Power supply device and method for providing a power supply device

Abstract

The present invention can provide a power supply device and a method for providing a power supply device that can suppress the increase in the number of man-hours required for providing a power supply device. A plurality of power supply modules (10) with various variations are manufactured and prepared in advance, and a plurality of controllers (20) with various variations are manufactured and prepared in advance. By selecting a power supply module (10) with desired power supply performance from the plurality of power supply modules (10) under consideration, selecting a controller (20) with desired functions from the plurality of controllers (20) under consideration, and combining them, a desired power supply device (1) can be constructed. A common power supply module-side connection portion (100) is provided on each power supply module (10), and a common controller-side connection portion (110) is provided on each controller (20).

Description

Technical Field

[0001] The present invention relates to a power supply device and a method for providing a power supply device. Background Art

[0002] Patent Document 1 discloses a power supply device comprising an electric double layer capacitor and a rechargeable battery. This power supply device includes, for example, a controller that switches the charge and discharge state while using the power supply as a backup in the event of a main power failure.

[0003] Patent Document 1: Japanese Patent Application Laid-Open No. 2008-62712

[0004] In these power supply devices, the required power supply performance and controller functions vary depending on the intended use. In recent years, the use of power supply devices has become increasingly diverse. To provide a power supply device tailored to each application requires redesigning the power supply device for each application, which can increase the time required to develop the power supply device. Summary of the Invention

[0005] An object of the present invention is to suppress an increase in man-hours required for providing a power supply device.

[0006] The power supply device for solving the above-mentioned problem is constructed by selectively combining one power supply module from a plurality of power supply modules having different power supply performances and one controller from a plurality of controllers having different functions. In order to selectively combine the above-mentioned one power supply module and the above-mentioned one controller, a common power supply module side connection part is respectively provided on the above-mentioned multiple power supply modules, and a common controller side connection part that can be connected to the above-mentioned power supply module side connection part is respectively provided on the above-mentioned multiple controllers.

[0007] A method for providing a power supply device for solving the above-mentioned problem, wherein the power supply device is constructed by selectively combining one power supply module from a plurality of power supply modules having different power supply performances and one controller from a plurality of controllers having different functions, wherein the method for providing a power supply device includes the following steps, namely: a power supply module selection step, in which one power supply module from a plurality of power supply modules having different power supply performances and respectively provided with a common power supply module side connection portion is selected; and a controller selection step, in which one controller from a plurality of controllers having different functions and respectively provided with a common controller side connection portion that can be connected to the above-mentioned power supply module side connection portion is selected.

[0008] According to the above structure, any of the multiple power modules can be combined with any of the multiple controllers. Therefore, by selecting a power module with desired power performance from the multiple power modules and a controller with desired functions from the multiple controllers, and combining them, a desired power supply device can be constructed. Therefore, when providing a desired power supply device, it is sufficient to pre-manufacture and prepare multiple power modules with the desired power performance and multiple controllers with the desired functions. This can reduce the increase in the number of man-hours required to provide the power supply device, compared to redesigning the power supply device for each application.

[0009] Preferably, in the power supply device and the method for providing a power supply device, the power supply performance is a discharge voltage of the power module.

[0010] According to the above configuration, it is possible to provide power supply modules having different discharge voltages as power supply performance, and it is possible to appropriately respond to demands for different desired discharge voltages.

[0011] Preferably, in the above-mentioned power supply device and the method for providing the power supply device, the auxiliary power supply device functions as an auxiliary power supply device arranged on the power supply path between the main power supply and the power supply object of the power supply, and the above-mentioned function is a function of controlling the charging and discharging of the above-mentioned power supply module, and a function of boosting the voltage of the above-mentioned main power supply through the charging and discharging of the above-mentioned power supply module; and a function of backing up the power supply when the above-mentioned main power supply fails through the charging and discharging of the above-mentioned power supply module.

[0012] According to the above structure, a controller having different functions as the above functions, such as boosting the voltage of the main power supply or backing up the power supply when the main power supply fails, can be provided, thereby being able to appropriately respond to different requirements for the desired functions of boosting the voltage of the main power supply or backing up the power supply when the main power supply fails.

[0013] The power supply device and the method for providing a power supply device preferably include a combination in which the controller is not combined and the power supply module is composed of only the single power supply module.

[0014] According to the above configuration, only the power module can be provided as the power supply device, thereby appropriately responding to the need for only the power module.

