Power conversion device

Abstract

The invention provides a power conversion device capable of ensuring workability related to connection between a connector and a bus bar and realizing miniaturization of external dimensions. A power conversion device is provided with an AC connector unit including an AC bus bar module (151) and a connector (156). The AC bus bar module (151) has three bus bars (152 to 154). Each of the bus bars (152 to 154) has a connection portion (152c, 153c, 154c). The connection portions (156b, 156c) of the connector (156) are disposed so as to be offset further toward the front side of the vehicle than the connection portion (156a). The connection parts (153c, 154c) of the bus bars (153, 154) connected to the connector (156) at the connection parts (156b, 156c) are arranged so as to bypass the outside of the region of the connector (156) in which the connection parts (156a-156c) are disposed in a side view from the left side of the vehicle.

Description

Technical Field

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

[0002] In recent years, the number of vehicles equipped with electric motors as driving sources for traveling has been increasing. Such vehicles are equipped with high-voltage batteries for supplying electric power to the electric motors. In addition, the vehicles are also equipped with power conversion devices for converting direct current supplied from the batteries into alternating current.

[0003] The power converter, the motor, and the battery form a mutual power supply path by connecting a connector connected to wiring extending from the motor and the battery to a connector of the power converter. Patent Document 1 discloses a power converter having a connector for electrically connecting to a motor.

[0004] The power conversion device of Patent Document 1 includes a connector fixed to a side wall of a housing. The connector has three plugs arranged to protrude outward from the housing. When the connector is viewed from the outside in the normal direction of the side wall to which the connector is fixed, the centers of the plugs are arranged in a ring shape.

[0005] On the other hand, three busbars (U-phase busbar, V-phase busbar, and W-phase busbar) electrically connecting the connector to the power module are arranged so as to extend from the inside of the housing toward the connector. The three busbars are arranged at the same height position in the depth direction of the housing so as to be separated from each other in the width direction of the one side wall and in parallel.

[0006] Prior art literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent No. 5455887

[0009] However, the power conversion device used in various applications is not limited to the vehicle-mounted power conversion device, and the power conversion device is required to be miniaturized. By miniaturizing the power conversion device, the space occupied by the entire device can be reduced, and the space can be effectively used.

[0010] However, in the power conversion device involved in the prior art, it is difficult to compactly arrange the three busbars connected to the connector. That is, in the power conversion device involved in the prior art, it is necessary to consider the connection operation of the busbar to the connector and increase the gap between the busbars. Assuming that the wiring method of the busbars of the prior art is adopted and the gap between the busbars is to be narrowed, it is necessary to connect the elements of each busbar to the connector after dividing each busbar in the length direction, and then connect the remaining elements to each element. Therefore, in the case of wanting to adopt such a method, the operation becomes complicated, and the number of components increases, and it is difficult to actually adopt it.

[0011] Furthermore, in the above, the problem is described by taking the connector related to the input and output of AC power in the power conversion device as an example, but the same problem may also occur in the connector related to the input and output of DC power. Summary of the invention

[0012] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a power conversion device that can ensure workability in connection between a connector and a bus bar and can achieve miniaturization of the external dimensions.

[0013] A power conversion device according to one embodiment of the present invention comprises a power module unit and a connector unit. The power module unit comprises n (n: an integer greater than or equal to 2) power modules. The connector unit comprises: n bus bars, the n bus bars being connected to the n power modules respectively; and a connector, the connector being connected to the n bus bars and being used for connection with an external device.

[0014] In the power conversion device involved in this method, the n busbars each have: a connection portion connected to the connector; a module-side connection portion connected to the n power modules respectively; and a connecting portion that continuously connects the connection portion to the module-side connection portion. In addition, the n power modules include a first power module and a second power module arranged along a first direction as a prescribed direction. In addition, the connector has n connection locations, which are respectively connected to the connection portions in the n busbars and are arranged in a plane intersecting the first direction.

[0015] In the power conversion device involved in this embodiment, the busbar connected to the first power module is set as a first busbar, the connection part of the first busbar is set as a first connection part, and the connection part of the first busbar is set as a first connection part. The busbar connected to the second power module is set as a second busbar, the connection part of the second busbar is set as a second connection part, and the connection part of the second busbar is set as a second connection part. The part for connecting the first connection part among the n connection parts is set as a first connection part, and the part for connecting the second connection part is set as a second connection part. In this case, the first connection part and the second connection part are arranged in a staggered manner in a second direction intersecting the first direction, and the first connection part is arranged in a part closer to the power module part than the second connection part in the second direction. In addition, the second connection part is formed to be longer than the length of the first connection part, and is arranged in a manner of bypassing the outside of the area where the n connection parts are arranged in the connector when viewed from the first direction.

[0016] In the power conversion device involved in the above-mentioned method, the second connecting portion of the second busbar is arranged in a manner that bypasses the outside of the area of ​​the connector where the connection part is arranged (hereinafter referred to as the "connection area"), so that the device size can be miniaturized compared to the arrangement method of the busbar disclosed in the above-mentioned patent document 1, and the operability involved in the connection of the busbar to the connector can be ensured. That is, in the power conversion device involved in the above-mentioned method, even if the gap between the connecting parts of the first busbar and the second busbar and the gap between the connecting parts are narrowed, by arranging the second connecting portion in a manner that bypasses the periphery of the connection area, it is easy for the operator to access it at least when the first busbar and the second busbar are connected to the connector. Therefore, in the power conversion device involved in the above-mentioned method, the operability involved in the connection between the connector and the busbar can be ensured, and the appearance size can be miniaturized.

[0017] In the power conversion device involved in the above-mentioned manner, the connector part may also be an AC connector part capable of inputting and outputting three-phase alternating current between the external device. In this case, the n is 3. In addition, the power module part may include a third power module arranged along the first direction in addition to the first power module and the second power module.

[0018] In the power conversion device involved in this embodiment, the busbar connected to the third power module is set as a third busbar, the connecting portion of the third busbar is set as a third connecting portion, the connecting portion of the third busbar is set as a third connecting portion, and the portion of the n connecting portions to which the third connecting portion is connected is set as a third connecting portion. In this case, the first connecting portion, the second connecting portion, and the third connecting portion may be arranged in a ring shape when viewed from the first direction. In addition, the third connecting portion may be formed to be longer than the first connecting portion, and arranged in a manner that bypasses the outside of the area where the n connecting portions are arranged in the connector when viewed from the first direction.

[0019] In the power conversion device involved in the above-mentioned method, the AC connector part has three busbars, and the connecting part of the third busbar is also arranged in a manner of bypassing the outside of the connection area. Therefore, even if the gap between the connecting parts of the third busbar and other busbars (first busbar, second busbar) is narrowed, high operability involved in connecting the busbar to the connector can be ensured.

[0020] In the power conversion device involved in the above-mentioned method, it can also be that the first connecting part, the second connecting part and the third connecting part are arranged in the following manner: the first connecting part and the third connecting part are opposite to each other at a first specified position, and the second connecting part is not opposite to the first connecting part and the third connecting part at the first specified position, and the second connecting part and the third connecting part are opposite to each other at a second specified position, and the first connecting part is not opposite to the second connecting part and the third connecting part at the second specified position.

