plate SC1, and one electrode of the film capacitor FIC1 in the first capacitor module 302 is connected to each of the conductive layers. One of the plates FC1 and SC1 is connected to one conductive plate, and the other electrode of the film capacitor FIC1 is connected to the other conductive plate of the conductive plates FC1 and SC1. In the connection portion JN1 of the electrode ET1 with the DC terminal IN of the first power module 502, according to each of the plurality of DC terminals IN arranged in parallel, Either one is connected (in the case of FIG. 12A, the conductive plate FC1 is connected, and in the case of FIG. 12B, the conductive plate SC1 is connected).

  In the external appearance of the electrode ET2, the wide conductor drawn outward from the inside at the bottom of the case CS2 of the second capacitor module 304 is bent toward the second power module 504 and the second power module 504 The connecting portion JN2 is designed to be connected to the DC terminal IN. The electrode ET2 is also made of a material having a three-layer structure of a first conductive plate FC2, an insulating sheet IS2, and a second conductive plate SC2, and one electrode of the film capacitor FIC2 in the second capacitor module 304 is One of the conductive plates FC2 and SC2 is connected to one conductive plate, and the other electrode of the film capacitor FIC2 is connected to the other conductive plate of the conductive plates FC2 and SC2. In the connection portion JN2 of the electrode ET2 with the DC terminal IN of the second power module 504, any one of the conductive plates corresponds to each of the plurality of DC terminals IN arranged in parallel. Connected.

  The electrodes ET1 and ET2 of the first capacitor module 302 and the second capacitor module 304 are the so-called U in the power module 500, respectively. Electrically connected to the first power module 502 and the second power module 504 by being connected to a pair of DC terminals in the phase arm, a pair of DC terminals in the V phase arm, and a pair of DC terminals in the W phase arm It has come to be. From this, the electrodes ET1 and ET2 (indicated by reference symbols JN1 or JN2 in FIG. 12) viewed from between the first capacitor module 302 and the second capacitor module 304 shown in FIG. The number corresponds to the number of the pair of DC terminals IN in the arm (six).

  As described above, the electrodes ET1 and ET2 have a three-layer structure of the first conductive plate FC, the insulating sheet IS, and the second conductive plate SC as described above. This is because the direction of the current flowing through each of the SCs is reversed, thereby causing inductance coupling and reducing the inductance.

  As shown in FIG. 12, the electrodes ET1 and ET2 are configured to be physically connected to each other from the beginning at the connection portions JN1 and JN2 with the DC terminal IN of the second power module 504. Alternatively, unlike the case of FIG. 13, they are configured in a separated state in advance and are physically (electrically) connected to each other when they are connected to the DC terminal IN of the power module 500. You may comprise.

  The connection portion JN of the electrodes ET1 and ET2 with the DC terminal IN of the power module 500 is fixed to the DC terminal IN of the power module 500 by a screw SC3 screwed into the DC terminal IN through the connection portion JN. It has become possible to have a good electrical connection.

  The first capacitor module 302, the second capacitor module 304, the first power module 502, and the second power module 504 shown in the schematic diagram of FIG. 12 are the same as the first capacitor module 302 and the second capacitor module 504 shown in FIG. This corresponds to the capacitor module 304, the first power module 502, and the second power module 504. In this case, the first capacitor module 302 and the second capacitor module 304 shown in FIG. 9 have bend structure portions BD1 and BD2 formed of curved portions in the middle portions of the electrodes ET1 and ET2. By providing the electrodes ET1 and ET2 with the bend structure portions BD1 and BD2, the stress in the electrodes ET1 and ET2 can be absorbed and relaxed at these portions.

  As shown in FIG. 11, the first capacitor module 302 is provided with a pair of electrodes TM1 connected to a battery 180 via a DC power terminal block 810, which will be described later. A pair of electrodes TM2 connected to the battery 180 via a DC power terminal block 810, which will be described later, are provided.

  Each electrode TM1 of the first capacitor module 302 is connected to the first conductive plate FC1 on one side and to the second conductive plate SC1 on the other side, and each electrode TM2 of the second capacitor module 304 is connected to the one side. The second conductive plate SC2 is connected to the first conductive plate FC2 and the other is connected to the second conductive plate SC2.