[0015] Effects of the Invention

[0016] According to the power supply device and the method for providing the power supply device of the present invention, it is possible to suppress an increase in the number of man-hours required for providing the power supply device. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG1 (a) and FIG1 (b) are schematic perspective views of a power supply device.

[0018] Figure 2 This is an exploded perspective view of the power module.

[0019] Figure 3 This is a simplified three-dimensional diagram of the power module.

[0020] Figure 4 This is a simplified perspective view of the tray of the power module.

[0021] Figure 5 This is an exploded perspective view of the controller.

[0022] Figure 6 This is a diagram schematically showing a combination of a power supply module and a controller.

[0023] Figure 7 This is a diagram schematically showing a method for providing a power supply device.

[0024] Description of reference numerals:

[0025] 1…Power supply device; 10…Power module; 11…Tray unit; 12…Tray cover; 13…Balance board; 13a…Control element; 13b…Power module-side communication connection; 14…Cover; 15…Module chassis; 20…Controller; 21…Controller housing; 21b…Connection hole; 22…Control board; 22a…Control element; 22b…Controller-side communication connection; 22c…Controller-side power connection; 22d…External communication connection; 22e…Power connection; 23…Controller cover; 23b…Connection hole; 23c, 23d…Busbar holes; 30…Tray; 31…Tray base; 32…Capacitor; 32b…Controller-side communication connection; 33…Terminal; 34…Connecting portion; 34a…Engineer; 34b…Engineered portion; 35…Busbar hole; 40…Tray cover base; 41…First busbar; 42…Engineer; 50 ...frame base; 50c ...connection portion hole; 51 ...engaged portion; 52 ...second busbar; 53 ...busbar hole; 54 ...protrusion; 100 ...power module side connection portion; 110 ...controller side connection portion. DETAILED DESCRIPTION

[0026] An embodiment of a power supply device will be described with reference to the accompanying drawings.

[0027] The power supply device 1 of this embodiment is installed in, for example, a vehicle's electric power steering system. This system assists the driver's steering operation by applying the motor's rotational force as a steering assist force to the steering mechanism that steers the steering wheels based on the driver's operation of the steering wheel. The power supply device 1, installed in the power supply path between a main power source and the motor (the target of power supply), functions as an auxiliary power supply, boosting the voltage of the main power source or providing backup power in the event of a main power source failure.

[0028] As shown in Figures 1(a) and 1(b), the power supply device 1 is generally rectangular in shape and includes a chargeable and dischargeable power module 10 and a controller 20 that controls the charging and discharging of the power module 10. The power supply device 1 is constructed by combining the power module 10 and the controller 20 via a power module-side connector 100 and a controller-side connector 110, which will be described later.

[0029] like Figure 2 As shown, the power module 10 includes a tray unit 11 , a tray cover 12 , a balance substrate 13 , a cover 14 , and a module chassis 15 .

[0030] The tray unit 11 is formed by a plurality of Figure 2 The four plate-shaped tray portions 30 are stacked in the plate thickness direction to form a rectangular parallelepiped. In addition, the four tray portions 30 have the same structure.

[0031] like Figure 4 As shown, the tray portion 30 includes a rectangular plate-shaped tray base 31 having long and short sides. The tray base 31 is made of a non-conductive material such as resin. A peripheral wall 31a extending in one direction in the plate thickness direction is provided around the periphery of the tray base 31. A receiving portion 31b is formed within the tray base 31 by the surface of the tray base 31 extending in the direction of the peripheral wall 31a and the inner surface of the peripheral wall 31a. The receiving portion 31b accommodates a rectangular plate-shaped capacitor 32 having long and short sides and a rectangular plate-shaped terminal portion 33 having long and short sides.

[0032] Capacitor 32 is housed so that its pair of long side surfaces and one short side side surface, perpendicular to the plate thickness, are located along the inner surface of the pair of long side walls 31a and the inner surface of the short side wall 31a. Capacitor 32 has a positive electrode plate and a negative electrode plate. In this embodiment, capacitor 32 is a lithium-ion capacitor. Lithium-ion capacitors offer advantages such as excellent heat resistance, long life, excellent charge and discharge performance, high energy density, and high safety.

[0033] The terminal portion 33 is housed so that the side surface of one of its long sides, perpendicular to the plate thickness direction, is aligned with the inner wall surface of the pair of long side peripheral walls 31a and the inner wall surface of the other short side peripheral wall 31a. The terminal portion 33 extends along the short sides of the tray base 31. Portions of each of the two sides of the terminal portion 33 in the plate thickness direction are exposed from the plate thickness direction of the tray base 31. The positive electrode plate of the capacitor 32 is connected to one end surface of the terminal portion 33 in the plate thickness direction by welding or other means.