[0021] In the power conversion device involved in the above-mentioned method, each connecting part is arranged in the following manner: the second connecting part is not opposite to the position where the first connecting part is opposite to the third connecting part (first prescribed position), and the first connecting part is not opposite to the position where the second connecting part is opposite to the third connecting part (second prescribed position), thereby realizing miniaturization of the layout area of ​​the busbar relative to the triple opposing method of the three connecting parts.

[0022] In the power conversion device involved in the above-mentioned aspect, it is also possible to further include a frame, the frame having a frame body and a cover, the frame body having an opening on one side of a third direction intersecting both the first direction and the second direction, accommodating the power module part and the connector part, and the cover closing the opening of the frame body. In addition, it is also possible that the second connecting part and the third connecting part are arranged in a manner of bypassing the n connection parts in the connector to the side opposite to the side provided with the opening in the third direction.

[0023] In the power conversion device involved in the above-mentioned manner, the second connection portion and the third connection portion are arranged in a manner of bypassing the connection area to the side opposite to the side (one side) where the opening portion of the frame is provided, so that the operator can access the connection area from the opening portion of the frame body during the operation of connecting the busbar to the connector. Therefore, the appearance size of the device can be miniaturized, and high operability involved in connecting the busbar to the connector can be ensured.

[0024] In the power conversion device according to the above aspect, the power conversion device and the external device may be mounted on a vehicle. In this case, the one side in the third direction may be an upper side of the vehicle.

[0025] In the power conversion device according to the above aspect, since the opening of the frame body is formed toward the upper side of the vehicle, the operator can easily access the connection area from above the vehicle when connecting the busbar and the connector. This is advantageous in ensuring high workability.

[0026] In the power conversion device according to the above-mentioned embodiment, the second connection portion may be arranged at a position closer to the input direction of the collision load assumed in the vehicle than the first connection portion and the third connection portion. In this case, the second connection portion may have a portion provided in a manner extending in the vertical direction of the vehicle in a portion near the second connection portion and separated from the first connection portion and the third connection portion.

[0027] In the power conversion device involved in the above-mentioned manner, the second connecting portion of the second busbar has a portion (hereinafter referred to as "upper and lower extending portion") provided in a manner extending in the upper and lower directions at a portion separated from the first connecting portion and the third connecting portion. Therefore, assuming that a collision load is input to the vehicle, the upper and lower extending portions of the second connecting portion will also be impacted and deformed independently. Therefore, in the power conversion device involved in the above-mentioned manner, a portion of the impact load can be absorbed by the deformation of the second connecting portion, and a short circuit with other busbars and an impact load acting on the power module portion can be suppressed. Therefore, in the power conversion device involved in the above-mentioned manner, there is an advantage in ensuring the high safety of the vehicle equipped with the power conversion device.

[0028] In the power conversion device involved in the above-mentioned manner, the external device may be an electric motor for driving the vehicle, and may have a motor housing as a shell. In addition, the vehicle may also be equipped with a transmission, which is arranged adjacent to the external device and has a bridge housing as a shell. In this case, the frame of the power conversion device may be arranged so that, on at least one of the motor housing and the bridge housing, the portion accommodating the connector portion is located on the input direction side of the collision load assumed in the vehicle compared to the portion accommodating the power module portion. Moreover, in such an arrangement state, the end of the frame on the input direction side of the collision load may be arranged to be coplanar with the motor housing or the bridge housing, or to be located at a position retreated to the side opposite to the input direction compared to the motor housing or the bridge housing.

[0029] In the power conversion device involved in the above-mentioned method, the part of the frame that accommodates the connector part (hereinafter referred to as the "connector accommodating part") is configured in a manner to become the input direction side of the collision load, and the end on the connector accommodating part side of the frame is configured in a manner to be located in the same plane as the motor housing or the bridge housing or set back therefrom. Therefore, even if an impact load is input, the load will not be concentratedly input to the above-mentioned end of the frame of the power conversion device, thereby ensuring a higher safety.

[0030] In the power conversion device according to the above aspect, the connection portions of the n bus bars may be integrally molded with an insulating material.

[0031] In the power conversion device according to the above aspect, since the connection parts of all busbars are integrally molded with insulating material, n busbars can be handled as one component. Therefore, when assembling the power conversion device, higher workability can be ensured compared with the case where n busbars are handled separately.

[0032] In the power conversion device according to each of the above-described aspects, it is possible to ensure workability in connection with the connector and the bus bar, and to achieve a reduction in the external dimensions. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram showing the structure of a vehicle including the power conversion device according to the first embodiment of the present invention.

[0034] Figure 2 This is a front view showing the arrangement of the power conversion device.

[0035] Figure 3 It is a side view showing the arrangement of the power conversion device.

[0036] Figure 4 It is a plan view showing the external appearance structure of the power conversion device.

[0037] Figure 5 It is a perspective view showing the internal structure of the power conversion device.

[0038] Figure 6 It is a perspective view showing the structure of an AC bus bar module and the structure of a motor-side connector in the power conversion device.

[0039] Figure 7 It is a perspective view showing the AC bus bar module in a state where the resin mold portion is omitted.

[0040] Figure 8 It is a plan view showing the layout of each connection part in the busbar.

[0041] Fig. 9 It is a side view showing the layout of each connection part in the busbar.

[0042] Fig.10 This is a rear view showing the layout of the various connection parts in the busbar.

[0043] Fig.11 It is a rear view showing a partial structure of an AC connector portion in the structure of the power conversion device according to the second embodiment of the present invention.

[0044] Fig.12 It is a side view showing a part of the structure of the AC connector part.

[0045] Fig.13 It is a rear view showing a partial structure of an AC connector portion in the structure of a power conversion device according to a third embodiment of the present invention.

[0046] Fig.14 It is a side view showing a part of the structure of the AC connector part.

[0047] Explanation of symbols

[0048] 100 Power conversion devices

[0049] 144a IGBT (first power module)

[0050] 144b IGBT (second power module)

[0051] 144c IGBT (third power module)

[0052] 150, 250, 350AC connector

[0053] 152, 252, 352U-phase busbar

[0054] 153, 253V phase bus

[0055] 154, 254W phase bus

[0056] 155 resin molding part

[0057] 156, 256, 356 connectors

[0058] 156a Connection part (first connection part)

[0059] 156b Connection part (second connection part)

[0060] 156c connection part

[0061] 255, 353N-phase bus

[0062] 511, 521 Motor housing

[0063] 531 Axle housing

[0064] M electric motor. DETAILED DESCRIPTION

[0065] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the embodiments described below are merely illustrative of the present invention, and the present invention is not limited to the embodiments described below except for its essential configuration.

[0066] [First embodiment]

[0067] 1. Structure of vehicle V

[0068] use Figure 1 The structure of a vehicle V equipped with the power conversion device 100 according to the first embodiment of the present invention is described. In addition, hereinafter, the front-rear direction of the vehicle V is simply described as the "front-rear direction", the left-right direction (vehicle width direction) of the vehicle V is simply described as the "left-right direction", and the up-down direction of the vehicle V is simply described as the "up-down direction".

[0069] like Figure 1 As shown, the vehicle V is equipped with a powertrain PT, a power conversion device 100 , a high voltage battery 200 , and a low voltage battery 300 .

