Embodiments of the present invention relate to a power converter for a vehicle.
Conventionally, Si insulated gate bipolar transistor (IGBT) modules for 1,500 A have been practically used in power converters for a vehicle such as variable voltage variable frequency (VVVF) inverters for a railway vehicle. When an inverter is constituted for 1,500 A using the Si IGBT modules (element modules), the current rating of the element module is about 1,500 A per one element module for 3.3 kV, and six element modules are mounted in an inverter that drives four induction motors (IMs) in parallel, which are generally used for railway vehicles, thereby constituting a three-phase inverter. For inverters for driving permanent magnet synchronous motors (PMSMs), which have recently been practically used, the PMSM requires one three-phase inverter for each motor. For this reason, although four inverters are required to drive four motors, a required current rating for one inverter is as low as about 500 A. Given these circumstances, a 2in1 element module, in which two IGBTs and diodes are mounted in one element module, is constituted, one inverter is constituted using three element modules, and four inverters, or a total of 12 2in1 element modules, are mounted on one cooler in a planar manner to constitute a 4in1 inverter.
Patent Literature 1: Japanese Patent No. 4594477
Patent Literature 2: Japanese Patent Application Laid-open No. 2011-229372
However, in both the inverter for IN and the inverter for PMSM in the above-described conventional technologies, the element modules are mounted on the cooler in a planar manner, and the outer size of the inverter is largely dependent on the size of an area occupied by the element modules. Given this situation, the current constitution using the Si IGBT modules has limitation in downsizing.
A power converter for a vehicle according to an embodiment comprises: four semiconductor element modules that each include silicon carbide (SiC) for a switching element that performs switching operation and a freewheeling diode that passes a freewheeling current and include circuits for three phases, each of the circuits being related to single-phase AC output and having arms each of which connects the freewheeling diode anti-parallel to the switching element, the arms being connected in series as circuits that perform three-phase AC output for driving one permanent magnet synchronous motor; and cooling unit that cools the four semiconductor element modules.
A power converter for a vehicle according to an embodiment comprises: three semiconductor element modules for an inverter that each include silicon carbide (SIC) for a switching element that performs switching operation and a freewheeling diode that passes a freewheeling current and include a circuit having arms each of which connects the freewheeling diode anti-parallel to the switching element, the arms being connected in series as a circuit that performs single-phase AC output for driving four induction motors connected in parallel; and a cooling unit that cools the three semiconductor element modules for an inverter for performing three-phase AC output for driving the four induction motors.
A power converter for a vehicle according to an embodiment comprises: two semiconductor element modules for an inverter that each include silicon carbide (SiC) for a switching element that performs switching operation and a freewheeling diode that passes a freewheeling current and include circuits for three phases, each of the circuits being related to single-phase AC output and having arms each of which connects the freewheeling diode anti-parallel to the switching element, the arms being connected in series as circuits that perform three-phase AC output for driving an induction motor; and a cooling unit that cools the two semiconductor element modules for an inverter. Three-phase AC output for driving four induction motors connected in parallel is performed from a neutral point at which the two semiconductor element modules for an inverter are connected in parallel.
The following describes power converters for a vehicle according to embodiments in detail with reference to the attached drawings. In the embodiments and modifications thereof described below, similar components will be attached with common symbols, and any duplicated description will be omitted.
A main circuit configuration of the power converter 100 for a vehicle includes a pantograph 4, a high-speed breaker 5, a charging resistor short-circuiting contactor 6, an open contactor 8, a filter reactor 9, a filter capacitor 14, a filter capacitor voltage detector 15, a filter capacitor discharge unit 16 (including a filter capacitor discharge resistor 10 and a switching element 11 for discharge), 6in1 semiconductor element modules 13a, 13b, 13c, and 13d, a cooling unit 1 that cools the semiconductor element modules, a wheel 12, the permanent magnet synchronous motors 2a, 2b, 2c, and 2d, motor open contactors 3a, 3b, 3c, and 3d, and current detectors 17a, 17b, 17c, 17d, 17e, 17f, 17g, and 17h.
