Power conversion device

Abstract

The present invention provides a power conversion device, which includes: a drive circuit for driving a load, a housing accommodating the drive circuit, a plurality of connection terminals connected to the drive circuit and arranged in a specified direction, a plurality of power lines with one end respectively connected to the load and the other end respectively connected to the connection terminals, and a sending portion that is disposed opposite to the plurality of connection terminals and sends out the other ends of the plurality of power lines with a sending pitch different from the arrangement pitch of the plurality of connection terminals. The housing includes a plurality of guide walls for guiding the other ends of the power lines to the connection terminals respectively, and the angle of the guide wall is set along the entering direction of the other ends of the power lines relative to the connection terminals.

Description

Technical Field

[0001] The present invention relates to a power conversion device.

[0002] This application claims priority based on Japanese Patent Application No. 2018-058302 filed on March 26, 2018, the content of which is incorporated herein by reference. Background Art

[0003] In an electric vehicle or the like, a power conversion device for controlling power from a storage battery is provided to drive a mounted electric motor. For example, in Patent Document 1 described below, there is disclosed a power conversion device including a power supply module (drive circuit) for driving an electric motor (load), a power supply module housing for housing the power supply module, and a plurality of bus bars for connecting the electric motor and the power supply module. The bus bar is composed of a motor-side bus bar connected to the electric motor and a power supply module-side bus bar having one end connected to the power supply module and the other end serving as a connection terminal connected to the motor-side bus bar. The connection terminals are arranged on the side surface of the power supply module housing.

[0004] Prior Art Documents

[0005] Patent Documents

[0006] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2017-184384 Summary of the Invention

[0007] In the above Patent Document 1, the arrangement pitch of the roots of the motor-side bus bars and the arrangement pitch of the connection terminals are different. In order to fill this difference in arrangement pitch and connect the motor-side bus bar to the connection terminal, a formed wire harness in which the root of the motor-side bus bar is bent according to the arrangement pitch of the connection terminals is used as the motor-side bus bar. However, since braided wires are used in this formed wire harness, the cost increases. In addition, from the viewpoint of assembling the power conversion device, it is desired that the connection operation between the electric motor and the power supply module is easy.

[0008] The present invention has been made in view of the above circumstances, and an object thereof is to provide a power conversion device that can suppress an increase in cost and facilitate the connection operation between a load and a drive circuit.

[0009] One aspect of the present invention provides a power conversion device, comprising: a drive circuit for driving a load, a housing accommodating the drive circuit, a plurality of connection terminals connected to the drive circuit and arranged in a specified direction, a plurality of power lines having one end respectively connected to the load and the other end respectively connected to the connection terminals, and a sending portion disposed opposite to the plurality of connection terminals and sending the other ends of the plurality of power lines at a sending pitch different from the arrangement pitch of the plurality of connection terminals. The housing has a plurality of guide walls for guiding the other ends of the power lines to the connection terminals respectively, and the angle of the guide walls is set along the entering direction of the other ends of the power lines with respect to the connection terminals.

[0010] In the power conversion device of the above aspect, it may also be that the guide wall has a first protruding wall and a second protruding wall facing each other with a specified distance therebetween, and the first protruding wall and the second protruding wall are formed such that the extending direction of the first protruding wall and the second protruding wall is along the entering direction of the other ends of the power lines.

[0011] In the power conversion device of the above aspect, it may also be that the entrance portions of the first protruding wall and the second protruding wall with respect to the other ends of the power lines are formed such that the interval between the first protruding wall and the second protruding wall becomes larger as it faces the entrance side with respect to the other ends.

[0012] In the power conversion device of the above aspect, it may also be that it further comprises a plurality of current sensors disposed between the plurality of connection terminals and respectively detecting the current flowing through the connection terminals.

[0013] In the power conversion device of the above aspect, it may also be that the lengths of the plurality of power lines are the same.

[0014] According to the present invention, it is possible to provide a power conversion device that can suppress an increase in cost and is easy to connect the load and the drive circuit. Description of the Drawings

[0015] Figure 1 is an exploded perspective view of a power conversion device according to an embodiment of the present invention.

[0016] Figure 2A is a front view of a power supply module housing of a power conversion device according to an embodiment of the present invention.

[0017] Figure 2B is a perspective view of a power supply module housing of a power conversion device according to an embodiment of the present invention.

[0018] Figure 3A is a front view of a power conversion device according to an embodiment of the present invention.

