INVERTER CONTROL DEVICE

Abstract

An inverter control device (10) for driving a motor (15), wherein the inverter control device (10) has the following features: a power module (13) that supplies the motor (15) with a drive current; a power module board (12) that outputs a drive signal to the power module (13); a control board (11) that outputs a control signal to the power module board (12); and a smoothing capacitor (14); wherein the power module (13), the power module board (12), the capacitor (14) and the control board (11) are arranged one above the other and are housed in a single enclosure (31) made of a metal material, wherein the power module (13) is a bottom layer; characterized by the fact that an input terminal (35) of a power supply current is located on one side surface of the housing (31), and an output terminal (37) of a drive current of the motor (15) is located on another side surface of the housing (31), which is orthogonal to the one side surface; the output terminal (37) and a busbar (41a to 41c) connected to the power module are directly connected to each other in the same plane; the output terminal (37) comprises metal plates (33a to 33c) arranged in parallel and at the same height on a terminal block (51) to correspond to a number of phases of the motor (15); and a parallel arrangement distance between the metal plates (33a to 33c) can be changed according to the size of a power supply input connection of the motor (15).

Description

CROSS-REFERENCE TO RELATED REGISTRATION

[0001] The present invention claims priority under 35 USC §119 of Japanese application no. 2018-084581, which was filed on April 25, 2018, and the entire contents of which are incorporated by reference into this document. 1. AREA OF INVENTION

[0002] The present disclosure relates to a structure of an inverter control device, which is a power conversion device located in a vehicle. 2. BACKGROUND

[0003] Electric cars, hybrid cars, and similar vehicles where an electric motor serves as the power source have become popular as environmentally friendly vehicles in recent years. These electric cars and similar vehicles are equipped with an inverter (power conversion device) that accelerates and decelerates the vehicle by converting direct current (DC) power from a battery (accumulator) into alternating current (AC) power to supply a drive motor, and by controlling motor speed, drive torque, and other parameters.

[0004] In addition to high performance and reliability, the inverter device described above requires a miniaturized design that focuses on its suitability for installation within the vehicle. In particular, there is currently strong demand for miniaturized inverter devices installed in vehicles due to space limitations.

[0005] For example, a power conversion device of the related technology includes a power system main circuit unit that performs the power conversion, a control circuit unit that controls the operation of the power system main circuit unit, an input / output filter circuit unit that suppresses the outward transmission of noise, a control circuit unit, and the like.

[0006] Furthermore, the power conversion device (inverter device) of the related technology can be miniaturized by placing an inverter, a capacitor, a reactor and the like on a base to form the power conversion device as a single structure.

[0007] In the power conversion device of the related technology, the main power system circuit unit, the control circuit unit, and the like are arranged planarly, and the miniaturization of the power conversion device depends on the miniaturization of the component parts. Furthermore, in a power conversion device of another exemplary embodiment, the capacitor, the reactor, and the like, which smooth the DC voltage, are miniaturized, and these parts are arranged planarly.

[0008] Therefore, the inverter device of the related technology has a problem in that a large area must be provided for installation in the vehicle, and miniaturizing the entire inverter device is difficult to achieve.

[0009] US 2016 / 0 105 123 A1 and JP 2004 - 312 866 A represent relevant state of the art. SUMMARY

[0010] The invention is defined by the subject matter of claim 1. The dependent claims describe advantageous embodiments. According to the invention, the inverter control device comprises a power module that supplies the motor with a drive current, a power module board that outputs a drive signal to the power module, a control board that outputs a control signal to the power module board, and a smoothing capacitor. The power module, the power module board, the capacitor, and the control board are stacked one above the other and housed in a single enclosure made of a metal material, with the power module forming the bottom layer. An input terminal for a power supply current is arranged on one side surface of the enclosure, and an output terminal for a drive current of the motor is arranged on another side surface of the enclosure, which is orthogonal to the first side surface.The output terminal and a busbar connected to the power module are directly connected in the same plane. The output terminal comprises metal plates arranged parallel and at the same height on a terminal block to correspond to a number of motor phases. The parallel spacing between the metal plates is variable according to the size of the motor's power supply input terminal.

