The present invention relates to a power conversion apparatus used to convert DC power to AC power or to convert AC power to DC power, and more particularly to a power conversion apparatus used for hybrid electric vehicles and electric vehicles.
With the reduction in size of hybrid electric vehicles or electric vehicles, there is a demand for reducing the size of the power conversion apparatus used in such vehicles. Further, it is required to achieve both the reduction in size of the power conversion apparatus as well as the improvement in the ease of assembly. In other words, requirements such as ensuring a space in the power conversion apparatus to insert tools or other equipment for the assembly of the power conversion apparatus run counter to the reduction in size of the power conversion apparatus.
Patent Literature 1 describes a method for connecting a terminal of a power semiconductor module and a terminal of a capacitor module by welding, as well as a method for connecting a driver circuit board and a power semiconductor module by solder material after the power semi conductor module and the capacitor module are provided in the power conversion apparatus.
However, further improvement in the ease of assembly of the power conversion apparatus is required.
Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2011-217550
Accordingly, an object of the present invention is to further improve the ease of assembly of power conversion apparatus.
A power conversion apparatus according to the present invention includes: a power semiconductor module including a power semiconductor element for converting a direct current to an alternating current; a first flow path forming body that forms a first flow path for allowing cooling refrigerant to flow therethrough; a second flow path forming body that forms a second flow path for allowing the cooling refrigerant to flow therethrough; a first base plate for mounting the second flow path forming body thereon; a drive circuit board mounted with a drive circuit so output a drive signal to drive the power semiconductor element; and a case for housing the power semiconductor module, the first flow path forming body, the second flow path forming body, the first base plate, and the drive circuit board. The drive circuit board is provided so that the mounting surface of the drive circuit faces a side wall of the second flow path forming body. The second flow path forming body forms a housing space to house the power semiconductor module. Further, the second flow path forming body forms an insertion opening that leads to the housing space, on the side wall facing the mounting surface of the drive circuit. The power semiconductor module has a control terminal that is connected to the drive circuit board by passing through the insertion opening The first flow path forming body is fixed to the case. At the same time, the first flow path forming body forms an opening that leads to the first flow path. The first base plate is designed to close the opening and to be connected to the first flow path forming body. Further, the first base plate forms a first through hole for connecting the first flow path and the second flow path.
According to the present invention, it is possible to improve the ease of assembly of power conversion apparatus.
Hereinafter, an embodiment of a power conversion apparatus according to the present invention will be described with reference to the accompanying drawings. Note that the same reference numerals are designated to the same elements in each figure, and the overlapping description will be omitted.
A case 101 houses a power semiconductor module 300U and the like described below. An outlet pipe 103 discharges a cooling refrigerant to the outside of the power conversion apparatus 100. The outlet pipe 103 is provided around a center portion in the height direction of a case side surface 101A. An inlet pipe 102 (see
The case 101 forms an opening portion 105 on a case side surface 101C. An AC buss bar 104U, an AC bus bar 104V, and an AC bus bar 104W protrude from the case 101 to the outside of the case 101 through the opening portion 105. The AC bus bar 104U is a conductive member for transferring the AC current of the U phase, the AC bus bar 104V is a conductive member for transferring the AC current of the V phase, and the AC bus bar 104W is a conductive member for transferring the AC current of the W phase.
Further, the case 101 forms an opening portion 106 on the case side surface 101A. The opening portion 106 is formed at a position facing the connection part, of the AC bus bar 104U and the other conductors, the connection part of the AC bus bar 104V and the other conductors, and the connection part of the AC bus bar 104W and the other conductors. In this way, an operator and a work robot can perform the connection operation of the AC bus bars and each of the other conductors, through the opening portion 106.
A cover 107 closes a first insertion opening 109 (see
A cover 108 closes a second insertion opening (not shown) formed in the lower portion of the case 101. The second insertion opening is formed to house a DC-DC converter 900 described below.
The power conversion apparatus 100 according to the present embodiment is mainly used in hybrid electric vehicles and electric vehicles, An example of a vehicle e system is described in Japanese Unexamined Patent Application Publication No. 2011-217550. Note that the power conversion apparatus 100 according to the present embodiment may be used in other applications in order to achieve the effect. For example, it may be used in an inverter for household appliances such as refrigerators and air conditioners for the purpose of improving the productivity and cooling performance. Further, the power conversion apparatus 100 may also be used in industrial inverter whose operating environment is similar to that of the vehicle inverter.
The first base plate 400, the second flow path forming body 401, the power semiconductor modules 300U to 300W, the capacitor module 500, the drive circuit board 200, the control circuit board 600 and the like are provided between the first flow path forming body 110 and The cover 107.