[0019] Figure 3B This is a cross-sectional view of a power conversion device according to an embodiment of the present invention. Detailed Embodiment

[0020] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0021] The power conversion device 1 of the present embodiment is mounted on a vehicle that runs using an electric motor as a power source, such as a hybrid vehicle or an electric vehicle.

[0022] Figure 1 This is an exploded perspective view of the power conversion device 1 of the present embodiment disassembled in the assembly direction. The power conversion device 1 includes a power supply module (drive circuit) that drives a drive motor (load). In addition, the power conversion device 1 includes: a main body case 2, a power supply module case (case) 3, a plurality of bus bars 5, a plurality of power lines 7, a sending unit 9, a circuit board 10, and a plurality of current sensors 11 ( Figure 1 not shown in the figure). The power supply module and the motor are connected via the bus bar 5 and the power line 7.

[0023] As Figure 1 shown, the main body case 2 is composed of an upper case 2a, a central case 2b, and a lower case 2c. The upper case 2a, the central case 2b, and the lower case 2c are assembled to each other via gaskets or the like not shown.

[0024] The power supply module case 3 is a resin case that houses the power supply module. As Figure 2A shown, a plurality of guide walls 4 are provided on the side surface 3a of the power supply module case 3. Details of the guide walls 4 will be described later. In addition, as Figure 3A and Figure 3B shown, a plurality of insertion holes 3b into which a later-described Hall element 11b of the current sensor 11 is inserted and a plurality of slits 3c that connect the insertion holes 3b and the side surface 3a are formed in the power supply module case 3. When viewed from the side, the plurality of slits 3c are arranged between the plurality of guide walls 4.

[0025] The bus bar 5 is a metal plate (for example, a copper plate) that connects the power supply module and the power line 7. In the present embodiment, three bus bars 5 are set as a group. One end of the bus bar 5 is connected to the power supply module inside the power supply module case 3. As Figure 2A shown, the other end of the bus bar 5 becomes a connection terminal 6 (6A to 6C) provided on the side surface 3a of the power supply module case 3. In the present embodiment, three connection terminals 6 are arranged as a group at a predetermined interval on the side surface 3a.

[0026] In addition, the installation attitude of the power conversion device 1 is not particularly limited. However, in the following description, for convenience of explanation, the arrangement direction of the connection terminals 6 (that is, Figure 2AThe left - right direction (i.e., the left - right direction of the power conversion device 1) is defined as the left - right direction of the power conversion device 1, and the direction parallel to the side surface 3a and orthogonal to the arrangement direction of the connection terminals 6 (i.e., Figure 2A the up - down direction) is defined as the up - down direction of the power conversion device 1.

[0027] As Figure 2A shown, among the three connection terminals 6, the connection terminal 6B arranged at the center in the left - right direction is rectangular. The connection terminals 6A and 6C arranged on both sides in the left - right direction are parallelograms with the two side edges in the left - right direction inclined with respect to the up - down direction. In addition, holes 6a for bolt fastening are formed in the connection terminals 6.

[0028] The power lines 7 connect the motor and the bus bar 5. In this embodiment, three power lines 7 are set as a group. The multiple power lines 7 have the same shape (the same length). One end of the power line 7 is connected to the motor. As Figure 1 and Figure 3A shown, the other end 7a of the power line 7 exits from the sending part 9 and is connected to the connection terminal 6. A wire terminal 8 for connecting to the connection terminal 6 is riveted to the other end 7a. Long holes 8a for bolt fastening are formed in the wire terminal 8.

[0029] As Figure 1 and Figure 3A shown, the sending part 9 is arranged on the lower housing 2c so as to face the connection terminal 6 in the up - down direction. The sending part 9 has a plurality of openings 9a through which the multiple power lines 7 are respectively inserted and the other ends 7a of the multiple power lines 7 are respectively sent out. The arrangement pitch of the openings 9a (i.e., the sending pitch of the other ends 7a) is narrower than the arrangement pitch of the connection terminals 6.

[0030] As Figure 3A shown, the sending part 9 is arranged such that the position of the opening 9a for sending out the power line 7B arranged at the center in the left - right direction among the three power lines 7 coincides with the position of the connection terminal 6B in the left - right direction. Therefore, when the wire terminal 8 (the other end 7a) of the power line 7B and the connection terminal 6B are connected, the power line 7B extends along the up - down direction.