[0011] The above and further elements, features, steps, characteristics and advantages of the present disclosure will become even clearer from the following detailed description of the preferred exemplary embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic configuration of a vehicle in which an inverter control device is installed according to an exemplary embodiment of the present disclosure. Fig. Figure 2 shows an external view of the inverter control device, in which a drive motor and a gearbox are combined and integrated. Fig. Figure 3 is a cross-sectional view of the inverter control device in Fig. 2 along line AA' in a vertical direction. Fig. Figure 4 is a view illustrating a current path from an input side to an output side of current in a unit of power. Fig. Figure 5 is a detailed external view of a capacitor of the inverter control device. Fig. Figure 6 is a detailed view of an output terminal of the inverter control device and a location near the output terminal. DETAILED DESCRIPTION

[0012] Exemplary embodiments according to the present disclosure are described in detail below with reference to the accompanying drawings. Fig. Figure 1 is a schematic configuration of a vehicle in which an inverter control device is installed according to an exemplary embodiment of the present disclosure. Fig. 1 is an electric motor 15, e.g., a three-phase AC motor, and is a drive force source for the vehicle. A rotating shaft of the electric motor 15 is connected to a reducer 6 and a differential gear 7, and a drive force (a torque) from the electric motor 15 is transmitted via the reducer 6, the differential gear 7, and a drive shaft 8 to a pair of wheels 5a and 5b.

[0013] An inverter unit 20 of an inverter control device 10 comprises a power module unit 13, which supplies the electric motor 15 with drive power, a power module control unit 12, which outputs a drive signal to the power module unit 13, an inverter control unit 11, which outputs a control signal to the power module control unit 12, and a smoothing capacitor 14. The inverter unit 20 is controlled by a control signal from a control device 3, which is responsible for controlling the entire vehicle.

[0014] The power module unit 13 comprises a bridge circuit (power conversion circuit) which is obtained by connecting two power switching elements (one power switching element of an upper arm and one power switching element of a lower arm) such as insulated gate bipolar transistors (IGBTs, Insulated Gate Bipolar Transistors) and metal oxide semiconductor field effect transistors (MOSFETs, Metal Oxide Semiconductor Field Effect Transistors) for each of a U-phase, a V-phase and a W-phase, i.e. a total of six power switching elements.

[0015] The power module unit 13 converts direct current power from a battery BT into alternating current power (three-phase alternating current power) by switching the ON / OFF of the power switching elements on the basis of a drive signal (PWM control signal) from the power module control unit 12 and driving the electric motor 15 by the conversion.

[0016] The battery (BT) is a power source for electrical energy, serving as a vehicle power source, and is typically comprised of multiple secondary batteries. Capacitor 14 is located in the inverter unit 20, connected to the battery (BT). Capacitor 14 is connected between a high-potential line (positive electrode potential B+) and a low-potential line (negative electrode potential B- (GND)) and is a high-capacitance smoothing capacitor (film capacitor) that smooths the input voltage from the battery BT.

[0017] Next, the structure of the inverter control device according to this exemplary embodiment will be described. Fig. Figure 2 is an external view of the inverter control device 10 and illustrates a state in which the inverter control device 10, the electric motor 15, and the gearbox 7 are combined and integrated. A housing 31 for the inverter control device 10 is obtained, for example, by forming a die-cast aluminum part. The inverter control device 10 includes a high-voltage circuit arrangement 10a, which provides an input unit for a high-voltage current from an external battery (the battery (BT) in Fig. 1) is, and a power controller 10b that supplies a drive motor with a drive current.

[0018] The high-voltage circuit assembly 10a and the power control unit 10b are separated from each other in the housing 31 by a partition 18. The upper surface sections of the high-voltage circuit assembly 10a and the power control unit 10b are covered with covers 39a and 39b, which are flat-plate components made of metal, such as aluminum.