[0034] Two connecting portions 34 are provided on the outer wall surfaces of the peripheral walls 31a on the pair of long sides of the tray base 31. Each connecting portion 34 includes an engaging portion 34a that can engage with an engaged portion 34b of a connecting portion 34 provided on another tray portion 30, and an engaged portion 34b that can engage with an engaging portion 34a of a connecting portion 34 provided on another tray portion 30. Furthermore, a busbar hole 35 for inserting a first busbar 41, described later, is provided on the outer wall surface of the peripheral wall 31a on the short side of the tray base 31 on the side where the terminal portion 33 is provided, projecting outward.

[0035] Each tray portion 30 constructed in this way is stacked in the direction of the plate thickness from the side of the tray portion 30 on the other side where the capacitor 32 is not exposed relative to the side of the tray portion 30 on one side where the capacitor 32 is exposed. At this time, the tray portions 30 on one side and the other side are assembled with each other by engaging the engaging portion 34a of the tray portion 30 on the other side with the engaged portion 34b of the tray portion 30 on one side. At the same time, the terminal portion 33 exposed in the direction of the plate thickness of the tray portion 30 on one side and the terminal portion 33 exposed in the direction of the plate thickness of the tray portion 30 on the other side are electrically connected via the electrode plates of the capacitor 32, i.e., the positive and negative electrodes of the capacitor 32. Thus, each capacitor 32 is electrically connected in series. In addition, between the tray portion 30 on one side and the tray portion 30 on the other side, each busbar hole 35 is connected in the direction of the plate thickness. As shown Figure 2 As shown in the example, when four tray units 30 are stacked in the thickness direction and four capacitors 32 are connected in series, the power supply performance of the tray unit 11, that is, the magnitude of the discharge voltage, is the sum of the discharge voltages of the four capacitors 32. For example, when the discharge voltage of one capacitor 32 is approximately 3V (volts), the magnitude of the discharge voltage of the tray unit 11 is approximately 12V.

[0036] like Figure 2 As shown, the tray cover 12 is stacked on the tray portion 30 where the capacitor 32 is exposed in the tray unit 11, that is, the tray portion 30 stacked on the uppermost side when the plate thickness direction is the vertical direction. The tray cover 12 includes a rectangular plate-shaped tray cover base 40 having long and short sides. The tray cover base 40 is made of a non-conductive material such as resin.

[0037] Two engaging portions 42 are provided on the side surfaces of each of the pair of long sides of the tray cover base 40. The engaging portions 42 have the same structure as the engaging portion 34a of the connecting portion 34 of the tray portion 30 and are engageable with the engaged portion 34b provided on the tray portion 30. A first bus bar 41 is connected to the side surface of one short side of the tray cover base 40.

[0038] One end of the first busbar 41 is connected to the tray cover base 40, and the other end extends in the plate thickness direction. The length of the first busbar 41 is set so that the tip of the other end protrudes from the stacking direction of the power modules 10. The end of the first busbar 41 connected to the tray cover base 40 is exposed on the side of the tray cover base 40 where the other end of the first busbar 41 extends.

[0039] Furthermore, the module chassis 15 is stacked on the tray portion 30 in the tray unit 11 where the capacitor 32 is not exposed, that is, on the tray portion 30 stacked at the bottom when the plate thickness direction is the vertical direction. The module chassis 15 includes a rectangular plate-shaped frame base 50 having long and short sides. The frame base 50 is made of a non-conductive material such as resin. A peripheral wall 50a extending in one direction in the plate thickness direction is provided around the periphery of the frame base 50. A housing portion 50b is formed in the frame base 50 between a surface of the frame base 50 in the direction in which the peripheral wall 50a extends and an inner wall surface of the peripheral wall 50a. The plate-shaped balance substrate 13 is fixed to the housing portion 50b using fastening members such as screws.

[0040] The balancing substrate 13 is a component used to adjust the discharge voltage of each capacitor 32 in the tray unit 11 in order to suppress variations in the discharge voltage. A control element 13a, which functions to adjust the discharge voltage of each capacitor 32, is provided on one end surface of the balancing substrate 13 in the thickness direction. In this embodiment, the control element 13a adjusts the discharge voltage of each capacitor 32 so that the discharge voltage of each capacitor 32 reaches the lowest discharge voltage.