Specifically, the pantograph 4 that collects electricity from the DC overhead electricity is connected to the high-speed breaker 5, and the high-speed breaker 5 is connected to the charging resistor short-circuiting contactor 6. The charging resistor short-circuiting contactor 6 is connected to a charging resistor 7 in parallel and is connected to the open contactor 8. The open contactor 8 is connected to the filter reactor 9. The filter reactor 9 is connected to one ends of the semiconductor element modules 13a, 13b, 13c, and 13d in the power converter 100 for a vehicle. The other ends of the semiconductor element modules 13a, 13b, 13c, and 13d are connected to the wheel 12.
One terminal of the filter capacitor discharge unit 16 is connected to between the filter reactor 9 and the semiconductor element modules 13a, 13b, 13c, and 13d, whereas the other terminal thereof is connected to between the wheel 12 and the semiconductor element modules 13a, 13b, 13c, and 13d. Both ends of the filter capacitor 14 are connected to between the filter capacitor discharge unit 16 and the semiconductor element modules 13a, 13b, 13c, and 13d.
On the three-phase AC output side output from the semiconductor element modules 13a, 13b, 13c, and 13d, the current detectors 17a, 17b, 17c, 17d, 17e, 17f, 17g, and 17h are provided, and the permanent magnet synchronous motors 2a, 2b, 2c, and 2d are connected via the motor open contactors 3a, 3b, 3c, and 3d, respectively.
The semiconductor element modules 13a, 13b, 13c, and 13d include switching elements 101 that perform switching operation based on voltages applied to gates by gate driver circuit boards 20a, 20b, 20c, and 20d (refer to
The cooling unit 1 radiates heat generated by the semiconductor element, modules 13a, 13b, 13c, and 13d from a heat radiating unit 1a (refer to
Silicon carbide (SiC), not Si, is included in the switching elements 101 and the freewheeling diodes 102. SiC is superior in semiconductor characteristics to conventional Si and, due to its high dielectric breakdown strength in particular, can achieve an element having a thinner semiconductor junction, that is, an element having smaller conduction losses than that including Si.
When the switching element 101 and the freewheeling diode 102 are used for power conversion, they have large heating values, and they are required to be cooled. While a semiconductor including Si has an allowable temperature of 125° C. to 150° C., a semiconductor including SiC has an allowable temperature of 200° C. to 250° C., by which an element can be used at higher temperatures. Consequently, by using SiC for the switching element 101 and the freewheeling diode 102, the cooling unit 1 can be simplified compared with a case of using Si.
When SiC is included in the switching element 101, switching losses occurring at the time of switching can be reduced. When SiC is included in the freewheeling diode 102, reverse recovery at the time of turning off as in conventional Si is reduced, and diode recovery losses can nearly be neglected. Consequently, there are the advantages that the power losses of the power converter 100 for a vehicle are reduced and that efficiency enhancement and downsizing of the apparatus can be achieved.
As compared with a Si IGBT module for 1,500 A, for example, when a wafer material is changed from Si to SiC, the thickness of chip junctions inside the semiconductor element modules 13a, 13b, 13c, and 13d can be reduced by one digit or more, and on resistance per unit area can be reduced. In other words, current density can be increased. Using SiC can practically increase current density at least twice the case of using Si. Consequently, by using SiC for the switching element 101 and the freewheeling diode 102, a chip having a larger current rating can be manufactured even with the same chip size. Consequently, also as the semiconductor element modules 13a, 13b, 13c, and 13d, modules having a larger current rating can be manufactured even with the same size as that of the Si IGBT.
Given this situation, using SiC for the switching element 101 and the freewheeling diode 102 can increase current density about twice the case of using Si, and simply even an inverter with the same current rating can halve the area occupied by the semiconductor element modules 13a, 13b, 13c, and 13d mounted on the cooling unit 1.