  The electrodes TM1 and TM2 of the first capacitor module 302 and the second capacitor module 304 are both arranged on the front wall 232 side of the housing 210. The electrodes TM1 and TM2 are arranged on the front wall portion 232 side of the housing 210 in this way because the DC power terminal block 810 arranged in the terminal box 800, which will be described in detail later, is a front wall portion of the housing 210. This is because it is positioned on the 232 side.

  Each electrode TM1 of the first capacitor module 302 and the DC power terminal block 810 are electrically connected via the bus bar BB1, and each electrode TM2 of the capacitor module CT2 and the DC power terminal block 810 are electrically connected. Connections are made through the bus bar BB2 (see FIG. 3).

  For example, as shown in FIG. 3, the first capacitor module 302 and the second capacitor module 304 have a slight gap therebetween, and a first discharge resistor (not shown) and a second gap are provided in the gap. Two discharge resistors 524 are juxtaposed along their axial directions. As shown in FIG. 11, the gap between the first capacitor module 302 and the second capacitor module 304 is formed by connecting the connection portions JN of the electrodes ET1 and ET2 of the first capacitor module 302 and the second capacitor module 304. The screw SC3 is necessary to electrically connect the first capacitor module 302 and the second capacitor module 304 to the first power module 502 and the second power module 504. After such a connection, the gap is effectively used by arranging the first discharge resistor (not shown) and the second discharge resistor 524.

  Further, the first capacitor module 302 and the second capacitor module 304 are each fixed to a holding plate 320. That is, as shown in FIG. 11, the first capacitor module 302 and the second capacitor module 304 viewed in plan are formed with fixing holes FH1 and FH2 in which nuts are embedded at the four corners, respectively. The first capacitor module 302 and the second capacitor module 304 are held by the holding plate 320 by screws SC4 screwed into the fixing holes FH1 and FH2 through holes corresponding to the fixing holes FH1 and FH2 of the holding plate 320. Fixed to. That is, each of the first capacitor module 302 and the second capacitor module 304 is fixed in a state of being suspended from the holding plate 320.

<Terminal box 800>
The terminal box 800 is fixed to the housing 210 of the power converter 200, and a DC power terminal block 810 and an AC terminal block 820 are disposed therein.

  FIG. 13 shows an external view of the power conversion device 200 viewed from the side on which the terminal box 800 is attached. The terminal box 800 is attached to the main side wall portion 234 of the housing 210 with a plurality of screws SC5.

  As shown in FIGS. 2-4, the terminal box 800 has a relatively small hole 266 and a relatively small hole 262 corresponding to the relatively small hole 262 and the relatively large hole 264 formed in the main side wall portion 234 of the housing 210, respectively. A large hole 268 is formed. The terminal box 800 is provided with a partition wall 852 that bisects each of the holes 266 and 268, a terminal block 810 for DC power is arranged in the space on the hole 266 side, and an AC is installed in the space on the hole 268 side. A terminal block 820 is arranged.

  The DC power terminal block 810 includes a noise filter, and the DC power supplied from the battery 180 through the DC power terminal 812 is removed by the noise filter provided in the DC power terminal block 810. Is done. The noise filter prevents noise generated by the switching operation of the power module 500 from going out.

  A pair of conductive materials having a rectangular cross section from the DC power terminal block 810 extend through the hole 266 and the hole 262 and are disposed close to the DC power terminal block 810. It is electrically connected to the terminal TT. The terminal TT is connected to the electrodes TM1 and TM2 of the first capacitor module 302 and the second capacitor module 304 via the bus bars BB1 and BB2, and is further electrically connected to the DC terminal of the power module 500. ing.

  The AC terminal block 820 is connected to the lead terminals OL1 and OL2 inserted through the hole 264 of the housing 210 and the hole 268 of the terminal box 800. The lead terminal OL1 is connected to the AC terminal OT1 of the first power module 502 via the bus bar BP1, and the lead terminal OL2 is connected to the AC terminal OT2 of the second power module 504 via the bus bar BP2. .

The lead terminal OL1 has lead terminals OL1w, OL1v, and OL1u, and is connected to the W-phase connection terminal and the V-phase connection of the first rotating electrical machine 130 via the AC power connection portion 822 provided in the terminal box 800, respectively. The terminal box 800 is configured to be connected to the terminal and the U-phase connection terminal. Similarly, the lead terminal OL2 has lead terminals OL2w, OL2v, and OL12, which are connected to the W-phase connection terminal, the V-phase connection terminal, and the U-phase connection terminal of the second rotating electric machine 140, respectively. The terminal box 800 is configured to be connected via 822. The AC terminal block 820 is a current sensor 53 that detects AC current.
6 and 538, and detects the current flowing through each phase of the first rotating electrical machine 130 and the second rotating electrical machine 140.