[0041] Furthermore, a power module-side communication connector 13b is provided on the other end face of the balance substrate 13 in the thickness direction, which facilitates electrical communication between the control element 13a and the controller 20. The balance substrate 13 is fixed so that its other end face in the thickness direction faces the frame base 50. Furthermore, the power module-side communication connector 13b is configured to protrude from the side of the frame base 50 opposite the direction in which the peripheral wall 50a of the frame base 50 extends, passing through a connection hole 50c provided in the center of the frame base 50.

[0042] Two engaged portions 51 are provided on the outer wall surfaces of the peripheral walls 50a of a pair of long sides of the frame base 50. The engaged portions 51 have the same structure as the engaged portions 34b of the connecting portion 34 of the tray portion 30 and are engageable with the engaging portions 34a provided on the tray portion 30. A second bus bar 52 is connected to a portion on one short side of the frame base 50.

[0043] One end of the second busbar 52 is connected to the frame base 50, and the other end extends in the plate thickness direction. The length of the second busbar 52 is set to the length of the tip of the other end protruding from the stacking direction of the power module 10. The end of the second busbar 52 connected to the frame base 50 is exposed on the side of the frame base 50 opposite to the side where the other end of the second busbar 52 extends. In addition, a busbar hole 53 for inserting the first busbar 41 is provided on one short side of the frame base 50, adjacent to the second busbar 52.

[0044] The tray cover 12 thus constructed is stacked in the plate thickness direction from the side extending from the first busbar 41 relative to the topmost tray section 30 stacked in the tray unit 11. At this point, the engaging portion 42 of the tray cover 12 engages with the engaged portion 34b of the topmost tray section 30, thereby assembling the tray cover 12 and the topmost tray section 30. Simultaneously, one end of the first busbar 41, exposed at the side extending from the other end of the first busbar 41, abuts against the terminal portion 33 of the topmost tray section 30, exposed in the plate thickness direction, via the capacitor 32, namely, the positive and negative electrode plates of the capacitor 32, thereby electrically connecting them. Furthermore, the first busbar 41 of the tray cover 12 is inserted through the busbar hole 35 that connects the tray sections 30 of the tray unit 11.

[0045] Furthermore, the module chassis 15 thus constructed is stacked in the plate thickness direction from the side opposite to the side where the second busbar 52 extends, relative to the tray section 30 stacked on the bottom of the tray unit 11. At this point, the module chassis 15 and the tray section 30 stacked on the bottom are assembled together by engaging the engaging portion 34a of the tray section 30 stacked on the bottom with the engaged portion 51 of the module chassis 15. Simultaneously, the end of the second busbar 52, exposed on the side opposite to the side where the other end of the second busbar 52 extends, and the terminal portion 33 of the tray section 30 stacked on the bottom, exposed in the plate thickness direction, abut against each other, thereby electrically connecting them. Furthermore, the busbar holes 53 of the module chassis 15 and the busbar holes 35 connecting the tray sections 30 of the tray unit 11 are connected in the plate thickness direction. Furthermore, the first busbar 41 of the tray cover 12 is inserted through the busbar holes 53.

[0046] At this time, if Figure 3 As shown, the front ends of the other ends of the first busbar 41 of the tray cover 12 and the second busbar 52 of the module chassis 15 protrude from the side where the second busbar 52 extends from the module chassis 15, and the power module-side communication connector 13b of the balance board 13 also protrudes. Protrusions 54, which protrude relative to other parts, are provided at the four corners of the surface of the module chassis 15 where the second busbar 52 extends.

[0047] Moreover, if Figure 2as well as Figure 3 As shown, a bottomed box-shaped cover 14 is assembled from the opening 14a side of the structure composed of the tray unit 11, tray cover 12, balance substrate 13, and module chassis 15 to accommodate the structure. Cover 14 is secured to the tray cover 12 on the side opposite to the side where the first busbar 41 extends, using fasteners such as screws. This completes the power module 10.

[0048] like Figure 5 As shown, the controller 20 includes a controller housing 21 , a control substrate 22 , and a controller cover 23 .

[0049] The controller housing 21 is in the shape of a bottomed box, and the plate-shaped control substrate 22 is fixed to the inside of the controller housing 21 by screws or other fastening components. The control substrate 22 controls the charging and discharging of each capacitor 32 of the tray unit 11. A control element 22a that functions to control the charging and discharging of each capacitor 32 is provided on one end face of the control substrate 22 in the plate thickness direction. Figure 2 In the example shown, the control element 22 a controls the charging and discharging of each capacitor 32 so as to boost the voltage of the main power supply and provide a backup power supply in the event of a main power supply failure.

