Power converter arrangement and method for providing a power converter arrangement

Abstract

The invention relates to a power converter arrangement (1) comprising a power converter (2) with a circuit board (3) on which power electronic components (4) of the power converter (2) are arranged, a support (5) configured to support the circuit board (3) of the power converter (2), and an EMC filter (6), wherein electronic components (7) of the EMC filter (6) are arranged on the circuit board (3) of the power converter (2), and wherein a magnetic core (8) or, in the case of multiple magnetic cores (8), the multiple magnetic cores (8) of the EMC filter (6) are arranged in and / or on the support (5). The invention further relates to a method for providing a power converter arrangement (1).

Description

[0001] The invention relates to a power converter arrangement and a method for providing a power converter arrangement.

[0002] Unshielded electrical systems are subject to stricter regulatory requirements regarding electromagnetic interference (EMI) compared to conventional applications. Consequently, a large amount of installation space is required for integrating an electromagnetic compatibility (EMC) filter, which is often unavailable. This negatively impacts the EMC filter's performance or increases costs due to the additional installation space.

[0003] DE 10 2022 208 450 A1 describes an electronic unit for a vehicle, wherein the vehicle has a drive inverter and an electric drive motor, and wherein the drive inverter controls the electric drive motor, and wherein the vehicle has at least one electrically driven refrigerant compressor and a refrigerant compressor inverter, and wherein the refrigerant compressor inverter controls the electrically driven refrigerant compressor, and wherein the electronic unit has an EMC filter and a DC link capacitor unit. It is proposed that the EMC filter and the DC link capacitor unit are designed as a single unit, and that the EMC filter and the DC link capacitor unit can be connected upstream of both the drive inverter and the refrigerant compressor inverter.

[0004] DE 10 2021 110 983 A1 relates to an EMC filter device for the power electronics of an electric machine, comprising an electrical conductor structure, at least one capacitance coupled to the conductor structure, and at least one inductor interacting with the conductor structure, wherein the conductor structure has at least two separate, mutually insulated conductive layers. A power electronics module incorporating this EMC filter device is also described.

[0005] The invention is based on the objective of proposing a solution in which an EMC filter can be provided in an improved manner, particularly with regard to installation space and costs.

[0006] The problem is solved according to the invention by a power converter arrangement with the features of claim 1 and a method with the features of claim 10. Advantageous embodiments of the invention are set forth in the dependent claims.

[0007] In particular, a power converter arrangement is provided, comprising a power converter with a circuit board on which power electronic components of the power converter are arranged, a support configured to support the circuit board of the power converter, and an EMC filter, wherein electronic components of the EMC filter are arranged on the circuit board of the power converter, and wherein a magnetic core or, in the case of multiple magnetic cores, the multiple magnetic cores of the EMC filter are arranged in and / or on the support.

[0008] Furthermore, in particular a method for providing a power converter arrangement is provided, wherein a power converter and an EMC filter are provided, wherein electronic components of the EMC filter are provided on a circuit board on which power electronic components of the power converter are arranged, and wherein a magnetic core or, in the case of several magnetic cores, the several magnetic cores of the EMC filter are provided arranged in and / or on a carrier that supports the circuit board of the power converter.

[0009] The power converter arrangement and the method enable space and cost savings. This is achieved by arranging the electronic components of the EMC filter, in particular at least one capacitor and / or at least one resistor, on the same circuit board as the power converter's power electronic components. This eliminates the need for a separate circuit board for the EMC filter, resulting in space savings. Furthermore, a magnetic core or cores (in the case of multiple cores) of the EMC filter are arranged in and / or on the substrate supporting the power converter circuit board. A magnetic core is, in particular, a ferrite core or a toroidal core. This allows for further space savings, as the power converter arrangement can be designed more compactly. A magnetic core is, in particular, guided over a busbar and / or the busbar passes through the magnetic core.In particular, existing installation space can be used more efficiently. Overall, this allows for a more efficient EMC filter to be provided with less installation space, or a more powerful EMC filter to be provided with the same installation space.

[0010] The support includes in particular a support plate and / or a support frame, or is designed as such.

[0011] The power converter can be designed, for example, as an inverter, rectifier, DC-DC converter, or AC-DC converter. The basic operating principle of a power converter is well-known, so it will not be discussed further here.

[0012] In one embodiment, the power converter arrangement comprises a housing, wherein the support is a mechanically integral part of the housing, at least in an assembled state. The support can, for example, be a modular part of the housing, which can be, or is already, plugged together with other modular parts of the housing and / or can be arranged on them to form the housing.

[0013] In one embodiment, the power converter assembly comprises at least one cooling element, wherein the electronic components of the EMC filter are arranged at least partially on and / or near the at least one cooling element. This allows the electronic components to be cooled by the at least one cooling element. This enables the EMC filter to operate, in particular, at higher power levels. The at least one cooling element can, for example, be a cooling element for cooling the power electronic components of the power converter and simultaneously cool the electronic components of the EMC filter.