[0019] Fig. Figure 3 is a cross-sectional view of the inverter control device 10, which is located in Fig. Figure 2 illustrates the vertical arrangement of the power module unit 13 and the like in the power controller 10b of the inverter control device 10. Specifically, the power module unit 13, the power module control unit (also referred to as the power module board) 12, the capacitor 14, and the inverter control unit (also referred to as the control board) 11 are arranged sequentially in the power controller 10b. The power module unit 13, which is attached to a lower housing surface of the power controller 10b by means of a screw and the like, is the bottom layer.

[0020] In the inverter control device 10, the stacking height in the normal direction (the height in the z-direction) H1 of the power module unit 13, the power module control unit 12, the capacitor 14, and the inverter control unit 11 is less than the depth H2 of the housing 31 in the z-direction (H1 < H2).

[0021] That is, all component building blocks can be accommodated within the capacity of the housing 31 of the inverter control device 10. Thus, instead of a box-shaped building block, flat-plate-like building blocks made of metal such as aluminum, like the covers 39 a and 39 b can be used as the covering building block that covers the housing 31. As a result, a reduction in height and a downsizing of the inverter control device 10 become possible.

[0022] Also, as in Fig. As illustrated in Figure 4, in the inverter control device 10, the high-voltage current input from an external power supply input terminal 34, which is a connector for connecting the external battery, is received by a connector (input terminal 35) of the high-voltage circuit arrangement 10a via a busbar 47 that runs through the partition 18 and leads to the power controller 10b. The power to drive the motor from the power module unit 13 is supplied to the drive motor via a connector (output terminal 37) provided on the power controller 10b.

[0023] Therefore, in the inverter control device 10, the power supply to the input terminal 35, which is located on the side of the partition 18 of the power control 10b, is provided by the external power supply input terminal 34, which is located on a front surface section (front surface wall section) 19a of the high voltage circuit arrangement 10a, and drive current is transferred to the motor via the power module unit 13 and the like through the output terminal 37, which is provided on a front surface section 19b of the power control 10b.

[0024] The partition 18 between the high-voltage circuit arrangement 10a and the power controller 10b is orthogonal to the front surface section 19b when the power controller 10b is viewed in a planar view, and thus the current path of the current from the input side to the output side at the power controller 10b is L-shaped, as indicated by a dashed arrow in Fig. 4 is specified. The L-shaped current path above is shorter than the current path when arranged in a U-shape by placing the input and output sides of the power supply on the same surface, thus allowing the inverter control device to be miniaturized even further.

[0025] Note that in the inverter control device 10, the busbar 47 of the high-voltage circuit arrangement 10a and the output terminal 37 of the power control 10b are arranged with a height difference H3 in the vertical direction (z-direction) of the housing 31, as shown in Fig. Figure 6 illustrates this. That is, by positioning the high-voltage circuit assembly 10a higher than the output terminal 37, a space is created on the lower side of the housing of the high-voltage circuit assembly 10a. Therefore, the gearbox and the like can be housed in this space.

[0026] As also in Fig. As illustrated in Figure 4, a projecting section 17 extends from the lower portion of the housing 31 segment in which the output terminal 37 is located on one side of the front surface of the housing 31 (the front surface section 19b of the power controller 10b). The projecting section 17 is located in a connecting element between the inverter controller 10 and the drive motor, and the projecting section 17 acts as a reinforcing element of the housing 31 of the inverter controller 10 when the motor is attached to the inverter controller 10.

[0027] Fig. Figure 5 shows a detailed external view of the capacitor 14 of the inverter control device 10. The capacitor 14 comprises a plurality of individual capacitors (here, six individual capacitors C1 to C6) connected in parallel to achieve the desired electrostatic capacitance. The plurality of individual capacitors are housed in an outer casing 21 made of resin.

[0028] In four side surface sections of the outer casing 21, notches (recessed sections) 23a to 23f are formed, corresponding to the contour of the individual capacitors when the individual capacitors are arranged so that they are adjacent to each other. Furthermore, rounded sections (rounding) 24a to 24d are provided on four edges (four corner sections) of the outer casing 21. The recessed sections and the rounding reduce the number of materials involved in the construction of the outer casing 21 of the capacitor, and thus reduce the weight of the capacitor.