[0050] A controller-side communication connector 22b is provided on one end surface of the control substrate 22 in the thickness direction. This connector is used for electrical communication with the control element 22a and the control element 13a of the power module 10. When the power module 10 and controller 20 are assembled, the controller-side communication connector 22b is positioned corresponding to the power module-side communication connector 13b.

[0051] A controller-side power connector 22c is provided on one end face of the control substrate 22 in the thickness direction for electrically connecting to the first bus bar 41 and the second bus bar 52. When the power module 10 and the controller 20 are assembled, the controller-side power connector 22c is located at a position corresponding to the front ends of the other ends of the first bus bar 41 and the second bus bar 52.

[0052] An external communication connection portion 22d for electrical communication with an external device (not shown) is provided on one end surface of the control board 22 in the thickness direction. The external communication connection portion 22d is provided on one end surface of the control board 22 so as to extend from one long side in a direction perpendicular to the thickness direction.

[0053] A power supply connection portion 22e for electrically connecting to a main power supply (not shown) is provided on one end surface of the control board 22 in the thickness direction. The power supply connection portion 22e is provided on one end surface of the control board 22, adjacent to the external communication connection portion 22d, extending from one long side in a direction perpendicular to the thickness direction.

[0054] The control board 22 is fixed so that one end face in the thickness direction faces the opening 21a of the controller housing 21. At this time, the external communication connection portion 22d and the power connection portion 22e protrude from the side of the side wall of the controller housing 21 through a connection portion hole 21b provided in the side wall of one long side of the controller housing 21.

[0055] like Figure 5 As shown, the controller cover 23 includes a rectangular plate-shaped controller cover base 23a having long and short sides. The controller cover base 23a is made of a non-conductive material such as resin. A connection hole 23b extending through the thickness of the plate is provided in the center of the controller cover base 23a. The connection hole 23b is located at a position corresponding to the controller-side communication connection portion 22b. Furthermore, busbar holes 23c and 23d extending through the thickness of the plate are provided on one short side of the controller cover base 23a. The busbar holes 23c and 23d are located at positions corresponding to the controller-side power connection portion 22c. On one end surface of the controller cover 23 in the thickness direction, recessed portions 23e are provided at each of the four corners. These recessed portions 23e are located at positions corresponding to the protrusions 54 on the module chassis 15 when the power module 10 and controller 20 are assembled.

[0056] The controller cover 23 thus constructed is assembled relative to the opening 21a of the controller housing 21, so that the structure in which the controller housing 21 and the control board 22 are assembled is accommodated from the other end surface opposite to the side where the recesses 23e are provided in the plate thickness direction. The controller cover 23 is secured to the controller housing 21 by fastening members such as screws. Thus, the controller 20 is constructed.

[0057] As shown in FIG. 1( a ) and FIG. 1 ( b ), the power module 10 and the controller 20 are assembled with the module chassis 15 side of the power module 10 and the controller cover 23 side of the controller 20 facing each other.

[0058] At this time, if Figure 3 as well as Figure 5 As shown, the power module-side communication connector 13b protruding from the module chassis 15 side of the power module 10 is engaged and connected to the controller-side communication connector 22b of the control board 22 via the connector hole 23b provided in the controller cover 23, thereby electrically connecting the power module 10 to the controller-side communication connector 22b. Furthermore, the first bus bar 41 and the second bus bar 52 protruding from the module chassis 15 side of the power module 10 are engaged and connected to the controller-side power connector 22c of the control board 22 via the bus bar holes 23c and 23d provided in the controller cover 23, thereby electrically connecting the power module 1 to the controller-side power connector 22c. Furthermore, the protrusions 54 protruding from the module chassis 15 side of the power module 10 and the recesses 23e of the controller cover 23 engage with each other. Thus, the power supply device 1 is formed.

[0059] In the above description, the power supply device 1 has been described as having power supply performance obtained by connecting four capacitors 32 in series, and having the function of boosting the voltage of the main power supply and the function of backing up the power supply in case of a main power supply failure.

[0060] In the power supply device 1 of this embodiment, Figure 2 In addition to the example shown, by using a tray unit 11 in which the number of tray portions 30, ie, the number of capacitors 32, is changed, it is also possible to configure a power module 10 having different power supply performance.