  The terminal box 800 includes a terminal box cover 846 on the upper end surface side and a bottom 844 having the DC power terminal block 810 on the lower end surface side. In this embodiment, it has a terminal box 800 and is connected to an external DC power source and each rotating electric machine via this terminal box. Even if the position of each rotating electric machine and DC power source differs depending on the vehicle type, There is an effect that can be dealt with without changing the structure of the main body or with a slight change.

<Output conductor bus bar BP>
FIG. 14A is an exploded perspective view showing the first power module 502 and the output conductor bus bar BP.

  The output conductor bus bar BP is made of a metal material such as copper, has a strip shape with a certain plate thickness, and has through holes at both ends for electrical connection using screws. Furthermore, the first output conductor bus bar BPu, the second output conductor bus bar BPv, and the third output conductor bus bar BPw are configured, and the plurality of output conductor bus bars fix the insulating sheet S1 made of, for example, a resin material. Protrusion shape for this purpose is provided, and the structure is laminated via the insulating sheet.

  As shown in FIG. 11, the stacked output conductor bus bars are arranged on the bottom of the housing 210, respectively, and each of a pair of power modules including the first power module 502 and the second power module 504. The AC terminal is electrically connected using the through hole. The plurality of output conductor bus bars may be configured to be physically stacked from the beginning in connection with the AC terminal OT of the first power module 502, or may be separated in advance. And may be configured to be physically stacked on each other at the stage of connection to the AC terminal OT of the power module 502 using a through hole. A connection portion JN of the power module 500 with the AC terminal OT is fixed to the AC terminal OT of the power module 500 by a screw SC screwed into the AC terminal OT through the connection portion JN, and has a reliable electrical property. Connection is planned.

  FIGS. 14B and 14C are enlarged views of a part of the B output conductor bus bar BP surrounded by the circular dotted line in FIG. 14A. In particular, FIG. 14B shows a state before the insulating sheet S1u is bent. The insulating sheet S1u is sandwiched between the output conductor bus bar BP1u illustrated in FIG. 14B and the output conductor bus bar BP1v not illustrated. However, the insulating sheet S1u has a surface 1402 exposed to the outside without being in contact with both output conductor bus bars. By this exposed surface 1402, the output conductor bus bars BP1u and BP1v, which are objects to be insulated, are kept in an insulated state.

  Further, as shown in FIG. 14B, a protruding portion 1401 is formed on the end side 1400 of the output conductor bus bar BP1u. The protruding direction of the protruding portion 1401 is a direction parallel to the contact surface between the output conductor bus bar and the insulating sheet S1u. Further, the shape of the protrusion 1401 may be circular, but it is preferable that the protrusion 1401 is rectangular so that the work can be easily performed when the insulating sheet is bent as will be described later.

  FIG. 14C shows a completed state after the insulating sheet S1u is bent. The insulating sheet S1u is bent along the protruding portion 1401 formed on the output conductor bus bar, and a bent portion 1403 is formed on the insulating sheet S1u. For this reason, the protrusion 1401 is positioned inside the bent portion 1403. Thereby, positioning with an insulating sheet and an output conductor bus bar can be performed easily. Further, as shown in FIG. 14C, by determining the shape of the insulating sheet so that the end of the insulating sheet and the end of the output conductor bus bar are substantially parallel, the output conductor bus bars BP1u and BP1v The insulation state can be maintained, and the reliability can be improved.

<Insulation sheet S1 and fixing bracket BR>
FIG. 15A is a perspective view showing the output conductor bus bar BP and the insulating sheet S1.

  The insulating sheet S1 is made of, for example, a resin material, has a strip shape with a certain plate thickness, and has a folded shape for fixing in accordance with the protruding shape of the output conductor bus bar described above. If the insulating sheet is too thin, the wear resistance against vibrations when mounted on the vehicle is lowered, and if it is too thick, the assemblability of the folding work and the like is deteriorated, so 0.2 mm to 0.3 mm is preferable. It is desirable that the thickness is between about 0.25 mm.