[0029] As also in Fig. As illustrated in Figure 5, fastening elements 25a to 25d, which are to be attached to a lower surface section of the housing 31, are formed in the corner sections of the lower section of the outer casing 21 of the capacitor 14. The fastening elements 25a and 25b, which are provided at both ends of a side surface section of the outer casing 21 in the x-direction, extend in the longitudinal direction (x-direction) of the main body of the capacitor. The fastening elements 25c and 25d, which are provided at end sections opposite the two side surface sections of the outer casing 21 in the y-direction, extend in the short direction (y-direction) of the main body of the capacitor.

[0030] The fastening elements 25a to 25d are now arranged and extended to fit the shape of the inner peripheral wall of the housing 31. Consequently, a space for cable guides for a cable set can be attached to the inner wall of the housing 31, and at the same time, the volume of the housing 31 for the inverter control device 10 can be reduced.

[0031] Fig. Figure 6 is a detailed view of the output terminal of the inverter control device 10 and a location near the output terminal. The output terminal 37 comprises metal plates corresponding to three phases, namely the U-phase, the V-phase, and the W-phase, for example, three copper terminal plates 33a to 33c. The terminal plates 33a to 33c are arranged in parallel on a terminal block 51, which is located on the side of the front surface section and near the lower surface of the power control device 10b, and project outwards from the front surface section 19b of the power control device 10b, as shown in Figure 6. Fig. Figure 4 illustrates how to connect to the drive motor.

[0032] Three copper busbars 41a to 41c, corresponding to the three phases (U-phase, V-phase, and W-phase), are connected to the output terminal of the power module unit 13, which provides power to drive the motor at the inverter control device 10. In a planar view, the busbars 41a to 41c are, for example, T-shaped components, and one end of each busbar 41a to 41c and one end of each of the terminal plates 33a to 33c of the output terminal 37 are connected to each other via the terminal block 51 to correspond to each of the three phases.

[0033] The terminal block 51 is made of an insulating resin, has an elongated shape extending in the x-direction along the front surface section 19a, and is designed so that one end of each of the busbars 41a to 41c and one end of each of the terminal plates 33a to 33c can be screwed together.

[0034] Screw sections 51a to 51c of the terminal block 51 each have a height that allows the terminal plates 33a to 33c and the busbars 41a to 41c to be arranged in the same plane in the vertical direction (z-direction). Consequently, the terminal plates 33a to 33c and the busbars 41a to 41c have the same height in the z-direction with respect to, for example, the lower housing section of the power controller 10b.

[0035] Note that the parallel spacing of the terminal plates 33a to 33c of the output terminal 37 can be changed according to the size of the power supply input terminal of the drive motor connected to the inverter control device 10 by changing the spacing of the screw sections of the terminal block 51. Consequently, the output terminal of the three-phase bridge circuit contained in the power module unit 13 can be modified to match the shape of the input terminal of the drive motor, which is its connection point.

[0036] As further in Fig.As illustrated in Figure 6, the inverter control device 10 includes a current sensor 45 for detecting the current flowing through each phase. The current sensor 45 has both end sections in the longitudinal direction which are fastened to the terminal block 51 by screws and is arranged such that it is placed over the busbars 41a to 41c of each phase, while extending in a direction (x-direction) that is orthogonal to the longitudinal direction (y-direction) of the output terminal of the power module unit 13.

[0037] As described above, terminal block 51 also serves as a mounting element for the current sensor, busbar, and similar components. Consequently, the arrangement and mounting of the current sensor at the output terminal can be optimized (saving space).

[0038] As described above, the inverter control device according to this exemplary embodiment has a configuration in which the power module unit, the power module control unit, the capacitor and the inverter control unit are stacked sequentially on top of each other in the housing, starting from the lower surface of the same and moving upwards, and are completely enclosed in the housing.

[0039] Furthermore, the current path of the current from the input side to the output side in the power control is an L-shape, in that the external power supply input terminal and the output terminal that supplies the motor with the drive current are arranged on the front surface section (front surface side wall section) of the inverter control device, and in that the power module unit and the like contained in the power control are supplied with power from the input terminal that is arranged on the side surface section that is orthogonal to the front surface section.