[0014] In one embodiment, the power converter arrangement comprises at least one cooling element, wherein the one or more magnetic cores are at least partially arranged on and / or near the at least one cooling element. This allows the magnetic core(s) to be cooled by the at least one cooling element. This enables the EMC filter to operate at a higher power level. The at least one cooling element can, for example, be a cooling element for cooling the power electronic components of the power converter and simultaneously cool the electronic components of the EMC filter.

[0015] In one embodiment, it is provided that the one magnetic core or the several magnetic cores are mechanically connected to the carrier via at least one retaining element.

[0016] This allows the magnetic core or multiple magnetic cores to be held in position on the carrier.

[0017] In one embodiment, the magnetic core or cores are arranged in and / or on the carrier such that at least a portion of the busbars running along and / or through the carrier passes through the magnetic core or through at least one of the cores. This allows for a particularly compact arrangement of the magnetic cores.

[0018] Furthermore, an on-board electrical system is created, comprising an on-board electrical system and at least one power converter arrangement according to one of the described embodiments. The on-board electrical system includes, for example, a high-voltage battery and electrical lines from the high-voltage battery to the power converter arrangement.

[0019] In one embodiment of the electrical system arrangement, the electrical system is unshielded at least in a section between a high-voltage battery and the converter arrangement. Since an unshielded electrical system places particularly high demands on the EMC filter, the advantages of the converter arrangement described in this disclosure can be especially well utilized. Because the magnetic core(s) required due to the higher requirements are integrated with the converter, installation space can be saved while simultaneously meeting the high EMC filter requirements.

[0020] Furthermore, a vehicle is also created, comprising at least one power converter arrangement according to one of the described embodiments and / or at least one on-board electrical system arrangement according to one of the described embodiments. The vehicle is, in particular, a motor vehicle. However, the vehicle can also be any other land, rail, water, air, or space vehicle.

[0021] Further features for the design of the method result from the description of the various configurations of the power converter arrangement. The advantages of the method are the same in each case as in the configurations of the power converter arrangement.

[0022] The invention is explained in more detail below with reference to preferred embodiments and the figures. These show: Fig. 1 a schematic representation of an embodiment of the power converter arrangement; Fig. 2 a schematic representation of an embodiment of the on-board network arrangement; Fig. 3 a schematic representation of another embodiment of the power converter arrangement.

[0023] The Fig. Figure 1 shows a schematic representation of an embodiment of the power converter arrangement 1. The power converter arrangement 1 comprises a power converter 2 with a circuit board 3 (PCB). The power converter 2 is, for example, a pulse inverter (PWR), such as in a vehicle powertrain. Power electronic components 4, such as power semiconductors, are arranged on the circuit board 3. The power converter arrangement 1 further comprises a support 5, which is configured to support the circuit board 3 of the power converter 2, and an EMC filter 6. The support 5 can, for example, comprise a support plate (not shown) or a support frame (not shown).

[0024] The EMC filter 6 comprises electronic components 7, for example, one or more capacitors and resistors. The electronic components 7 of the EMC filter 6 are arranged on the circuit board 3 of the power converter 1. The EMC filter 6 does not, in particular, have its own circuit board. A magnetic core 8, or, in the case of multiple magnetic cores 8, the multiple magnetic cores 8 of the EMC filter 6 are arranged in and / or on the support 5. Current rails 9 are, in particular, routed through the magnetic core(s) 8 (shown here only schematically).

[0025] It can be provided that the power converter arrangement 1 has a housing 10, wherein the support 5 is a mechanically integral part of the housing 10, at least in an assembled state.

[0026] The power converter arrangement 1 may be provided with at least one cooling element 11, wherein the electronic components 7 of the EMC filter 6 are arranged at least partially on and / or near the at least one cooling element 11. The at least one cooling element 11 may, for example, serve to simultaneously cool the power electronic components 4 of the power converter 2 and the electronic components 7 of the EMC filter 6. The at least one cooling element 11 may, for example, comprise a water- or oil-filled element (not shown) through which the generated heat can be dissipated.

[0027] The power converter arrangement 1 may be provided with at least one cooling element 11, wherein the one or more magnetic cores 8 are arranged at least partially on and / or near the at least one cooling element 11. The at least one cooling element 11 may, for example, serve to simultaneously cool the power electronic components 4 of the power converter 2 and the magnetic core(s) 8 of the EMC filter 6. The at least one cooling element 11 may, for example, comprise a water- or oil-filled element (not shown) through which the generated heat can be dissipated.

[0028] It may be that the one magnetic core 8 or the several magnetic cores 8 are mechanically connected to the carrier 5 via at least one retaining element 12.