[0031] In addition, the openings 9a of the power lines 7A and 7C arranged on both sides in the left - right direction among the three power lines 7 are arranged at positions closer to the inside in the left - right direction than the connection terminals 6A and 6C. Therefore, when the wire terminals 8 (the other ends 7a) of the power lines 7A and 7C and the connection terminals 6A and 6C are connected, the power lines 7A and 7C extend in a manner inclined outward with respect to the up - down direction from the lower end to the upper end. In addition, since the power lines 7A - 7C have the same length, the upper ends of the wire terminals 8 of the power lines 7A and 7C are arranged at positions lower than the upper end of the wire terminal 8 of the power line 7B.

[0032] Next, with reference to Figure 2A , Figure 2B and Figure 3A , the structure of the guide wall 4 will be described. A plurality of guide walls 4 are provided corresponding to a plurality of connection terminals 6. That is, in the present embodiment, three guide walls 4 are set as a group. The guide wall 4 guides the other end 7a of the power line 7. The angle of the guide wall 4 is set along the entering direction of the other end 7a with respect to the connection terminal 6.

[0033] Specifically, as shown in Figure 2A , the guide wall 4 includes a first protruding wall 41 and a second protruding wall 42 that face each other with a predetermined distance therebetween. The first protruding wall 41 and the second protruding wall 42 protrude from the side surface 3a. The first protruding wall 41 and the second protruding wall 42 extend parallel to each other. When viewed from the side, the first protruding wall 41 and the second protruding wall 42 are arranged to sandwich the connection terminal 6.

[0034] The angles of the extending directions of the first protruding wall 41 and the second protruding wall 42 are set along the entering direction of the other end 7a.

[0035] Among the three guide walls 4, the first protruding wall 41 and the second protruding wall 42 of the guide wall 4B arranged at the center in the left - right direction extend along the up - down direction. The first protruding wall 41 and the second protruding wall 42 of the guide walls 4A and 4C arranged on both sides in the left - right direction of the three guide walls 4 extend in a manner that inclines outward with respect to the up - down direction as they go from the lower end to the upper end. That is, the first protruding wall 41 and the second protruding wall 42 of the guide walls 4A and 4C incline in a direction away from the guide wall 4B as they go from the lower end to the upper end.

[0036] As shown in Figure 2B , in order to facilitate the entry of the wire terminal 8 (the other end 7a), the lower end portions 41a, 42a of the mutually opposing surfaces of the first protruding wall 41 and the second protruding wall 42 are inclined in such a manner that the distance between the first protruding wall 41 and the second protruding wall 42 becomes larger as it goes toward the lower end side. That is, the shapes of the lower end portions 41a, 42a of the first protruding wall 41 and the second protruding wall 42 are set such that the interval for the wire terminal 8 (the other end 7a) becomes larger at the entrance position.

[0037] As shown in Figure 1 and Figure 3A , the circuit board 10 is fixedly arranged on the upper surface of the power module housing 3. A control circuit (not shown) is mounted on the circuit board 10. The circuit board 10 (control circuit) is connected to an upper - level control device such as a motor ECU via a predetermined communication cable or the like, and controls a step - up / down converter, an inverter, etc. mounted on the vehicle based on a control instruction input from the upper - level control device.

[0038] As shown in Figure 3A and Figure 3BAs shown, a plurality of current sensors 11 are arranged between a plurality of connection terminals 6. The plurality of current sensors 11 respectively detect the current flowing through the bus bar 5 (connection terminal 6) and output a detection signal to the control circuit mounted on the circuit board 10.

[0039] As Figure 3B shown, the current sensor 11 includes a magnetic core 11a and a Hall element 11b. The magnetic core 11a is a magnetic component integrally formed on the side of the power module housing 3 and is formed in a substantially C shape with a magnetic gap 11c. The bus bar 5 is inserted through the magnetic core 11a. Since the magnetic core 11a is made of a ferromagnetic material with a high magnetic permeability, the magnetic lines of force generated around the bus bar 5 due to the current flowing through the bus bar 5 are concentrated and flow through the magnetic core 11a.

[0040] The Hall element 11b is mounted on the lower surface of the circuit board 10 and inserted into the magnetic gap 11c. That is, the Hall element 11b is a magnetic sensor that mainly detects the above-mentioned magnetic lines of force passing through the magnetic gap 11c. As Figure 3B shown, the Hall element 11b is inserted into the insertion hole 3b. The insertion hole 3b and the side surface 3a are connected by a slit 3c, so that the Hall element 11b can be visible from the outside of the power module housing 3 through the slit 3c. The first protruding walls 41 and the second protruding walls 42 of the guiding walls 4A and 4C arranged on both sides in the left-right direction among the three guiding walls 4 extend in a manner that inclines outward with respect to the up-down direction as they go from the lower end to the upper end. Therefore, a space for providing the slit 3c can be sufficiently ensured between the guiding walls 4A and 4B and between the guiding walls 4B and 4C.