[0061] For example, Figure 6 As shown, by using tray units 11 with two capacitors 32, a power module 10 can be constructed in which the discharge voltage of one capacitor 32 is approximately 6V, as the power supply performance discharge voltage, when the discharge voltage is approximately 3V. Furthermore, by using tray units 11 with eight capacitors 32, a power module 10 can be constructed in which the discharge voltage of one capacitor 32 is approximately 24V, as the power supply performance discharge voltage, when the discharge voltage is approximately 3V. Furthermore, various variations of the number of capacitors 32, such as three or five, are conceivable.

[0062] Thus, among the various variations of the power module 10, the number of tray sections 30 is changed to the desired number, the length of the first busbar 41 of the tray cover 12 is changed to a length where the tip of the other end protrudes from the stacking direction of the power module 10, and the number of control elements 13a of the balance board 13 is changed according to the number of tray sections 30. Furthermore, among the various variations of the power module 10, the size of the cover 14 is changed to accommodate the tray units 11 with the changed number of tray sections 30. Meanwhile, among the various variations of the power module 10, the power module-side communication connector 13b of the balance board 13 and the module chassis 15 share the same structure. Specifically, among the various variations of the power module 10, the tip of the other end of the first busbar 41 of the tray cover 12, the tip of the other end of the second busbar 52 of the module chassis 15, the power module-side communication connector 13b of the balance board 13, and the protrusions 54 of the module chassis 15, which protrude from the side extending from the second busbar 52 of the module chassis 15, are common. The common structures in these power modules 10, namely the first bus bar 41 of the tray cover 12, the second bus bar 52 of the module chassis 15, the power module side communication connection part 13b of the balance substrate 13, and the various protrusions 54 of the module chassis 15, are equivalent to the common power module side connection part 100 (refer to Figure 1(b) etc.).

[0063] In addition, in the power supply device 1 of this embodiment, Figure 2In addition to the example shown, by using a control substrate 22 in which the function of the control element 22a is changed, a controller 20 with a different function can be configured.

[0064] For example, Figure 6 As shown, the controller 20 considers various variations by changing the function of the control element 22a to only boost the voltage of the main power supply or only back up the power supply when the main power supply fails.

[0065] In this way, the processing program stored in the ROM (not shown) of the control board 22 is modified to the desired functional processing program among the various variations of the controller 20. Meanwhile, the controller-side communication connector 22b, controller-side power connector 22c, external communication connector 22d, power connector 22e, controller housing 21, and controller cover 23 all share the same structure. Specifically, the power module-side communication connector 13b of the power module 10 is mated to the controller-side communication connector 22b of the control board 22, the first busbar 41 and second busbar 52 of the power module 10 are mated to the controller-side power connector 22c of the control board 22, and the protrusions 54 are mated to the recesses 23e. The common structures in these controllers 20, namely the controller-side communication connection part 22b of the control substrate 22, the controller-side power connection part 22c of the control substrate 22, and the recesses 23e of the controller cover 23, are equivalent to the common controller-side connection part 110 (refer to Figure 1(b) etc.).

[0066] That is, Figure 6 As shown, in this embodiment, any of the various variations of the power supply module 10 can be combined with the various variations of the controller 20. Therefore, by selecting a power supply module 10 with desired power supply performance from the various variations of the power supply module 10, and selecting a controller 20 with desired functionality from the various variations of the controller 20, and combining these, a desired power supply device 1 can be constructed. Furthermore, in this embodiment, a power supply device 1 can be constructed that consists solely of the power supply module 10 without combining the controller 20.

[0067] Hereinafter, a method of providing the power supply device 1 according to the present embodiment will be described in detail.

[0068] In this embodiment, the power supply module 10 and the controller 20 are manufactured and prepared in advance. In this state, the power supply device 1 is provided according to the following flow.

[0069] Specifically, if Figure 7As shown, when an order is sent from a customer indicating requirements for the power performance of the power module 10 and the functions of the controller 20, a power module selection process and a controller selection process are respectively implemented to select the desired power module 10 and the desired controller 20 corresponding to the requirements.

[0070] In the power module selection step, a power module 10 having a configuration of power performance corresponding to the requirements of the received order is selected from a plurality of modified power modules 10 manufactured and prepared in advance.

[0071] In the controller selection process, a controller 20 having functions corresponding to the requirements of the received order is selected from a plurality of pre-manufactured and prepared controllers 20. Furthermore, in the controller selection process, if the received order requires a controller, no controller 20 is selected.