[0040] Based on the configuration described above, the weight of the device can be reduced, and the footprint can be decreased by miniaturizing and reducing the overall height of the inverter control device. Furthermore, the current path in the power control unit and the wiring distance of a cable set, etc., are reduced, power loss can be minimized, radiated noise can be prevented from occurring in the first place, and the influence of external noise can be suppressed due to the reduced resistance value resulting from the short power supply path length, etc.

[0041] Furthermore, the current path can be made as short as possible, the generation of electromagnetic noise can be prevented, and the influence of external noise can be avoided by arranging the current output terminal to the motor and the busbar of the power module unit in the power control system in such a way that the busbar and the current output terminal do not rise vertically, but are directly connected to each other in the same plane to be flat in the horizontal direction.

[0042] Although exemplary embodiments of the present disclosure have been described above, it is understood that variations and modifications of the prior art will be readily apparent to those skilled in the art without deviating from the scope of protection and the nature of the present disclosure. The scope of protection of the present disclosure shall therefore be determined solely by the following patent claims.

Claims

[1] An inverter control device (10) for driving a motor (15), wherein the inverter control device (10) has the following features: a power module (13) that supplies the motor (15) with a drive current; a power module board (12) that outputs a drive signal to the power module (13); a control board (11) that outputs a control signal to the power module board (12); and a smoothing capacitor (14); wherein the power module (13), the power module board (12), the capacitor (14) and the control board (11) are arranged one above the other and are housed in a single enclosure (31) made of a metal material, wherein the power module (13) is a bottom layer; characterized by , that an input terminal (35) of a power supply current is located on one side surface of the housing (31), and an output terminal (37) of a drive current of the motor (15) is located on another side surface of the housing (31), which is orthogonal to the one side surface; the output terminal (37) and a busbar (41a to 41c) connected to the power module are directly connected to each other in the same plane; the output terminal (37) comprises metal plates (33a to 33c) arranged in parallel and at the same height on a terminal block (51) to correspond to a number of phases of the motor (15); and a parallel arrangement distance between the metal plates (33a to 33c) can be changed according to the size of a power supply input connection of the motor (15). [2] The inverter control device (10) according to claim 1, wherein the terminal block (51) is adjacent to the other side surface of the housing (31) so that the output terminal (31) and the busbar (41a to 41c) connected to the power module (13) have the same height. [3] The inverter control device (10) according to claim 1 or 2, wherein the stacking height of the power module (13), the power module board (12), the capacitor (14) and the control board (11) does not exceed a depth dimension of the housing (31). [4] The inverter control device (10) according to any one of claims 1 to 3, wherein: a pair of fastening elements (25a and 25b) provided on one side of a side surface of the capacitor (14) and consisting of fastening elements (25a and 25b) that fasten the capacitor (14) to the housing (31), extends in a longitudinal direction of a main body of the capacitor (14); and a pair of fastening elements (25c and 25d) provided on another side of the side surface of the capacitor (14) extends in a short direction of the main body of the capacitor (14); and the fastening components conform to the shape of an inner peripheral wall of the housing (25a to 25d). [5] The inverter control device (10) according to any one of claims 1 to 4, wherein: the capacitor (14) comprises a plurality of individual capacitors; a plurality of recessed sections (23a to 23f) are provided in a side surface of an outer casing (21) of the capacitor (14) to conform to a contour of an arrangement of the individual capacitors; and the outer casing (21) includes a rounded corner section (24a to 24d). [6] The inverter control device (10) according to any one of claims 1 to 5, wherein a power supply path to the input terminal (35) is located in a vertical direction of the housing (31) above the output terminal (37). [7] The inverter control device (10) according to any one of claims 1 to 6, wherein a current sensor (45) is provided which is attached to the terminal block (51) and is located above the output terminal (37) while extending in a direction which is orthogonal to a longitudinal direction of the output terminal (37). [8] The inverter control device (10) according to any one of claims 1 to 7, wherein: a projecting section (17) protrudes from the housing (31) which is adjacent to a segment of the housing (31) in which the output terminal (37) is located; and the preceding section (17) is a connecting segment between the inverter control device (10) and the motor (15).

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