Considering that element modules including Si with a rating of 1,500 A are already put into practical use and that using SiC for the switching element 101 and the freewheeling diode 102 doubles their current density, an element module including SiC with a rating of 3,000 A can be constituted with the external shape identical to that of an element module including Si with a rating of 1,500 A. When an element rating for driving one motor is about 500 A as in PMSM drive, up to six elements with a current rating of 500 A can be incorporated into one element module. Consequently, based on the fact that a three-phase inverter provides the switching elements 101 on the positive electrode side and the negative electrode side of the respective phases, by packaging the six switching elements 101 in one module, an inverter that causes one of the semiconductor element modules 13a, 13b, 13c, and 13d to drive one of the permanent magnet synchronous motors 2a, 2b, 2c, and 2d can be constituted, and thus downsizing of the inverter can be achieved.
As illustrated in
Specifically, as illustrated in
The AC side output terminal conductors 23a, 23b, 83c, and 23d are conductors that perform three-phase output to the permanent magnet synchronous motor 2a, 2b, 2c, and 2d. The AD side output terminal conductor 23a performs three-phase AC output of (U1, V1, W1) to the permanent magnet synchronous motor a. The AC side output terminal conductor 23b performs three-phase AC output of (U2, V2, W2) to the permanent magnet synchronous motor b. The AC ide output terminal conductor 3c performs three-phase AC output of (U3, V3, W3) to the permanent magnet synchronous motor 2c. The AC side output terminal conductor 23d performs three-phase AC output of (U4, V4, W4) to the permanent magnet synchronous motor 2d.
The gate driver circuit boards 20a, 20b, 20c, and 20d are thus directly connected to the semiconductor element modules 13a, 13b, 13c, and 13d, respectively, via the connecting bushes, thereby reducing gate control wiring and increasing the responsiveness of gate control. The positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 are connected to the semiconductor element modules 13a, 13b, 13c, and 13d via the connecting bushes to share the positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 by the four element modules, thereby reducing inductance with the filter capacitor 14 and increasing cutoff characteristics in the switching element 101.
In this situation, the gate driver circuit boards 20a and 20c of the semiconductor element modules 13a and 13c are arranged side-by-side on one end of the cooling unit 1. The gate driver circuit boards 20b and 20d of the semiconductor element modules 13b and 1d are arranged side-by-side on the end opposite to the one end. With this configuration, terminals connected to the AC side output terminal conductors 23a, 23b, 23c, and d concentrate in the central part of the cooling unit 1. The connecting parts between the respective AC side output terminal conductors 23 and the respective semiconductor element modules are brought close to each other, thereby making the lengths of the conductors nearly the same and also making inductances, which are proportional to the length of the conductor, nearly the same, and malfunction in terms of control caused by differences in inductance can be reduced.
In this situation, the AC side output terminal conductor 23a has a substantially L shape and extends from the left side of
With this configuration, the AC side output terminal conductor 23b is positioned on the obliquely upper side of the AC side output terminal conductor 23a, the AC side output terminal conductor 23c is positioned on the lower side of the AC side output terminal conductor 23b, and the AC side output terminal conductor 23d is positioned on the obliquely upper side of the AC side output terminal conductor 23c. Consequently, as long an insulation distance as possible can be ensured while making the differences in inductance among the AC side output terminal conductors 23 small. From the foregoing, the power converter for a vehicle having the configuration of the present embodiment can achieve downsizing and energy saving.
A main circuit configuration of the power converter 100a for a vehicle includes the pantograph 4, the high-speed breaker 5, the charging resistor short-circuiting contactor 6, the open contactor 8, the filter reactor 9, the filter capacitor 14, the filter capacitor voltage detector 15, the filter capacitor discharge unit 16 (including the filter capacitor discharge resistor 10 and the switching element 11 for discharge), 2in1 semiconductor element modules 18a, 18b, and 15c, a cooling unit 27 that cools the semiconductor element modules, the wheel 12, the induction motors 19a, 19b, 19c, and 19d, and current detectors 24a and 24b.