[0072] After the power module selection process and the controller selection process are performed, a combining process is performed to combine the power module 10 and the controller 20 selected in each selection process. This combining process provides the power supply device 1. If the controller 20 is not selected in the controller selection process, the power module 10 selected in the power module selection process is provided as the power supply device 1. In this case, the combining process is omitted.

[0073] The functions and effects of this embodiment will be described.

[0074] (1) According to this embodiment, any power module 10 among the various variations can be combined with any controller 20 among the various variations. Therefore, by selecting a power module 10 having a desired power performance from the various variations, and selecting a controller 20 having a desired function from the various variations, and combining them, a desired power supply device 1 can be constructed. Therefore, when providing a desired power supply device 1, it is sufficient to pre-manufacture and prepare a plurality of power modules 10 having different power performances, and a plurality of controllers 20 having different functions. This can suppress the increase in the number of man-hours required to provide the power supply device 1, compared to a case where the power supply device 1 is redesigned for each application.

[0075] (2) The power module 10 can be provided with different discharge voltages as power supply performance, thereby appropriately responding to different demands for desired discharge voltages.

[0076] (3) A controller 20 capable of providing different functions as a function of boosting the voltage of the main power supply or backing up the power supply when the main power supply fails, thereby being able to appropriately respond to the needs of the different desired functions of boosting the voltage of the main power supply or backing up the power supply when the main power supply fails.

[0077] (4) According to the present embodiment, only the power module 10 can be provided as the power supply device 1 , and it is possible to appropriately meet the needs that require only the power module 10 .

[0078] (5) When the power supply device 1 is no longer used for its current purpose, the power module 10 and the controller 20 can be disassembled and the power module 10 can be reused for the next purpose. Since the power module side connection portion 100 and the controller side connection portion 110 are common, the power module 10 can be combined with the controller 20 having the desired function for the next purpose. In addition, when reused, the engagement between the engaged portion 34b and the engaging portion 34a can be disengaged and the tray portion 30 can be reused individually. In particular, since a lithium-ion capacitor is used for the capacitor 32, its life is long, and it is assumed that there are more opportunities for reuse. Therefore, it is possible to appropriately respond to the need to reuse the power supply device 1. In addition, since the tray portion 30 can be removed from the tray unit 11 individually, it is possible to appropriately respond to repairs and replacements on a tray portion 30 basis.

[0079] (6) In this embodiment, since capacitor 32 is formed in a rectangular plate shape, compared with the case where electric double layer capacitors, which are often cylindrical in shape, are generally used, it is possible to reduce waste of space when mounting power supply device 1 .

[0080] This embodiment can also be modified as follows: In addition, the following other embodiments can be combined with each other within the scope of no technical contradiction.

[0081] Alternatively, a provision method may be employed in which a plurality of variations of the power modules 10 are prepared in advance, arranged in a store, etc., and a customer is allowed to select a desired power module 10 from the prepared plurality of variations. Alternatively, a plurality of variations of the controllers 20 may be prepared in advance, arranged in a store, etc., and a customer is allowed to select a desired controller 20 from the prepared plurality of variations. Even when this provision method is employed, the same effects as those of the above-described embodiment can be achieved.

[0082] When the power supply device 1 is used for its current purpose, the power module 10 and the controller 20 may be disconnected and the controller 20 may be reused for the next purpose.

[0083] The controller 20 may also have a communication function for communicating information such as the charging status of the power module 10 to an external device. Furthermore, the controller 20 may also have a communication function for communicating with an external device. In this case, the presence or absence of the external communication connection portion 22d may be modified in the control substrate 22. That is, at least the power module-side connection portion 100 and the controller-side connection portion 110 may be common, and the external communication connection portion 22d and the power supply connection portion 22e may not be common in the control substrate 22. In other words, as variations in the function of the controller 20, variations may also be prepared that include different structures of the external communication connection portion 22d and the power supply connection portion 22e.

[0084] The power performance of the power module 10 may include the capacitor capacity of the power module 10 or the current of the power module 10 .

[0085] The power module 10 can also be used as a main power source. In this case, the function of the controller 20 includes a function of operating the power module 10 as a main power source.

[0086] The overall shape of the power supply device 1 is not limited to a rectangular parallelepiped, and may be, for example, a cylindrical shape.

[0087] In the power module 10, an electric double layer capacitor (EDLC), a lithium ion battery, a lead acid battery, or the like may be used as a power source instead of the capacitor 32. In these cases, the same effects as those of the above embodiment can be obtained.