[0029] It may be provided that the one magnetic core 8 or the several magnetic cores 8 are arranged in and / or on the support 5 in such a way that at least a part of the busbars 9 running along and / or through the support 5 passes through the magnetic core 8 or through at least one of the several magnetic cores 8.

[0030] The Fig. Figure 2 shows a schematic representation of an on-board electrical system 20. The on-board electrical system 20 comprises an on-board electrical system 21 and a power converter arrangement 1 according to one of the described embodiments. Furthermore, the on-board electrical system 20 can include a high-voltage battery 22. The high-voltage battery 22 and the power converter arrangement 1 are connected to each other via electrical conductors 23.

[0031] It may be provided that the on-board electrical system 21 is unshielded at least in one section between a high-voltage battery 22 and the power converter assembly 21. In particular, the electrical conductors 23 then lack any electrical shielding.

[0032] The power converter arrangement 1 and the on-board network arrangement 20 can be arranged in a vehicle 50, in particular in a motor vehicle.

[0033] The Fig. Figure 3 shows a schematic representation of a section of an embodiment of the power converter arrangement 1. The power converter arrangement 1 is basically like the one in the Fig.The embodiment shown in Figure 1 is designed as follows; the same reference numerals denote the same terms and features. In this embodiment, the circuit board 3, on which the power electronic components 4 of the power converter 2 and the electronic components 7 of the EMC filter 6 are arranged, is located below a housing cover 13 of the housing 10. By arranging the electronic components 7 on the circuit board 3 of the power converter 2, the available space within the housing 10 can be optimally utilized. Reference symbol list 1 Power converter arrangement 2 power converters 3 circuit boards 4 power electronic components (power converters) 5 carriers 6 EMC filters 7 electronic components (EMC filters) 8 magnetic core 9 busbar 10 cases 11 Cooling element 12 retaining elements 13 Housing covers 20 On-board electrical system arrangement 21 On-board electrical system 22 high-voltage battery 23 electrical conductor (unshielded) 50 vehicles QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 208 450 A1

[0003] DE 10 2021 110 983 A1

[0004]

Claims

[1] Converter assembly (1) comprising: a power converter (2) with a circuit board (3) on which power electronic components (4) of the power converter (2) are arranged, a carrier (5) designed to support the circuit board (3) of the power converter (2), and an EMC filter(6), wherein electronic components (7) of the EMC filter (6) are arranged on the circuit board (3) of the power converter (2), and wherein a magnetic core (8) or, in the case of multiple magnetic cores (8), the multiple magnetic cores (8) of the EMC filter (6) are arranged in and / or on the carrier (5). [2] Power converter arrangement (1) according to claim 1, characterized by a housing (12), wherein the support (5) is a mechanically integral part of the housing (12), at least in an assembled state. [3] Power converter arrangement (1) according to claim 1 or 2, characterized by, that the power converter arrangement (1) has at least one cooling element (11), wherein the electronic components (7) of the EMC filter (6) are arranged at least partially on and / or near the at least one cooling element (11). [4] Power converter arrangement (1) according to any one of the preceding claims, characterized by , that the power converter arrangement (1) has at least one cooling element (11), wherein the one magnetic core (8) or the several magnetic cores (8) are arranged at least partially on and / or near the at least one cooling element (11). [5] Power converter arrangement (1) according to any one of the preceding claims, characterized by that the one magnetic core (8) or the several magnetic cores (8) are mechanically connected to the support (5) via at least one retaining element (12). [6] Power converter arrangement (1) according to any one of the preceding claims, characterized by, that the one magnetic core (8) or the several magnetic cores (8) are arranged in and / or on the support (5) such that at least a part of the busbars (9) running along and / or through the support (5) passes through the magnetic core (8) or through at least one of the several magnetic cores (8). [7] On-board power supply arrangement (20) comprising an on-board power supply (21) and at least one converter arrangement (1) according to any of the preceding claims. [8] On-board electrical system arrangement (20) according to claim 7, characterized by , that the on-board network (21) is unshielded at least in one section between a high-voltage battery (22) and the power converter arrangement (1). [9] Vehicle (50) comprising at least one converter arrangement (1) according to one of claims 1 to 6 and / or at least one on-board electrical system arrangement (20) according to claim 7 or 8. [10] Method for providing a power converter arrangement (1), wherein a power converter (2) and an EMC filter (6) are provided, wherein electronic components (7) of the EMC filter (6) are provided on a circuit board (3) on which power electronic components (4) of the power converter (2) are arranged, and wherein a magnetic core (8) or, in the case of multiple magnetic cores (8), the multiple magnetic cores (8) of the EMC filter (6) are provided arranged in and / or on a carrier (5) which carries the circuit board of the power converter (2).

Images