[0070] The vehicle V is a so-called hybrid electric vehicle (HEV), and is equipped with an engine E and a motor M that function as driving sources for traveling, that is, driving sources of the vehicle V (wheels W). The powertrain PT includes the engine E and the motor M. In addition to the engine E and the motor M, the powertrain PT also includes a transmission TM and a differential gear DF.

[0071] The motor M is a three-phase three-wire AC motor that rotates by receiving a three-phase AC power supply, and includes: an output shaft; a rotor having a permanent magnet disposed around the output shaft; and a stator, which is disposed on the outer periphery of the rotor and is formed by winding coils around a plurality of teeth. The plurality of coils are composed of a U-phase coil, a V-phase coil, and a W-phase coil, and currents of different phases are supplied to the coils of each phase.

[0072] The transmission TM is connected to the motor M, and reduces the speed of rotation input from the motor M and outputs the rotation. The differential gear DF ​​transmits the rotation output from the transmission TM to the wheels W via the drive shaft S and the like.

[0073] In the present embodiment, as an example, a parallel hybrid electric vehicle is used as a vehicle V, and it is possible to travel based on the driving force of the motor M alone, based on the driving force of both the motor M and the engine E, and based on the driving force of the engine E alone. In addition, the vehicle V can perform deceleration regeneration, and the motor M generates electricity through the transmission force from the wheels W when the vehicle V is decelerated.

[0074] The high voltage battery 200 is a battery that exchanges electric power with the electric motor M. When the electric motor M is driven as a driving source for traveling, the high voltage battery 200 supplies electric power to the electric motor M. On the other hand, when the electric motor M is driven as a generator when the vehicle V is decelerating, the high voltage battery 200 stores the electric power generated by the electric motor M.

[0075] The power conversion device 100 is an inverter device connected to a three-phase three-wire motor M, and converts DC power from a high voltage battery 200 into AC power and supplies the power to the motor M. Specifically, the power conversion device 100 converts DC power into three-phase AC power.

[0076] Furthermore, when the motor M is driven as a generator during deceleration of the vehicle V, the power conversion device 100 converts the AC power generated by the motor M into DC power and supplies the DC power to the high voltage battery 200 .

[0077] The low voltage battery 300 is a battery for supplying electric power to electrical components provided in various parts of the vehicle V. The low voltage battery 300 is a battery having a lower nominal voltage than the high voltage battery 200 .

[0078] The high voltage battery 200 is, for example, a lithium ion battery or a nickel metal hydride battery having a nominal voltage of 24V or more, whereas the low voltage battery 300 is, for example, a lead battery or a lithium ion battery having a nominal voltage of 12V or 24V.

[0079] In this embodiment, the powertrain PT, the power conversion device 100 and the low voltage battery 300 are housed in a powertrain room R1 defined in the front of the vehicle V. The high voltage battery 200 is mounted under the floor of a vehicle room R2 defined behind the powertrain room R1.

[0080] Furthermore, the vehicle V is equipped with a PCM (powertrain control module) 400 which is a controller that performs overall control of a powertrain PT including an electric motor M and an engine E.

[0081] 2. Configuration of the Power Conversion Device 100

[0082] use Figure 2 and Figure 3 The arrangement of the power conversion device 100 in the powertrain room R1 will be described. Figure 2 This is a front view of the power conversion device 100 and its peripheral devices as viewed from the front side of the vehicle V. Figure 3 1 is a side view of the power conversion device 100 and the motor M as viewed from the left side of the vehicle V. Figure 2 and Figure 3 In the figure, the low voltage battery 300 is omitted.

[0083] like Figure 2 As shown, in the powertrain room R1, the engine E, the motor M, and the transmission TM are arranged in order from the right. The engine E has an engine lower portion 501 and an engine upper portion 502 arranged above the engine lower portion 501. The motor M is arranged adjacent to the engine lower portion 501 of the engine E on the left.

[0084] The motor M has a first motor case 511 and a second motor case 521 as housings. The first motor case 511 is joined to the left outer surface of the engine lower portion 501 , and the second motor case 521 is connected to the left side of the first motor case 511 without a gap.

[0085] The transmission TM has an axle housing 531 as a housing. The axle housing 531 has a conical shape in which the cross-sectional size gradually decreases from the right to the left.

[0086] The power conversion device 100 is disposed in a portion extending from above the second motor case 521 to above the axle case 531 in the left-right direction of the vehicle V.

[0087] The power conversion device 100 has an AC connector unit 150 at the front portion in the front-rear direction of the vehicle V. The AC connector unit 150 has a bus bar and a connector for connecting to the motor M built in, and is formed so that the lower surface of the housing (frame) is located below the other parts of the power conversion device 100. In addition, in the present embodiment, the housing 101 is configured as a combination of a housing body (frame body) 102 having an opening portion opened upward and a cover 103 that closes the opening portion of the housing body 102.

[0088] Here, when an imaginary line L1 is drawn that abuts against the front end 511a of the first motor housing 511 in the motor M and extends in the up-down direction, the end (front end) 150a of the housing 101 of the power conversion device 100 that houses the AC connector unit 150 is arranged at a position that is substantially consistent with the imaginary line L1. That is, in the present embodiment, the power conversion device 100 is arranged so that the front end 150a of the AC connector unit 150 and the front end 511a of the first motor housing 511 are coplanar.

[0089] Furthermore, the power conversion device 100 includes a PCM connector 143 that protrudes upward from the upper surface 101a of the housing 101. Figure 1 ) is connected to the power conversion device 100 via the PCM connector 143.

[0090] 3. Structure of the Power Converter 100

[0091] use Figure 4 The structure of the power conversion device 100 will be described. Figure 4 This is a plan view of the power conversion device 100 as viewed from above in the vertical direction of the vehicle V.

[0092] like Figure 4 As shown, the power conversion device 100 includes a DC connector unit 110, a noise removal unit 120, a smoothing unit 130, a power module unit 140, and an AC connector unit 150, which are accommodated in a housing 101. The DC connector unit 110, the noise removal unit 120, the smoothing unit 130, the power module unit 140, and the AC connector unit 150 are arranged in order from the rear side to the front side in the front-rear direction of the vehicle V.

[0093] Here, the left-right center line L3 of the AC connector unit 150 is arranged to be offset to the right with respect to the center line L2 of the other parts of the power conversion device 100 excluding the AC connector unit 150 (arrow A).

[0094] The DC connector 110 has a plurality of terminals for connection with the high voltage battery 200. The noise removal unit 120 is a functional unit for preventing high frequency noise from leaking from the power conversion device 100, and is configured to include a ferrite core, for example. The noise removal unit 120 is inserted into the power flow path provided between the DC connector 110 and the smoothing unit 130.

[0095] The smoothing unit 130 is a functional unit for smoothing direct current, and is configured to include a smoothing capacitor (a film capacitor as an example). The smoothing unit 130 is inserted into a power flow path provided between the noise removal unit 120 and the power module unit 140 .

[0096] The power module unit 140 includes a module body unit 141 having three IGBTs (Insulated Gate Bipolar Transistors) The control circuit unit 142 electrically controls the IGBT 144 and the like in the module body 141. In addition, the three IGBTs in the module body 141 Arranged along the left-right direction (first direction).

[0097] The PCM connector 143 is connected to the control circuit unit 142. The control unit formed in the control circuit unit 142 receives a command from the PCM 400 to control the IGBT of the module body 141. In addition, IGBT is sometimes referred to as They are uniformly recorded as "IGBT144".