[0041] Moreover, when assembling the power conversion device 1 of the present embodiment having such a structure, the wire terminal 8 (the other end 7a) of the power line 7 is inserted into the connection terminal 6 from below. That is, the wire terminal 8 (the other end 7a) is inserted into the space between the first protruding wall 41 and the second protruding wall 42 of the guiding wall 4 along the Figure 2A direction of the arrow shown. Specifically, the wire terminal 8 (the other end 7a) of the power line 7B is guided by the guiding wall 4B and inserted from below along the up-down direction. The wire terminals 8 (the other end 7a) of the power lines 7A and 7C are respectively guided by the guiding walls 4A and 4C and inserted from below along a direction inclined outward with respect to the up-down direction.

[0042] When the wire terminal 8 (the other end 7a) is disposed between the first protruding wall 41 and the second protruding wall 42 of the guiding wall 4, the wire terminal 8 (the other end 7a) and the connection terminal 6 are respectively in contact, and the bus bar 5 and the power line 7 are respectively connected. At this time, when viewed from the side, the positions of the long hole 8a of the wire terminal 8 and the hole 6a of the connection terminal 6 coincide. By inserting and tightening a bolt through the hole 6a and the long hole 8a, the wire terminal 8 is fixed relative to the connection terminal 6. In addition, since the long hole 8a is formed in the wire terminal 8, even if the position of the long hole 8a is slightly misaligned with respect to the hole 6a, the bolt can be inserted through the hole 6a and the long hole 8a and tightened.

[0043] Then, the circuit board 10 on which the Hall element 11b and the control circuit are mounted is disposed in parallel and opposed to the power supply module housing 3. In this state, the circuit board 10 is lowered, and the Hall element 11b mounted on the lower surface of the circuit board 10 is inserted into the insertion hole 3b. At this time, the position of the Hall element 11b with respect to the insertion hole 3b can be confirmed from the outside of the power supply module housing 3 through the slit 3c. Then, the circuit board 10 is fixed to the upper part of the power supply module housing 3 using a prescribed fixing member (such as a screw).

[0044] As described above, according to the present embodiment, the power supply module housing 3 includes the guiding wall 4 that respectively guides the other ends 7a of the power lines 7, and the angle of the guiding wall 4 is set along the entering direction of the other ends 7a with respect to the connection terminal 6. The arrangement pitch of the connection terminals 6 is different from the sending pitch at which the other ends 7a of the power lines 7 are sent out from the sending portion 9. However, through the guiding wall 4, the other ends 7a can enter the connection terminal 6 in a state where the entering angle of the other ends 7a is adjusted according to the difference in pitch and be connected to the connection terminal 6. Therefore, the mountability of the power lines 7 is improved, and the operation of connecting the motor and the power supply module via the connection terminal 6 and the power line 7 becomes easy. In addition, in the connection between the motor and the power supply module, it is not necessary to use a formed wire harness. Therefore, it is possible to absorb the deviation in the mutual position between the connection terminal 6 and the other end 7a caused by the difference between the arrangement pitch of the connection terminals 6 of the wire harness and the sending pitch at which the other ends 7a of the power lines 7 are sent out from the sending portion 9, and suppress an increase in cost.

[0045] In addition, in the present embodiment, the guiding wall 4 includes a first protruding wall 41 and a second protruding wall 42 that face each other with a predetermined distance therebetween, and the first protruding wall 41 and the second protruding wall 42 are formed such that the extending direction of the first protruding wall 41 and the second protruding wall 42 is along the entering direction of the other end 7a. Therefore, by inserting the other end 7a between the first protruding wall 41 and the second protruding wall 42, the other end 7a can be easily arranged at the connection position with the connection terminal 6. In addition, since the connection terminal 6 and the other end 7a are respectively arranged between the first protruding wall 41 and the second protruding wall 42, the insulation performance between the adjacent connection terminal 6 and the other end 7a can be ensured. In addition, through the first protruding wall 41 and the second protruding wall 42, the insulation performance with the main body housing 2 and / or other conductive parts can be ensured.