  The projecting shape of the output conductor bus bar has a projecting dimension equal to or greater than the creeping distance necessary for insulation between the bus bars, and the required creeping insulation distance is obtained by pasting the folded shape of the insulating sheet to match the projecting shape. It has a structure that can be maintained. The required creeping insulation distance is determined by the voltage to be insulated and the contamination level of the atmosphere, and is preferably 5 mm or more. In particular, the voltage to be insulated is an input voltage applied to the power modules 602 and 604 or a voltage such that the maximum voltage value of the output voltage is 450 V or more. By setting the protrusion shape of the output conductor bus bar to 2.5 mm or more, the creeping insulation distance between the bus bars can be reliably set to 5 mm or more.

  Further, by attaching the fixing bracket BR functioning as a stopper in accordance with the protruding shape of the output conductor bus bar, the position of the insulating sheet and the output conductor bus bar can be easily fixed. As shown in FIG. 15A, the fixed brackets are preferably attached alternately from the vertical direction of the output conductor bus bar. This is because this mounting method can suppress the vertical movement of the bus bar due to vibration, and a plurality of bus bars can be disposed in the housing in a state of being laminated in advance, thereby improving the assemblability.

  These structures are shown in FIG. 15B showing a cross section taken along the line VV-VV in FIG.

  In particular, the fixing bracket BR includes a plurality of output conductor bus bars sandwiched from the thickness direction and having a substantially U-shaped sandwiching portion. The clamping portion is attached so that the protruding portion of the output conductor bus bar is located inside the substantially U-shape. Thus, the folded insulating sheet can be sandwiched, and the insulating sheet can be prevented from floating in the inverter device and adversely affecting other components.

  Further, by using the bus bar structure described in FIG. 14 and FIG. 15 as the output conductor of the inverter device described in FIG. 2 and the like, the space for arranging the bus bar can be suppressed, and the size of the entire inverter device can be reduced. Can be achieved.

  Further, as shown in FIG. 3, a multi-phase AC power terminal is provided on one surface of the housing 210 of the inverter device having a substantially box shape, and the main surface of the output conductor bus bar described in FIG. 14 and FIG. By arranging the bus bar along the inner wall of the housing and connecting the bus bar to the AC power terminal, the entire inverter device can be further reduced in size.

  Further, in the inverter apparatus shown in FIG. 3, the output conductor bus bar is disposed on the inner wall opposite to the inner wall of the housing where the cooling water channel inlet 214 and the cooling water channel outlet 212 are located, so that the water channel forming body 220 and the output are formed. The inverter device as a whole can be further reduced in size without causing interference with the conductor bus bar.

  Each of the embodiments described above may be used alone or in combination. This is because the effects of the respective embodiments can be achieved independently or synergistically.

1 is a system diagram showing an embodiment of a hybrid electric vehicle equipped with a power conversion device according to the present invention. It is a disassembled perspective view which shows one Example of the whole structure of the power converter device by this invention. FIG. 3 is an exploded perspective view showing an embodiment of the overall configuration of the power conversion device according to the present invention, viewed from a direction different from the case of FIG. 2. FIG. 4 is an exploded perspective view showing an embodiment of the overall configuration of the power conversion device according to the present invention, as viewed from a direction different from the case of FIG. 2 or FIG. 3. It is an external appearance perspective view which shows one Example of the power converter device by this invention. It is a circuit diagram which shows one Example of each circuit board with which the power converter device by this invention is equipped, and connection relation of these circuit boards, is a figure which shows the left half, and is drawing which makes FIG. It is a circuit diagram which shows one Example of each circuit board with which the power converter device by this invention is equipped, and connection relation of these circuit boards, and is a figure which shows the right half, and is drawing which makes FIG. It is the figure which looked at one Example of the power converter device by this invention from the front wall surface side. It is sectional drawing in the VIII-VIII line of FIG. In the power converter device by this invention, it is a top view which shows the state which has arrange | positioned the power module and the switch drive circuit board inside the housing. In the power converter device by this invention, it is a top view which shows the state which has arrange | positioned the capacitor module inside the housing. It is the figure which showed typically one Example of the capacitor module with which the power converter device by this invention was equipped, and is sectional drawing in the plane orthogonal to the longitudinal direction of each capacitor module. It is the side view which shows one Example of the power converter device by this invention, and the figure seen from the side in which the terminal box was attached. It is a disassembled perspective view which shows one Example of the bus-bar structure by this invention. It is a perspective view which shows one Example of the bus-bar structure by this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 Hybrid type electric vehicle 110 Front wheel 112 Axle 114 Rear wheel 120 Engine 124 Engine control device 130 First rotary electric machine 140 Second rotary electric machine 150 Transmission 154 Transmission control device 160 Differential gear 170 General control device 174 In-vehicle local Area network 180 Battery 184 Battery control device 200 Power conversion device 210 Housing 220 Water channel forming body 232 Front wall (housing)
234 Main side wall (housing)
300 Capacitor module 500 Power module 600 Switching drive circuit board 700 Rotating electrical machine control circuit board SC Screw S1 Insulation sheet IT DC terminal (for power module 500)
OT AC terminal (for power module 500)
OL lead terminal JN connection BR fixing bracket