[0098] In the power conversion device 100 , the portions of the module body 141 of the power module unit 140 corresponding to the U phase, the V phase, and the W phase are formed by combining electronic components such as power semiconductors including the IGBT 144 .

[0099] The module body portion 141 of the power module portion 140 is inserted into a power flow path provided between the smoothing portion 130 and the AC connector portion 150 .

[0100] The AC connector unit 150 includes a connector and a bus bar for electrically connecting to the motor M. The power conversion device 100 sends AC power to the motor M via the AC connector unit 150 . When the motor M functions as a generator when the vehicle V is decelerating, the power conversion device 100 receives AC power from the motor M via the AC connector unit 150 .

[0101] When AC power for running is supplied to the motor M, DC power output from the high voltage battery 200 is input to the noise removal unit 120 via the DC connector unit 110 . The DC power passing through the noise removal unit 120 is smoothed by the smoothing unit 130 and sent to the power module unit 140 .

[0102] In the power module unit 140 , the three-phase AC power is converted into a three-phase AC power according to a command from the PCM 400 . Then, the converted three-phase AC power is sent to the motor M via the AC connector unit 150 .

[0103] On the contrary, when the motor M functions as a generator during deceleration of the vehicle V, the three-phase AC power generated by the motor M is input to the power module unit 140 via the AC connector unit 150. Then, the input AC power is converted into DC power by the power module unit 140. The converted DC power is smoothed by the smoothing unit 130, and after the high-frequency component noise is removed by the noise removal unit 120, it is sent to the high-voltage battery 200 via the DC connector unit 110. Thus, the high-voltage battery 200 is charged.

[0104] Furthermore, a DC-DC converter (not shown) is interposed in the electric power flow path between the power conversion device 100 and the high voltage battery 200 .

[0105] 4. Connection Structure between the Electric Motor M and the Power Converter 100 and Internal Structure of the AC Connector 150

[0106] use Figures 5 to 7 The connection structure between the electric motor M and the power conversion device 100 and the internal structure of the AC connector unit 150 will be described. Figure 5 It is a perspective view showing the power conversion device 100 in a state where the cover 103 is removed from the case body 102 . Figure 6 It is a perspective view showing a part of the structure of the motor-side connector 512 and the AC connector unit 150 . Figure 7 It is a perspective view showing a part of the structure of the AC connector unit 150 in a state where the resin molded portion 155 is omitted.

[0107] like Figure 5 As shown, the electric connection between the motor M and the power conversion device 100 is performed by fitting the motor side connector 512 with the connector 156 of the AC connector unit 150 (arrow B portion). The motor side connector 512 is fixed to the first motor housing 511, and a part of the motor side connector 512 penetrates into the housing body 102 of the housing 101. Specifically, as shown in FIG. Figure 6 As shown, the motor-side connector 512 includes a cylindrical base portion 512a and three terminal portions 512b to 512d protruding toward the left from an end surface of the base portion 512a.

[0108] In addition, the terminal The motor coils of the U-phase, V-phase, and W-phase of the motor M are electrically connected to each other via wiring (not shown).

[0109] The motor side connector 512 is arranged so that a part of the base portion 512a and three terminal portions The motor side connector 512 is inserted into the housing body 102. In addition, in the housing body 102, the terminal portions 512b to 512d of the motor side connector 512 are inserted into the female terminal portions (not shown) of the connector 156 in the AC connector portion 150. Figure 6 , thereby electrically connecting the motor side connector 512 to the connector 156.

[0110] In addition, in the present embodiment, as an example, the terminal portion 512b is a U-phase terminal portion, the terminal portion 512c is a V-phase terminal portion, and the terminal portion 512d is a W-phase terminal portion.

[0111] like Figure 7 As shown, the connector 156 has three connection parts 156a to 156c on the side opposite to the side (left side) where the terminal parts 512b to 512d of the motor side connector 512 are embedded. Each connection part 156a to 156c has a cylindrical shape. Moreover, the three connection parts 156a to 156c are arranged in a ring shape when viewed from the left and right directions.

[0112] like Figure 6 As shown, in the AC connector unit 150, the AC busbar module 151 is connected to the connector 156 by fastening with bolts BLT. The AC busbar module 151 has three busbars. and a resin molded portion 155 .

[0113] like Figure 7 As shown, the busbar (first busbar) 152 has: a connecting portion (first connecting portion) 152a, which is connected to a connecting portion (first connecting portion) 156a of a connector 156; a module-side connecting portion 152b, which is connected to an IGBT 144a of a power module portion 140; and a connecting portion (first connecting portion) 152c, which continuously connects the connecting portion 152a to the module-side connecting portion 152b.

[0114] The busbar (second busbar) 153 has: a connecting portion (second connecting portion) 153a, which is connected to a connecting portion (second connecting portion) 156b of the connector 156; a module-side connecting portion 153b, which is connected to the IGBT144b of the power module portion 140; and a connecting portion (second connecting portion) 153c, which continuously connects the connecting portion 153a and the module-side connecting portion 153b.

[0115] The busbar (third busbar) 154 has: a connecting portion (third connecting portion) 154a, which is connected to a connecting portion (third connecting portion) 156c of the connector 156; a module-side connecting portion 154b, which is connected to the IGBT144c of the power module portion 140; and a connecting portion (third connecting portion) 154c, which continuously connects the connecting portion 154a and the module-side connecting portion 154b.

[0116] The resin mold 155 is formed of an insulating material (eg, epoxy resin), covers the outer periphery of the bus bars 152 to 154, and fills the gaps formed between the bus bars 152 to 154. Thus, when assembling the power conversion device 100, the AC bus bar module 151 is handled as a single component.

[0117] In the present embodiment, the bus bar 152 is a U-phase bus bar, the bus bar 153 is a V-phase bus bar, and the bus bar 154 is a W-phase bus bar.

[0118] 5. Busbar The layout structure of each connecting part 152c, 153c, 154c

[0119] use Figures 8 to 10 To the busbar The layout structure of each connecting part 152c, 153c, and 154c is explained. Figure 8 The busbar is viewed from above Top view of the . Fig. 9 The busbar is viewed from the left and a side view of connector 156. Fig.10 The busbar is viewed from the rear Rear view of.

[0120] like Figure 8As shown, the connection part 156a of the connector 156 and the connection parts 156b and 156c are arranged staggered in the front-to-back direction (the second direction). Specifically, the connection part 156a is arranged on the rear side (the side close to the power module part 140) compared with the connection parts 156b and 156c. In addition, in the present embodiment, the connection part 156c is arranged on the rear side compared with the connection part 156b. In other words, the connection part 152a of the busbar 152 is arranged staggered to the rear side compared with the connection parts 153a and 154a of the busbars 153 and 154. In addition, the connection parts 156a to 156c of the connector 156 are arranged in a ring shape when viewed from the left and right directions.

[0121] Each of the connecting portions 152c, 153c, 154c of the busbars 152 to 154 has a portion extending linearly in the front-to-back direction and parallel to each other near the module-side connecting portions 152b, 153b, 154b. In the present embodiment, current sensors 157 to 159 are installed at the portion extending linearly in each of the busbars 152 to 154. The current sensors 157 to 159 are known sensors, and therefore detailed descriptions thereof are omitted. The current sensors are sensors for detecting the current value flowing through each of the busbars 152 to 154.