[0046] In addition, in the present embodiment, the entrance portions of the first protruding wall 41 and the second protruding wall 42 with respect to the other end 7a are formed such that the interval between the first protruding wall 41 and the second protruding wall 42 becomes larger as it approaches the entrance side with respect to the other end 7a (refer to the lower end portions 41a, 42a of Figure 2B ). Therefore, the other end 7a can be smoothly inserted between the first protruding wall 41 and the second protruding wall 42. That is, the insertability of the other end 7a can be ensured at the entrance portion, and the other end 7a is gradually positioned as it approaches the connection terminal 6.

[0047] In addition, in the present embodiment, a plurality of current sensors 11 are also provided, which are arranged between the plurality of connection terminals 6 and respectively detect the current flowing through the connection terminals 6. Therefore, the current sensors 11 can be arranged near the connection terminals 6 to be detected, and the current flowing through the connection terminals 6 can be detected by the current sensors 11.

[0048] In addition, in the present embodiment, the lengths of the plurality of power lines 7 are the same. Therefore, the impedances of the plurality of power lines 7 can be made equal.

[0049] Furthermore, the present invention is not limited to the above-described embodiment described with reference to the drawings, and may also include various modification examples within its technical scope.

[0050] For example, in the above-described embodiment, the guiding wall 4 has a structure including a first protruding wall 41 and a second protruding wall 42 that face each other with a predetermined distance therebetween, but the present invention is not limited thereto. For example, the guiding wall 4 may also have a structure with only one protruding wall.

[0051] In addition, in the above-described embodiment, the delivery unit 9 is configured such that the position of the opening 9a for delivering the power line 7B disposed at the center in the left-right direction coincides with the position of the connection terminal 6B in the left-right direction. However, the present invention is not limited thereto. For example, the delivery unit 9 may be configured such that the position of the opening 9a for delivering the power line 7A coincides with the position of the connection terminal 6A in the left-right direction. In this case, the power line 7A extends along the up-down direction, but the power lines 7B and 7C extend in a manner inclined with respect to the up-down direction. In addition, the inclination angle of the power line 7C with respect to the up-down direction is greater than the inclination angle of the power line 7B with respect to the up-down direction.

[0052] Moreover, within the scope not departing from the concept of the present invention, the structural elements in the above-described embodiment can be appropriately replaced with well-known structural elements. In addition, the above-described modified examples can be appropriately combined.

[0053] Reference Signs

[0054] 1... Power conversion device

[0055] 3... Power supply module housing (housing)

[0056] 4... Guide wall

[0057] 5... Bus bar

[0058] 6... Connection terminal

[0059] 7... Power line

[0060] 7a... Other end

[0061] 9... Delivery unit

[0062] 11... Current sensor

[0063] 41... First protruding wall

[0064] 42... Second protruding wall

Claims

1. A power conversion device, characterized in that, Comprising: A drive circuit for driving a load, A housing accommodating the drive circuit, A plurality of connection terminals connected to the drive circuit and arranged in a specified direction, A plurality of power lines having one end respectively connected to the load and the other end respectively connected to the connection terminals, and A sending portion provided opposite to the plurality of connection terminals and sending the other ends of the plurality of power lines at a sending pitch different from the arrangement pitch of the plurality of connection terminals, The housing includes a plurality of guide walls for guiding the other ends of the power lines to the connection terminals respectively, The connection terminals are formed by an arrangement combining a rectangle and a parallelogram, The angles of all the guide walls are set along the entry direction of the other ends of the power lines with respect to the shape of the connection terminals.

2. The power conversion device according to claim 1, wherein The guide wall includes a first protruding wall and a second protruding wall spaced apart by a specified distance, and the first protruding wall and the second protruding wall are formed such that the extending direction of the first protruding wall and the second protruding wall is along the entry direction of the other ends of the power lines.

3. The power conversion device according to claim 2, wherein The entry portions of the first protruding wall and the second protruding wall with respect to the other ends of the power lines are formed such that the interval between the first protruding wall and the second protruding wall becomes larger as it faces the entry side with respect to the other ends.

4. The power conversion device according to claim 1, wherein It further includes a plurality of current sensors disposed between the plurality of connection terminals and respectively detecting the current flowing through the connection terminals.

5. The power conversion device according to claim 1, wherein The lengths of the plurality of power lines are the same.

6. The power conversion device according to any one of claims 1 to 5, wherein The other ends include long holes fastened to the connection terminals by fastening members.

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