[0088] The power supply device 1 can be applied to an uninterruptible power supply device, can be mounted on an unmanned guided vehicle, can be mounted on an overhead power line, and can be mounted on industrial machinery.

Claims

1. A power supply device, wherein: A combination of a power supply module from among multiple power supply modules with different power supply performances and a controller from among multiple controllers with different functions, Each of the plurality of power modules comprises a tray unit having a different number of tray portions, wherein the tray unit is formed by stacking a plurality of plate-shaped tray portions in a plate thickness direction, and each tray portion accommodates a plate-shaped capacitor and a plate-shaped terminal portion. The capacitors are electrically connected in series via the plate-shaped terminal portions, In each tray unit, the first busbar is connected to the tray cover portion stacked on the uppermost tray portion, and is electrically connected to the plate-shaped terminal portion of the uppermost tray portion exposed in the plate thickness direction via the capacitor. The second busbar is connected to the module chassis stacked below the lowermost tray portion, and is electrically connected to the plate-shaped terminal portion of the lowermost tray portion exposed in the plate thickness direction. In order to selectively combine the one power module and the one controller, each of the multiple power modules includes a power module-side connection portion common to the multiple power modules and having the first bus bar and the second bus bar, and each of the multiple controllers includes a controller-side connection portion common to the multiple controllers and having a first bus bar hole and a second bus bar hole, and the controller-side connection portion is connectable to the power module-side connection portion. In each power module, the first bus bar and the second bus bar are configured to protrude from the power module in the stacking direction and can be fitted into the first bus bar hole and the second bus bar hole provided in the controller cover of each controller for electrical connection.

2. The power supply device according to claim 1, wherein The power performance is the discharge voltage of the power module.

3. The power supply device according to claim 1 or 2, wherein: The power supply device functions as an auxiliary power supply device provided on a power supply path between a main power supply and a power supply target. The function is to control the charging and discharging of the power module, to boost the voltage of the main power supply by charging and discharging the power module, and to back up the power supply when the main power supply fails by charging and discharging the power module.

4. The power supply device according to claim 1 or 2, wherein: In the combination, the controller is not combined, and only the one power supply module is included.

5. A method for providing a power supply device, wherein: The power supply device is formed by selectively combining one power module among a plurality of power modules having different power performances and one controller among a plurality of controllers having different functions, wherein: Each of the plurality of power modules comprises a tray unit having a different number of tray portions, wherein the tray unit is formed by stacking a plurality of plate-shaped tray portions in a plate thickness direction, and each tray portion accommodates a plate-shaped capacitor and a plate-shaped terminal portion. The capacitors are electrically connected in series via the plate-shaped terminal portions, In each tray unit, the first busbar is connected to the tray cover portion stacked on the uppermost tray portion, and is electrically connected to the plate-shaped terminal portion of the uppermost tray portion exposed in the plate thickness direction via the capacitor. The second busbar is connected to the module chassis stacked below the lowermost tray portion, and is electrically connected to the plate-shaped terminal portion of the lowermost tray portion exposed in the plate thickness direction. The method for providing a power supply device comprises the following steps, namely: a power module selection step of selecting one power module from a plurality of power modules having different power performances, wherein each of the plurality of power modules includes a power module-side connection portion having the first bus bar and the second bus bar, which is common to the plurality of power modules; and a controller selection step, in which one controller is selected from a plurality of controllers having different functions, wherein each of the plurality of controllers includes a controller-side connection portion common to the plurality of controllers and includes a first busbar hole and a second busbar hole, wherein the controller-side connection portion is connectable to the power module-side connection portion; In each power module, the first bus bar and the second bus bar are configured to protrude from the power module in the stacking direction and can be fitted into the first bus bar hole and the second bus bar hole provided in the controller cover of each controller for electrical connection.

6. The method for providing a power supply device according to claim 5, wherein: The power performance of the power module selected in the power module selection step is a discharge voltage of the power module.

7. The method for providing a power supply device according to claim 5 or 6, wherein: The power supply device functions as an auxiliary power supply device provided on a power supply path between a main power supply and a power supply target. The functions of the controller selected in the controller selection process are to control the charging and discharging of the power module, to boost the voltage of the main power supply through the charging and discharging of the power module, and to back up the power supply when the main power supply fails through the charging and discharging of the power module.

8. The method for providing a power supply device according to claim 5 or 6, wherein: In the controller selection step, a combination in which the controller is not composed of only the single power module is selected.

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