[0122] like Fig. 9 and Fig.10 As shown, the connecting portions 152c, 153c, 154c of the busbars 152 to 154 are bent downward at the front end of the portion extending linearly in the front-rear direction. The connecting portion 152c of the busbar 152 changes direction to the right from the portion extending downward, further changes direction to the front, and extends to connect to the connecting portion 152a.

[0123] The connecting portion 153c of the busbar 153 changes direction from the portion extending downward to the right and further changes direction in the order of downward, forward, upward, and rightward to connect to the connecting portion 153a. Fig. 9 As shown, in the bus bar 153, the connecting portion 153c is connected to the connecting portion 153a from the front side. In addition, the connecting portion 153c of the bus bar 153 is configured to have three connecting locations without crossing the connector 156. (Refer to Figure 7 etc.) Fig. 9 That is, the connecting portion 153c of the busbar 153 is arranged in such a manner that it does not cross the region (E1 region) where the three connecting portions 156a to 156c of the connector 156 are arranged in the front-to-back direction, and bypasses below the outer periphery of the region.

[0124] The connection portion 153c of the bus bar 153 is arranged to extend in the vertical direction near the connection portion with the connecting portion 153a, but this portion is arranged so that the connection portions 152c and 154c of the bus bars 152 and 154 are not close to the periphery.

[0125] The connecting portion 154c of the busbar 154 changes direction from the portion extending downward to the right and extends, further changes direction in the order of downward and right and extends to connect to the connecting portion 154a. Fig. 9 As shown, in the bus bar 154, the connecting portion 154c is connected to the connecting portion 154a from the lower side. Moreover, the connecting portion 154c of the bus bar 154 is arranged in a manner not to cross the above-mentioned area of ​​the connector 156. That is, the connecting portion 154c of the bus bar 154 is arranged in a manner not to cross the above-mentioned area (E1 area) and to bypass the lower part within the outer periphery of the area.

[0126] Furthermore, in the AC connector unit 150 of the present embodiment, the connection portions 152c, 153c, and 154c of the three bus bars 152 to 154 are arranged so that only two bus bars 152 to 154 overlap in the portion where they overlap (the portion where the main surfaces face each other). Specifically, the connection portion 152c of the bus bar 152 and the connection portion 153c of the bus bar 153 are arranged so that the main surfaces do not face each other.

[0127] The connecting portion 152c of the busbar 152 and the connecting portion 154c of the busbar 154 are arranged as follows: Figure 8 D2 part, Fig.10 The busbars 153 are opposed to each other at the F2 portions, but the connecting portions 153c of the busbars 153 are separated at these portions.

[0128] Similarly, the connecting portion 153c of the busbar 153 and the connecting portion 154c of the busbar 154 are arranged as follows: Figure 8 D1 and D3 parts, Fig. 9 The E2 part, Fig.10 The busbars 152 are opposed to each other at the F1 portions, but the connecting portions 152c of the busbars 152 are separated at these portions.

[0129] As described above, the connecting portions 152c, 153c, and 154c of the bus bars 152 to 154 are arranged so as to overlap each other with a maximum of two pieces. Therefore, compared with the case where the connecting portions 152c, 153c, and 154c of the three bus bars 152 to 154 overlap three times, the thickness of the overlapping portion (the portion where the main surfaces face each other) can be made thinner.

[0130] 6. Effect

[0131] In the power conversion device 100 according to the present embodiment, the connecting portion 153c of the bus bar 153 is located in the region ( Fig. 9 The busbars 152 to 154 are arranged in a manner that bypasses the periphery of the E1 region, and therefore, compared with the arrangement of the busbars disclosed in the above-mentioned Patent Document 1, the device size can be reduced, and the workability involved in connecting the busbars 152 to 154 to the connector 156 can be ensured. That is, in the power conversion device 100, even if the gap between the connecting portions 152a and 153a of the busbar 152 and the gap between the connecting portions 152c and 153c are narrowed, the connecting portion 153c is arranged in a manner that bypasses the periphery of the E1 region, and it is easy for an operator to access at least when the busbars 152 and the busbars 153 are connected to the connector 156. Therefore, in the power conversion device 100, the workability involved in connecting the connector 156 to the busbars 152 to 154 can be ensured, and the external dimensions can be reduced.

[0132] In addition, in the power conversion device 100 involved in this embodiment, the AC connector part 150 has three bus bars 152~154, and the connecting part 154c of the bus bar 154 is also arranged in a manner of bypassing the outer periphery of the area E1. Therefore, even if the gap between the bus bar 154 and the connecting parts 152c, 153c of other bus bars 152, 153 is narrowed, it is possible to ensure higher operability involved in connecting the bus bars 152~154 to the connector 156.

[0133] In addition, in the power conversion device 100 involved in the present embodiment, the connection portion 153c of the busbar 153 is separated (not opposite) at the portion where the connection portion 152c of the busbar 152 is opposite to the connection portion 154c of the busbar 154, and the connection portion 152c of the busbar 152 is separated (not opposite) at the portion where the connection portion 153c of the busbar 153 is opposite to the connection portion 154c of the busbar 154. Therefore, compared with the triple opposite manner of the connection portions 152c, 153c, and 154c of the three busbars 152 to 154, the size of the AC busbar module 151 can be miniaturized.

[0134] In addition, in the power conversion device 100 according to the present embodiment, the connecting portion 153c of the busbar 153 and the connecting portion 154c of the busbar 154 are arranged in a manner of meandering downward (on the side opposite to the opening of the housing body 102) relative to the E1 region, so that during the operation of connecting the busbars 152 to 154 to the connector 156, the operator can easily access the E1 region from the opening of the housing body 102. Therefore, the external dimensions of the power conversion device 100 can be miniaturized, and high operability when connecting the busbars 152 to 154 to the connector 156 can be ensured.

[0135] In the power conversion device 100 according to the present embodiment, since the opening of the case body 102 is open upward, the operator can easily access the E1 area from above the vehicle V when connecting the bus bars 152 to 154 to the connector 156 . This is advantageous in ensuring high workability.

[0136] In addition, in the power conversion device 100 according to the present embodiment, the connecting portion 153c of the busbar 153 has an upper and lower extending portion extending in the upper and lower directions at a portion separated from the connecting portion 152c of the busbar 152 and the connecting portion 154c of the busbar 154. Therefore, if a collision load is input to the vehicle V from the front, the upper and lower extending portion of the connecting portion 153c of the busbar 153 is also deformed by the impact alone. Therefore, in the power conversion device 100, a part of the impact load can be absorbed by the deformation of the connecting portion 153c of the busbar 153, and a short circuit with other busbars 152 and 154 and an impact load acting on the power module unit 140 can be suppressed. Therefore, in the power conversion device 100, there is an advantage in ensuring high safety of the vehicle V equipped with the power conversion device 100.

[0137] In addition, in the power conversion device 100 involved in the present embodiment, the connector housing portion in the shell 101 that houses the AC connector portion 150 is configured in a manner that becomes the input direction side (front side) of the collision load, and the end 150a on the connector housing portion side in the shell 101 is configured in a manner that is coplanar with the first motor shell 511. Therefore, even if a collision load is input from the front, the load will not be concentratedly input to the above-mentioned end 150a of the shell 101 of the power conversion device 100, which can ensure higher safety.