Similarly to the cooling unit 1, the cooling unit 27 radiates heat generated by the semiconductor element modules 18a, 18b, and 18c from a heat radiating unit through a coolant or the like, thereby cooling the semiconductor element modules 18a, 18b, and 18c.
The semiconductor element modules 18a, 18b, and 18c include the switching elements 101 that perform switching operation based on voltages applied to gates by the gate driver circuit boards 20a, 20b, and 20c (refer to
Silicon carbide (SIC), not Si, is included in the switching elements 101 and the freewheeling diodes 102 of the semiconductor element modules 18a, 18b, and 18c. Consequently, for the same reason as for the power converter 100 for a vehicle, the power converter 100a for a vehicle, which drives the four induction motors 19a, 19b, 19c, and 19d in parallel, can incorporate up to two switching elements 101 with a current rating of 1,500 A into one of the semiconductor element modules 16a, 16b, and 18c, and downsizing of the inverter can be achieved.
As illustrated in
Specifically, as illustrated in
The gate driver circuit boards 20a, 20b, and 20c are thus directly connected to the semiconductor element modules 18a, 18b, and 18c, respectively, via the connecting bushes, thereby reducing gate control wiring and increasing the responsiveness of gate control. The positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 are connected to the semiconductor element modules 18a, 18b, and 18c via the connecting bushes to share the positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 by the three element modules, thereby reducing inductance with the filter capacitor 14 and increasing cutoff characteristics in the switching element 101.
In this situation, the AC side output terminal conductors 23 have substantially the same length. Consequently, inductances, which are proportional to the conductor lengths, are also substantially the same, and handling in terms of control is easy. The respective gate driver circuit boards 20 on the respective semiconductor element modules 18 are positioned on the respective ends opposite to the respective ends from which the respective AC side output terminal conductors 23 of the respective semiconductor element modules 18 extend. Thus, distances are ensured between the respective AC side output terminal conductors 23 and the respective gate driver circuit boards 20, and the influence of noise occurring from respective AC side output terminal conductors 23 on the respective gate driver circuit boards 20 can be reduced. From the foregoing, the power converter for a vehicle having the configuration of the present embodiment can achieve downsizing and energy saving.
A main circuit configuration of the power converter 100b for a vehicle includes the pantograph 4, the high-speed breaker 5, the charging resistor short-circuiting contactor 6, the open contactor 8, the filter reactor 9, the filter capacitor 14, the filter capacitor voltage detector 15, the filter capacitor discharge unit 16 (including the filter capacitor discharge resistor 10 and the switching element 11 for discharge), 6in1 semiconductor element modules 13e and 13f, a cooling unit 31 that cools the semiconductor element modules, the wheel 12, the induction motors 19a, 19b, 19c, and 19d, and the current detectors 24a and 24b.
Similarly to the cooling unit 1, the cooling unit 31 radiates heat generated by the semiconductor element modules 13e and 13f from a heat radiating unit through a coolant or the like, thereby cooling the semiconductor element modules 13e and 1f.
The semiconductor element modules 13e and 13f include the switching elements 101 that perform switching operation based on voltages applied to gates by gate driver circuit boards 20e and 20f (refer to
The current rating of the semiconductor element modules 13e and 13f with a configuration of 6in1 is about 500 A, and by connecting the semiconductor element module 13e and the semiconductor element module 13f in parallel to constitute a rating equivalent to 1,000 A, the induction motors 19a, 19b, 19c, and 19d connected in parallel can be driven. SiC, not Si, is included in the switching elements 101 and the freewheeling diodes 102 of the semiconductor element modules 13e and 13f. Consequently, for the same reason as for the power converter 100 for a vehicle, downsizing of the inverter can be achieved.
As illustrated in
Specifically, as illustrated in
The gate driver circuit boards 20e and 20f are thus directly connected to the semiconductor element modules 13e and 13f, respectively, via the connecting bushes, thereby reducing gate control wiring and increasing the responsiveness of gate control. The positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 are connected to the semiconductor element modules 13e and 13f via the connecting bushes to share the positive electrode side laminate conductor 21 and the negative electrode side laminate conductor 22 by the two element modules, thereby reducing inductance with the filter capacitor 14 and increasing cutoff characteristics in the switching element 101.