Claims (11)

A plurality of conductor plates;
Comprises a strip-shaped insulating sheet member,
A predetermined surface region in the same plane of the sheet member is sandwiched between the plurality of conductor plates, the other surface region different from the predetermined surface region is exposed to the outside,
A bus bar structure in which a protruding portion is formed on at least one side surface of the plurality of conductor plates, a bent portion is formed on the exposed surface of the sheet member, and the protruding portion is positioned inside the bent portion. A plurality of conductor plates;
An insulating sheet member having a first region surface sandwiched between the plurality of conductor plates and a second region surface exposed to the outside without being sandwiched between the plurality of conductor plates;
A protrusion that protrudes in a direction parallel to the second area surface is formed on at least one end of the plurality of conductor plates, and the protrusion is positioned on the inner side of the second area surface. A bus bar structure in which such a bent portion is formed. It is a bus-bar structure in any one of Claim 1 or 2,
The protrusion is a conductor plate protrusion,
A sheet member protrusion is formed at an edge of the exposed surface of the sheet member, and the bent portion is formed at a predetermined position of the sheet member protrusion;
A bus bar structure in which an edge of the exposed surface of the sheet member and an edge of the conductor plate on which the conductor protrusion is formed are substantially parallel. It is a bus-bar structure in any one of Claim 1 or 2,
The said sheet | seat member is a product made from resin, and the thickness is 0.2 mm or more and 0.3 mm or less. It is a bus-bar structure in any one of Claim 1 or 2,
Wherein said plurality of conductive plates that the sheet member is interposed pinching the thickness direction, provided with a clamping member in the substantially U-shaped, and
The sandwiching member has a bus bar structure that sandwiches the plurality of conductor plates so that the protruding portion is positioned inside the substantially U-shape. It is a bus-bar structure in any one of Claim 1 or 2,
A protruding portion different from the protruding portion is formed on the side surface opposite to the side surface of the conductor plate on which the protruding portion is formed, and the exposed surface of the sheet member is positioned on the exposed surface of the sheet member so that the different protruding portion is positioned inside. A bus bar structure in which a bent portion different from the bent portion is formed. The bus bar structure according to claim 6,
Sandwiching the plurality of conductor plates with the sheet member interposed therebetween from the thickness direction, and having a plurality of sandwiching members having a substantially U shape,
Each of the plurality of sandwiching members has a bus bar structure that sandwiches the plurality of conductor plates such that the projecting portion or the different projecting portion is positioned inside the substantially U-shape. A power conversion device using a bus bar that is the bus bar structure according to claim 1,
A power module mounted with a power semiconductor that converts DC power into multi-phase AC power by switching operation; and
A housing for housing the power module and the bus bar;
The power conversion device in which the plurality of conductor plates transmit the plurality of phases of AC power to a rotating electrical machine installed outside the housing. The power conversion device according to claim 8, wherein
When the maximum value of the input or output voltage applied to the power module is 450 V or more,
The power conversion device wherein the height of the protrusion formed on the conductor plate is 2.5 mm or more. The power conversion device according to claim 8, wherein
The housing has a substantially box shape, and includes a plurality of phases of AC power terminals on a predetermined surface of the housing,
A power conversion device in which a main surface of the bus bar is disposed along an inner wall of the housing, and the bus bar is connected to the AC power terminal. The power conversion device according to claim 10,
A smoothing capacitor for smoothing the DC power supplied to the power module ;
A cooling flow path for flowing the cooling medium inside,
The cooling channel is formed at the bottom of the casing, the power module is installed so as to contact the cooling water channel, the smoothing capacitor is installed above the power module, and the bus bar is connected to the smoothing capacitor. And a power conversion device disposed between the cooling water channel.

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