[0138] In addition, in the power conversion device 100 according to the present embodiment, the connection portions 152c, 153c, and 154c of all the bus bars 152 to 154 are integrally molded by the resin mold portion 155, so the three bus bars 152 to 154 can be handled as a single component. Therefore, when assembling the power conversion device 100, higher workability can be ensured compared to the case where the three bus bars 152 to 154 are handled separately.

[0139] As described above, in the power conversion device 100 according to the present embodiment, it is possible to achieve a reduction in the external dimensions while ensuring workability in connection between the connector 156 and the bus bars 152 to 154 .

[0140] [Second embodiment]

[0141] use Fig.11 and Fig.12A power conversion device 160 according to a second embodiment of the present invention will be described. The power conversion device 160 according to this embodiment has the same structure as the first embodiment except that it is connected to a three-phase four-wire motor M. Fig.11 and Fig.12 In the figure, a part of the structure of the AC connector part 250 is extracted and shown. In addition, the description of the part overlapping with the above-mentioned 1st embodiment is abbreviate|omitted below.

[0142] like Fig.11 and Fig.12 As shown, the power conversion device 160 is an inverter device connected to the three-phase four-wire AC motor M. The AC connector unit 250 of the power conversion device 160 has a connector 256 and an AC bus module 251 for electrically connecting to the motor M. The power conversion device 160 also sends AC power to the motor M via the AC connector unit 250. In addition, when the motor M functions as a generator when the vehicle V is decelerating, the power conversion device 160 receives AC power from the motor M via the AC connector unit 250.

[0143] like Fig.12 As shown in FIG. 2 , the connector 256 has four connection parts (H regions). Each connection part has a cylindrical shape similar to the connection parts 156a to 156c of the first embodiment.

[0144] In the AC connector unit 250, the AC bus bar module 251 is connected to the connector 256 by fastening with bolts BLT. Fig.11 and Fig.12 As shown in FIG. 2 , the AC busbar module 251 has four busbars 252 to 255 and a resin molded portion. Fig.11 and Fig.12 In the figure, the resin molded portion is omitted.

[0145] In the present embodiment, as an example, the busbar 252 is a U-phase busbar, the busbar 253 is a V-phase busbar, the busbar 254 is a W-phase busbar, and the busbar 255 is a neutral line (N-phase) busbar.

[0146] like Fig.11 and Fig.12 As shown, the busbar (first busbar) 254 has: a connecting portion (first connecting portion) 254a, which is connected to the connecting portion (first connecting portion) of the W phase of the connector 256; a module-side connecting portion 254b, which is connected to the IGBT of the W phase of the power module portion; and a connecting portion (first connecting portion) 254c, which continuously connects the connecting portion 254a and the module-side connecting portion 254b.

[0147] The busbar (second busbar) 253 has: a connecting portion (second connecting portion) 253a, which is connected to the connecting portion (second connecting portion) of the V phase of the connector 256; a module-side connecting portion 253b, which is connected to the IGBT of the V phase of the power module portion; and a connecting portion (second connecting portion) 253c, which continuously connects the connecting portion 253a and the module-side connecting portion 253b.

[0148] The busbar (third busbar) 252 has: a connecting portion (third connecting portion) 252a, which is connected to the connecting portion (third connecting portion) of the U phase of the connector 256; a module-side connecting portion 252b, which is connected to the IGBT of the U phase of the power module; and a connecting portion (third connecting portion) 252c, which continuously connects the connecting portion 252a and the module-side connecting portion 252b.

[0149] The busbar 255 has: a connecting portion 255a, which is connected to a connecting portion of a neutral line of a neutral point of the motor M connected to the connector 256; a module-side connecting portion 255b, which is connected to an IGBT of a neutral line of a power module or the neutral line itself; and a connecting portion 255c, which continuously connects the connecting portion 255a and the module-side connecting portion 255b.

[0150] Although not shown in the figure, the resin molded portion is formed of an insulating material (e.g., epoxy resin) similarly to the first embodiment, covers the outer periphery of the busbars 252 to 255, and is inserted into the gap between the busbars 252 to 255. Thus, when assembling the power conversion device 160, the AC busbar module 251 is handled as a single component.

[0151] Next, the layout structure of each of the connection portions 252c, 253c, 254c, and 255c in the bus bars 252 to 255 will be described.

[0152] like Fig.12 As shown, the connection portion 254a of the busbar 254 is arranged to be offset to the rear side compared to the connection portions 253a and 255a of the busbars 253 and 255. The connection portion 252a of the busbar 252 is arranged to be offset to the front side compared to the connection portions 253a and 255a of the busbars 253 and 255, and is arranged at a position substantially the same as the connection portion 254a of the busbar 254 in the front-rear direction.

[0153] Although detailed illustration is omitted, each connection portion 252c, 253c, 254c, 255c of the busbars 252 to 255 has a portion extending linearly in the front-to-back direction and parallel to each other near the module-side connection portion 252b, 253b, 254b, 255b. In this embodiment, a current sensor is also installed at the portion of each busbar 252 to 255 extending linearly.

[0154] like Fig.11 As shown in FIG. 2 , each of the connecting portions 252c, 253c, 254c, and 255c of the busbars 252 to 255 is bent downward at the front end portion of the portion extending linearly in the front-rear direction. Fig.11 and Fig.12 As shown, the connecting portion 254c of the bus bar 254 changes direction from the portion extending downward to extend to the right, further changes direction to extend forward, and connects to the connecting portion 254a.

[0155] The connecting portion 253c of the busbar 253 changes direction from the portion extending downward to the right and further changes direction in the order of downward, forward, and upward to connect to the connecting portion 253a. Fig.12 As shown, in the bus bar 253, the connecting portion 253c is connected to the connecting portion 253a from the lower side. Moreover, the connecting portion 253c of the bus bar 253 is arranged in a manner not to cross the H region where the four connecting portions of the connector 256 are arranged. That is, the connecting portion 253c of the bus bar 253 is arranged in a manner that it does not cross the H region where the four connecting portions of the connector 256 are arranged in the front-back direction, and bypasses below the outer periphery of the region.

[0156] The connecting portion 252c of the busbar 252 changes direction from the portion extending downward to the right and extends, and further changes direction in the order of downward, right, and front and extends to connect with the connecting portion 252a. Fig.12 As shown, in the busbar 252, the connecting portion 252c is connected to the connecting portion 252a from the rear side. Moreover, the connecting portion 252c of the busbar 252 is arranged in a manner not to cross the H region of the connector 256. That is, the connecting portion 252c of the busbar 252 is also arranged in a manner not to cross the H region and to bypass the rear of the outer periphery of the region.

[0157] The connecting portion 255c of the busbar 255 changes direction from the portion extending downward to the right and extends, and further changes direction in the order of downward, front, upward, and rearward and extends to connect with the connecting portion 255a. Fig.12As shown, in the busbar 255, the connecting portion 255c is connected to the connecting portion 255a from the front side. Moreover, the connecting portion 255c of the busbar 255 is arranged in a manner not to cross the H region of the connector 256. That is, the connecting portion 255c of the busbar 255 is also arranged in a manner not to cross the H region and to bypass the rear of the outer periphery of the region.