A main circuit configuration of the power converter 100c for a vehicle includes the pantograph 4, a high-speed breaker 34, a main transformer 35, a charging resistor 38, a charging resistor short-circuiting contactor 37, an open contactor 36, positive electrode side filter capacitors 39a and 39b, negative electrode side filter capacitors 40a and 40b, a positive electrode side filter capacitor voltage detector 41, a negative electrode side filter capacitor voltage detector 42, the filter capacitor discharge unit 16 (including the filter capacitor discharge resistor 10 and the switching element 11 for discharge), semiconductor element modules 16d, 18e, 16f, and 18g for a 2in1 converter, neutral point clamping diodes 46a and 46b, a cooling unit 44 that cools the semiconductor element modules and the neutral point clamping diodes, semiconductor element modules 18h, 18i, 18j, 18k, 18l, and 18m for a 2in1 inverter, neutral point clamping diodes 46c, 46d, and 46e, a cooling unit 45 that cools the semiconductor element modules and the neutral point clamping diodes, the wheel 12, the induction motors 19a, 19b, 19c, and 19d, the current detectors 24a and 24b, and a converter input current detector 43.
Specifically, the pantograph 4 that collects electricity from AC overhead electricity (not illustrated) is connected to the wheel 12 via the high-speed breaker 34 and the main transformer 35. Output from the secondary coil of the main transformer 35 is input to the three-level single-phase converter using the semiconductor element modules 18d, 18e, 18f, and 18g via the open contactor 36, the charging resistor short-circuiting contactor 37, the charging resistor 38, and the converter input current detector 43. Output of the three-level single-phase converter using the semiconductor element modules 18d, 18e, 18f, and 19g is input to the semiconductor element modules 18h, 18i, 18j, 18k, 18l, and 18m for an inverter via an intermediate DC circuit including the positive electrode side filter capacitor 39a, the negative electrode side filter capacitor 40a, the filter capacitor discharge unit 16, the positive electrode side filter capacitor voltage detector 41, the negative electrode side filter capacitor voltage detector 42, the positive electrode side filter capacitor 39b, and the negative electrode side filter capacitor 40b. In an inverter unit, a three-level three-phase inverter is constituted using the semiconductor element modules 18h, 18i, 16j, 18k, 18l, and 18m for an inverter including circuits each having arms each of which connects the freewheeling diode 102 anti-parallel to the switching element 101, the arms being connected in series. From this inverter unit, three-phase C output for driving the induction motors 19a, 19b, 19c, and 19d connected in parallel is performed.
When the power converter 100c for a vehicle is started, the high-speed breaker 34 is turned on, the open contactor 36 is turned on, and then the positive electrode side filter capacitors 39a and 39b and the negative electrode side filter capacitors 40a and 40b are charged from the AC overhead electricity via the charging resistor 38 and the freewheeling diodes 102 of the semiconductor element modules 18d, 18e, 18f, and 18g. When the charge to the positive electrode side filter capacitors 39a and 39h and the negative electrode side filter capacitors 40a and 40b is completed, the charging resistor short-circuiting contactor 37 is turned on, a gate signal (gate voltage) is output to the semiconductor element modules 18d, 18e, 16f, and 18g for a converter, and the single-phase converter starts its operation. Similarly, the inverter unit also starts operation after a gate signal is output to the semiconductor element modules 18h, 18i, 18j, 18k, 18l, and 18m for an inverter.