The power semiconductor modules 300U to 300W, descried below, are designed to convert a direct current to an alternating current. The capacitor module 500, described below, is designed to smooth the DC voltage. The drive circuit board 200 is mounted with the drive circuit to output a drive signal to drive the power semiconductor modules 300U to 300W. The control circuit board 600 is mounted with the control circuit to output a control signal to the drive circuit board 200 in order to control the power semiconductor modules 300U to 300W. An example of these circuit systems is described in Japanese Unexamined Patient Application Publication 2011-217550.
The DC-DC converter 900 is provided between the first flow path forming body 110 and the cover 108. The DC-DC converter 900 is designed to convert the DC voltage. An example of the circuit system of the DC-DC converter 900 is described in Japanese Patent No. 4643695. The opening portion 106 described in
The second flow path forming body 401 is mounted on the first base plate 400. The second flow path forming body 401 and she first base plate 400 may be integrally formed in order to improve the productivity and the thermal conductivity. As shown in
The first base plate 400 includes multiple support members 404 to fix she capacitor module 500. The capacitor module 500 is fixed in a state of being thermally connected to the first base plate 400 by the multiple support members 404. In this way, the heat generated in the capacitor module 500 is transferred to the first base plate 400 to be able to cool the capacitor module 500.
As shown in
Further, the second base plate 601 supports a third base plate 602. The third base plate 602 protrudes in the arrangement direction of the first base plate 400, which is the direction perpendicular to the mounting surface of the control circuit board 600 in the second base plate 601.
The drive circuit board 200 is mounted on the surface of the third base plate 602 on the side on which the power semiconductor modules 300U to 300W are provided. In this way, the drive circuit board 200 is cooled by the third base plate 602 and the second base plate 601.
Further, the second base plate 601 includes a fixing part 601B that is connected to the support member 405 extending from the second flow path forming body 401. In this way, the second base plate 601 is thermally connected to the second flow path forming body 401 through the fixing part 601B. Thus, it is possible to achieve improvement of the cooling performance of the control circuit board 600 or the drive circuit board 200.
Further, the second base plate 601 and the third base plate 602 are configured by a material with high electrical conductivity such as aluminum. Then, the case 101 described in
In the present embodiment, the drive circuit board 200 is provided so that the mounting surface of the drive circuit faces the side wall 401A of the second flow path forming body 401. The power semiconductor modules 300U to 300W include a control terminal 325 connected to the drive circuit board 200 by passing through the insertion opening 403. In the present embodiment, the connection operation of the control terminal 325 and the drive circuit board 200 is performed before the power semiconductor modules 300U to 300W and the drive circuit board 200 are mounted in the case 101.
Note that the third base plate 602 forms the opening portion 603 that is formed at a position facing the connection part 201 of the control terminal 325 and the drive circuit board 200. In this way, it is possible to obtain the effect of removing the electromagnetic noise of the third base plate 602, and to achieve improvement in the connection workability.
A current sensor 202 is provided so that the AC bus bars 104U to 104W pass through the through hole formed in the current sensor 202. As shown in
The first flow path forming body 110 forms a flow path 112a that leads to the inlet pipe 102. The flow path 112a is formed so as to lead to the first through hole 406 shown in
The flow path 112a, the flow path 112b, and the flow path 112c lead no the opening portion that is closed by the first base plate 400 as described below.
As shown in
As shown in
As shown in
Thus, the first flow path forming body 110 and the second flow path forming body 401 are separately formed. Then, the second flow path forming body 401 is connected to the first base plate 400. Further, the main electrical components such as the power semiconductor modules 300U to 300W are mounted on the first base plate 400. The connection operation is performed outside the case 101 instead of inside the case 101. Then, the first base plate 400 on which the main electrical components are mounted is fixed to the second flow path forming body 401. In this way, the outside wall of the power conversion apparatus 100, namely, the wall of the case 101 is not present at the time of assembly. Thus, the directionality of the operation is eliminated and the flexibility in the design and assembly is increased. In addition, the flexibility in the direction of the electrical connection of the power semiconductor modules 300U to 300W is also increased. Thus, it is possible to arrange the power semiconductor modules 300U to 300W so that the protruding direction of the electrical connection part of the power semiconductor modules 300U to 300W runs to the inner wall of the case 101. In this way, it is possible to reduce the dimension in the height direction of the power conversion apparatus 100.
Further, the capacitor module 500 is mounted. Then, the fitting operation such as screwing, welding, and soldering of the electrical parts, as well as the fixing operation of the capacitor module 500 itself are performed. However, it has been difficult to perform the operation at a position deep from the opening portion of the case 101.