[0158] Furthermore, in the AC connector unit 250 of the present embodiment, the connecting portions 252c, 253c, 254c, and 255c of the four bus bars 252 to 255 are also arranged so that only two bus bars overlap in the overlapping portions (portions where the main surfaces face each other). Specifically, the connecting portion 254c of the bus bar 254 and the connecting portion 253c of the bus bar 253 are arranged as follows: Fig.11 The G4 portions of the bus bars 252 and 255 are opposite to each other, but at this portion, the connecting portions 252c and 255c of the other bus bars 252 and 255 are separated.

[0159] The connecting portion 253c of the busbar 253 and the connecting portion 252c of the busbar 252 are arranged as follows: Fig.11 The G2 portions of the bus bars 254 and 255 are opposite to each other, but at this portion, the connecting portions 254c and 255c of the other bus bars 254 and 255 are separated.

[0160] The connecting portion 252c of the busbar 252 and the connecting portion 255c of the busbar 255 are arranged as follows: Fig.11 The G1 portions of the bus bars 253 and 254 are opposed to each other, but the connecting portions 253c and 254c of the other bus bars 253 and 254 are separated at this portion.

[0161] The connecting portion 253c of the busbar 253 and the connecting portion 255c of the busbar 255 are arranged as follows: Fig.11 The G3 portions of the bus bars 252 and 254 are opposite to each other, but the connecting portions 252c and 254c of the bus bars 252 and 254 are separated at this portion.

[0162] As described above, the connecting portions 252c, 253c, 254c, and 255c of the bus bars 252 to 255 are arranged so as to overlap each other with a maximum limit of two pieces. Therefore, compared with the case where the connecting portions 252c, 253c, 254c, and 255c of the four bus bars 252 to 255 overlap three or four times, the thickness of the overlapping portion (the portion where the main surfaces face each other) can be made thinner.

[0163] The power converter 160 according to this embodiment also has the same configuration as the first embodiment except that the AC connector unit 250 has four bus bars 252 to 255. Therefore, the power converter 160 according to this embodiment can also obtain the same effects as the first embodiment.

[0164] Here, the neutral line in the three-phase four-wire system has a method of being electrically connected to a groundable portion of the vehicle body or the negative electrode of the battery and grounded. In this case, by making the busbar 255 connected to the neutral line located in front of the vehicle compared to the other busbars 252 to 254, it is possible to further suppress the risk of short circuit with the housing when a collision load is input from the front to the housing (not shown) of the power conversion device 160 compared to the first embodiment. Therefore, in the power conversion device 160, there is an advantage in ensuring high safety of the vehicle V equipped with the power conversion device 160.

[0165] [Third Embodiment]

[0166] use Fig.13 and Fig.14 A power conversion device 170 according to a third embodiment of the present invention will be described. The power conversion device 170 according to this embodiment has the same structure as the first embodiment except that it is connected to a single-phase two-wire motor M. Fig.13 and Fig.14 In the figure, a part of the structure of the AC connector part 350 is extracted and shown. In addition, the description of the parts overlapping with the above-mentioned first embodiment will be omitted below.

[0167] like Fig.13 and Fig.14 As shown, the power conversion device 170 is an inverter device connected to the single-phase two-wire AC motor M. The AC connector unit 350 of the power conversion device 170 has a connector 356 and an AC bus module 351 for electrically connecting to the motor M. The power conversion device 170 also sends AC power to the motor M via the AC connector unit 350. In addition, when the motor M functions as a generator when the vehicle V is decelerating, the power conversion device 170 receives AC power from the motor M via the AC connector unit 350.

[0168] like Fig.13 and Fig.14 As shown in FIG. 1 , the connector 356 has two connection parts (J regions). Each connection part has a cylindrical shape similar to the connection parts 156a to 156c of the first embodiment.

[0169] In the AC connector unit 350, the AC bus bar module 351 is connected to the connector 356 by fastening with bolts BLT. Fig.13 and Fig.14 As shown, the AC busbar module 351 has two busbars 352, 353 and a resin molded portion. Fig.13 and Fig.14 In the figure, the resin molded portion is omitted.

[0170] In this embodiment, as an example, the busbar 352 is a U-phase busbar, and the busbar 353 is an N-phase busbar. The busbar (first busbar) 352 has: a connection portion (first connection portion) 352a connected to the U-phase connection portion (first connection portion) of the connector 356; a module-side connection portion 352b connected to the U-phase IGBT of the power module; and a connection portion (first connection portion) 352c that continuously connects the connection portion 352a and the module-side connection portion 352b.

[0171] The busbar (second busbar) 353 has: a connecting portion (second connecting portion) 353a, which is connected to the connecting portion (second connecting portion) of the N phase of the connector 356; a module-side connecting portion 353b, which is connected to the N-phase IGBT of the power module portion; and a connecting portion (second connecting portion) 353c, which continuously connects the connecting portion 353a and the module-side connecting portion 353b.

[0172] Although not shown in the figure, the resin molded portion is formed of an insulating material (e.g., epoxy resin) similarly to the first embodiment, covers the outer periphery of the busbars 352 and 353, and is inserted into the gap between the busbars 352 and 353. Thus, when assembling the power conversion device 170, the AC busbar module 351 is handled as a single component.

[0173] Next, the layout structure of each connection part 352c, 353c in the busbars 352, 353 is demonstrated.

[0174] like Fig.14 As shown, the connection portion 353a of the busbar 353 is arranged to be offset to the front side compared to the connection portion 352a of the busbar 352. Although the detailed illustration is omitted, each connection portion 352c, 353c of the busbars 352, 353 has a portion extending linearly in the front-to-back direction and parallel to each other in the vicinity of the module-side connection portions 352b, 353b. In this embodiment, a current sensor is also installed in the portion extending linearly in each busbar 352, 353.

[0175] like Fig.13 As shown in FIG. 1 , each connecting portion 352c, 353c of the busbars 352, 353 is bent downward at the front end portion of the portion extending linearly in the front-rear direction. Fig.13 and Fig.14 As shown, the connecting portion 352c of the bus bar 352 changes direction from the portion extending downward to extend to the right, further changes direction to extend forward, and connects to the connecting portion 352a.

[0176] The connecting portion 353c of the busbar 353 changes direction from the portion extending downward to the right and further changes direction in the order of downward, forward, upward, and backward to connect to the connecting portion 353a. Fig.14 As shown, in the busbar 353, the connecting portion 353c is connected to the connecting portion 353a from the front side. Moreover, the connecting portion 353c of the busbar 353 is arranged in a manner not to cross the J region where two connecting portions are arranged in the connector 356. That is, the connecting portion 353c of the busbar 353 is arranged in a manner that it does not cross the J region where two connecting portions are arranged in the connector 356 in the front-back direction, and bypasses the lower part of the outer periphery of the region.

[0177] Furthermore, in the AC connector portion 350 of the present embodiment, since only two bus bars 352 and 353 are provided, there will not be a situation where three or more bus bars face each other. Fig.13 As shown, the connecting portion 352c of the bus bar 352 and the connecting portion 353c of the bus bar 353 are opposed to each other only at the I1 portion.

[0178] The power converter 170 according to this embodiment also has the same configuration as the first embodiment except that the AC connector 350 has two bus bars 352 and 353. Therefore, the power converter 170 according to this embodiment can also obtain the same effects as the first embodiment.