SiC, not Si, is included in the switching elements 101 and the freewheeling diodes 102 of the semiconductor element modules 18d, 18e, 18f, and 18g for a converter, and the neutral point clamping diodes 46a and 46b that clamp neutral points. Consequently, for the same reason as for the power converter 100 for a vehicle, downsizing of the converter unit of the power converter 100c for a vehicle can be achieved. Similarly, SiC, not Si is included in the switching elements 101 and the freewheeling diodes 102 of the semiconductor element modules 18h, 18i, 18j, 18k, 18l, and 18m for an inverter and the neutral point clamping diodes 46c, 46d, and 46e that clamp neutral points. Consequently, for the same reason as for the power converter 100 for a vehicle, downsizing of the converter unit can be achieved. SIC is also included the neutral point clamping diodes 46a, 46b, 46c, 46d, and 46e that clamp the neutral points, thereby reducing generation losses.
Modification 1
The following describes modifications of the first to fourth embodiments. In the above embodiments, the conductors (the AC side output terminal conductors 23a, 23b, 23c, and 23d in
As illustrated in
As illustrated in
As described above, the three-phase AC output from the semiconductor element modules 13a, 13b, 13c, and 13d is performed by the AC side output terminal conductors 51a, 51b, and 51c that extend substantially perpendicularly to the face on which the semiconductor element modules 13a, 13b, 13c, and 13d are arranged through direct connection to the terminal unit 52, and the influence of noise by the three-phase AC output on the semiconductor element modules 13a, 13b, 13c, and 13d can be reduced. For example, as is clear from comparison with the case in
Modification 2
Specifically, the semiconductor element module 13a is connected to a negative electrode side laminate conductor 22a via the connecting bushes 49a, 49b, and 49c and is connected to a positive electrode side laminate conductor 21a via the connecting bushes 50a, 50b, and 50c. Similarly, the semiconductor element module 13b is connected to a positive electrode side laminate conductor 21b and a negative electrode side laminate conductor via connecting bushes. The semiconductor element module 13c is connected to a positive electrode side laminate conductor 21c and a negative electrode side laminate conductor 22c via connecting bushes. The semiconductor element module 13d is connected to a positive electrode side laminate conductor 21d and a negative electrode side laminate conductor 22d via connecting bushes. Thus, in the configuration in which the semiconductor element modules 13a, 13b, 13c, and 13d are independent of each other, even when damage or the like occurs in any semiconductor element module, influence on the other semiconductor element modules can be reduced, and redundancy can be increased.
By thus resin-sealing the gate driver circuit board, the negative electrode side laminate conductor, and the positive electrode side laminate conductor with the insulating resin, a low voltage part of the gate driver circuit board, the negative electrode side laminate conductor, and the positive electrode side laminate conductor are separated from each other by the insulator, and thus ensuring withstand voltage of a high voltage part and the low voltage part and causing the low voltage part less likely to be subjected to noise or the like from the high voltage part. From the foregoing, the power converter for a vehicle having the configuration of the present embodiment can achieve downsizing and energy saving.
Modification 3
Modification 3 exemplifies a configuration in which the conductors that perform AC output from the respective semiconductor element modules extend substantially perpendicularly to the face on which the semiconductor element modules are arranged as a modification of the second embodiment.
As illustrated in
As illustrated in
As described above, the three-phase AC output may be performed by causing the AC side output terminal conductors 48a, 48b, and 48c that extend substantially perpendicularly to the face on which the semiconductor element modules 18a, 18b, and 18c are arranged to be screwed into the conductor receivers 49a, 49b, and 49c.
The present invention is not limited to the above embodiments as they are and can be embodied with the components modified without departing from the essence thereof in the stage of implementation. Appropriate combinations of a plurality of components disclosed in the embodiments can form various inventions. For example, some components may be deleted from all components disclosed in the embodiments. Furthermore, components across different embodiments may appropriately be combined.
While the foregoing describes the embodiments of the present invention, these embodiments are presented as examples and do not intend to limit the scope of the invention. These novel embodiments can be performed in various other forms, and various omissions, replacements, and changes can be made without departing from the essence of the invention. These embodiments and modifications thereof are included in the scope and essence of the invention and are included in the inventions described in the claims and equivalents thereof.
Filing Document | Filing Date | Country | Kind |
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PCT/JP13/56524 | 3/8/2013 | WO | 00 |