Thus, in the present embodiment, as shown in
Further, the capacitor element 505 shown in
Thus, the second flow path forming body 110 is formed to the position in which the flow path 12a and the flow path 112c face the capacitor module 500. In this way, it is possible to cool the capacitor module 500. As a result, the performance and life of the capacitor element 505 can be increased to a desired level.
Further, in the present embodiment, the capacitor module 500 includes a capacitor case 506 for housing a part of the capacitor side terminal 504 and the capacitor element 505. The capacitor case 506 is formed with a capacitor side opening portion 507 with a capacitor side terminal 505 protruding outward. Further, the capacitor case 506 is provided on the first base plate 400 so that the capacitor side opening portion 507 faces the first flow path forming body 110 that houses the power semiconductor module.
Because of this structure, the wiring distance of the capacitor side terminal 505 connected to the power semiconductor module can be reduced. As a result, it is possible to reduce the inductance and reduce the heat generated by the capacitor side terminal 505 itself.
Further, in the present embodiment, the power semiconductor module 300V is provided at a position facing the first base plate 400 with the power semiconductor module 300W interposed therebetween. Then, a flow path space 116a through which the cooling refrigerant flows is formed between the power semiconductor module 300V and the second power semiconductor module 300W. Further, the power semiconductor module 300U is provided at a position facing the first base plate 400 with the power semiconductor module 300V and the power semiconductor module 300W interposed therebetween. Then, a flow path space 116b through which the cooling refrigerant flows is formed between the power semiconductor module 300U and the second power semiconductor module 300V.
Because of this structure, the power semiconductor modules 300U to 300W are directly brought into contact with the cooling refrigerant. At the same time, the cooling refrigerant flows through both surfaces of each power semiconductor module, so that it is possible to improve the cooling performance of the power semiconductor modules 300U to 300W.
Further, in the present embodiment, the case 101 is divided into a first housing space 117 and a second housing space 118 by the first flow path forming body 110. The first base plate 400 on which the main electrical components are mounted is housed in the first housing space 117. Or the other hand, the circuit components of the DC-DC converter 900 are housed in the second housing space 118 and are provided on the first flow path forming body 110. In this way, the inverter circuit is cooled by one surface of the first flow path forming body 110, and the DC-DC converter is cooled by one surface of the first flow path forming body 110, so that the cooling area of the first flow path forming body 110 can be effectively used. This can contribute to miniaturization of the whole apparatus.
Further in the present embodiment, the second base plate 601 of metal is provided at a position facing the first base 400 with the power semiconductor modules 300U to 300W interposed therebetween. Further, the second base plate 601 has a fixing part 601C connected to the case 101 of metal. Further, the control circuit board 600 is provided, at a position facing the power semiconductor modules 300U to 300W with the second base pate 601 interposed therebetween. In this way, the second base plate 601 blocks the electromagnetic noise emitted from the power semiconductor modules 300U to 300W. Thus, it is possible to protect the control circuit board 600 from the electromagnetic noise.
100 . . . power conversion apparatus, 101 . . . case, 101A . . . case side surface, 101B . . . case side surface, 101C . . . case side surface, 102 . . . inlet. pipe, 103 . . . outlet Pipe 104U . . . AC bus bar, 104V . . . AC bus bar, 104W . . . AC bus bar, 105 . . . opening portion, 106 . . . opening portion, 107 . . . cover, 108 . . . cover, 109 . . . first insertion opening, 110 . . . first flow path forming body, 111 . . . cover, 112a . . . flow path, 112b . . . flow path, 112c . . . flow path, 113 . . . partition wall, 114 . . . flow of cooling refrigerant, 115 . . . flow of cooling refrigerant, 116a . . . flow path space, 116b . . . flow path space, 200 . . . drive circuit board, 201 . . . connection part, 202 . . . current sensor, 300U . . . power semiconductor module, 300V . . . power semiconductor module, 300W . . . power semiconductor module, 325 . . . control terminal, 400 . . . first base plate, 401 . . . second flow path forming body, 401A . . . side wall, 402 . . . housing space, 403 . . . insertion opening, 404 . . . support member, 405A . . . support member, 405B . . . support member, 406 . . . first through hole, 407 . . . second through hole, 500 . . . capacitor module, 501 . . . DC positive electrode terminal, 502 . . . DC negative electrode terminal, 503 . . . resin sealant, 504 . . . capacitor side terminal, 505 . . . capacitor element, 506 . . . capacitor case, 507 . . . capacitor side opening portion, 600 . . . control circuit board, 601A . . . fixing part, 601B . . . fixing part, 601C . . . fixing part, 601 . . . second base plate, 602 . . . third base plate, 603 . . . opening portion, 900 . . . DC-DC converter
Number | Date | Country | Kind |
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2012-215456 | Sep 2012 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2013/069971 | 7/24/2013 | WO | 00 |