[0179] [Modifications]

[0180] In the first to third embodiments, an inverter device is used as an example of the power conversion device 100, 160, 170, but the present invention is not limited thereto. For example, the present invention may be applied to a DC-DC converter or the like.

[0181] In addition, in the first to third embodiments, the power conversion devices 100, 160, 170 mounted on the vehicle V are used as an example, but in the present invention, it can also be applied to power conversion devices used in industrial equipment, etc. In addition, as a vehicle, not only a hybrid electric vehicle (HEV) can be used, but also a battery electric vehicle (BEV) that does not have an engine as a driving source for traveling, etc. can be used.

[0182] Furthermore, in the first to third embodiments, the AC bus bar modules 151 , 251 , 351 of the AC connector units 150 , 250 , 350 are used as an example, but the present invention can also be applied to the DC connector units.

[0183] In the first to third embodiments, the AC busbar modules 151, 251, and 351 have the resin molded portion 155. However, in the present invention, the resin molded portion is not an essential structure. In this case, it is preferable to set the gap between adjacent busbars to be greater than the insulation distance, or to insert an insulating material at a location where the busbars are close to each other.

[0184] In addition, in the first to third embodiments, the structures are set to allow access to the E1, H, and J areas of the connectors 156, 256, and 356 from above, but in the present invention, it is not necessarily necessary to be able to access from above. That is, it is sufficient to be able to access the connection between the busbar and the connector from any one of the front, rear, and bottom. In addition, when the access direction is specified as described above, it is preferable to also provide an opening portion of the housing.

[0185] In addition, in the first to third embodiments, an IGBT is used as an example of a power module, but the type of power module of the present invention is not limited thereto. For example, a MOSFET (Metal Oxide Semiconductor Field Effect Transistor) or a module combining a switch element and a diode element may also be used.

[0186] In the first to third embodiments, the busbar is fixed with bolts BLT. 352, 353 are connected to the connectors 156, 256, 356, but in the present invention, the connection method of the busbar to the connector is not limited to this. For example, connection based on nuts, connection based on riveting, connection based on welding, etc. can also be adopted.

[0187] In addition, in the first to third embodiments, the power conversion devices 100, 160, 170 are arranged so that the end (front end) 150a of the AC connector portion 150, 250, 350 faces the front side, but in the present invention, the arrangement direction of the power conversion device is not limited to this. That is, the power conversion device can also be arranged so that the end of the AC connector portion faces the rear side or either side.

[0188] In addition, in the first to third embodiments, the power conversion devices 100, 160, 170 are arranged so that the front end portion 150a of the AC connector portion 150, 250, 350 is coplanar with the front end portion 511a of the first motor housing 511, but in the present invention, the power conversion device can be arranged so that the front end portion of the AC connector portion is located at a position retreated from the motor housing and the axle housing. In this case, it is also possible to suppress the concentrated load on the power conversion device when the vehicle collides.

Claims

1. A power conversion device comprising: a power module unit, the power module unit having n power modules, where n is an integer greater than or equal to 2; and A connector part, the connector part having n busbars and a connector, the n busbars are respectively connected to the n power modules, the connector is connected to the n busbars and is used for connection with external devices, It is characterized in that The n busbars each have: a connection portion connected to the connector; a module-side connection portion connected to each of the n power modules; and a connecting portion that continuously connects the connection portion to the module-side connection portion. The n power modules include a first power module and a second power module arranged along a first direction as a predetermined direction, The connector has n connection locations, each of which is connected to the connection portion of the n bus bars and is arranged in a plane intersecting the first direction. The busbar connected to the first power module is set as a first busbar, the connecting portion of the first busbar is set as a first connecting portion, the connecting portion of the first busbar is set as a first connecting portion, the busbar connected to the second power module is set as a second busbar, the connecting portion of the second busbar is set as a second connecting portion, the portion to which the first connecting portion is connected among the n connecting portions is set as a first connecting portion, and the portion to which the second connecting portion is connected is set as a second connecting portion. In this case, The first connection portion and the second connection portion are arranged to be staggered in a second direction intersecting the first direction, and the first connection portion is arranged at a portion closer to the power module portion than the second connection portion in the second direction. The second connection portion is formed to be longer than the first connection portion and is arranged to bypass an outside of a region in the connector where the n connection locations are arranged when viewed from the first direction.

2. The power conversion device according to claim 1, characterized in that: The connector portion is an AC connector portion capable of inputting and outputting three-phase alternating current to and from the external device. The n is 3, The power module unit includes, in addition to the first power module and the second power module, a third power module arranged along the first direction. The busbar connected to the third power module is set as a third busbar, the connecting portion of the third busbar is set as a third connecting portion, the connecting portion of the third busbar is set as a third connecting portion, and the portion of the n connecting portions to which the third connecting portion is connected is set as a third connecting portion. In this case, The first connection part, the second connection part, and the third connection part are arranged in a ring shape when viewed from the first direction. The third connection portion is formed to have a length longer than that of the first connection portion, and is arranged so as to bypass an outside of a region where the n connection locations are arranged in the connector in a plan view from the first direction.

3. The power conversion device according to claim 2, characterized in that: The first connection part, the second connection part and the third connection part are arranged as follows: the first connection part and the third connection part are opposite to each other at a first specified position, and the second connection part is not opposite to the first connection part and the third connection part at the first specified position, and the second connection part and the third connection part are opposite to each other at a second specified position, and the first connection part is not opposite to the second connection part and the third connection part at the second specified position.

4. The power conversion device according to claim 2, characterized in that: A frame is also provided, the frame having a frame body and a cover, the frame body having an opening on one side of a third direction intersecting both the first direction and the second direction, accommodating the power module part and the connector part, and the cover closing the opening of the frame body. The second connection portion and the third connection portion are arranged so as to bypass the n connection locations in the connector toward a side opposite to the side where the opening is provided in the third direction.

5. The power conversion device according to claim 4, characterized in that: The power conversion device and the external device are mounted on a vehicle, The one side in the third direction is an upper side of the vehicle.

6. The power conversion device according to claim 5, characterized in that: The second connection portion is arranged at a position on the input direction side of the collision load assumed in the vehicle, relative to the first connection portion and the third connection portion. The second link portion has a portion provided to extend in the vertical direction of the vehicle in a portion near the second connection portion and separated from the first link portion and the third link portion.

7. The power conversion device according to claim 5, characterized in that: The external device is a motor for driving the vehicle and has a motor case as a housing. The vehicle is further equipped with a transmission, which is arranged adjacent to the external device and has a bridge housing as a housing. The frame of the power conversion device is configured so that, on at least one of the motor housing and the bridge housing, a portion accommodating the connector portion is located on the input direction side of a collision load assumed in the vehicle compared to a portion accommodating the power module portion, and an end portion of the frame on the input direction side of the collision load is coplanar with the motor housing or the bridge housing, or is located at a position retreated to the side opposite to the input direction compared to the motor housing or the bridge housing.

8. The power conversion device according to any one of claims 1 to 6, characterized in that: The connecting portions of the n bus bars are integrally molded from an insulating material.

9. The power conversion device according to any one of claims 1 to 7, characterized in that: A neutral bus bar connected to a neutral point of the motor is further connected to the connector portion.

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